HM 300

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
Printed in Japan 08-12 (02)
00-1
(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
2
HM300-1
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HM300-1
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 dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
Always wear safety glasses when hitting

parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
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
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
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 judgements. 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 further 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 understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance 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 component, 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
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
When a manual is revised, an edition mark

((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol
Item
Remarks
Safety
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

must be drained, and
quantity to be drained.
3
2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted
with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
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
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth 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

k Before carrying out the following work, release
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 hydraulic 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
Type 1
FOREWORD
Type 3
1) Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
Disassembly
Type 2
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
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.
LT-1A
790-129-9030
LT-1B
790-129-9050
LT-2
09940-00030
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
LT-4
790-129-9040
Holtz
MH 705
790-126-9120
Three bond
1735
790-129-9140
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
LG-1
790-129-9010
LG-5
790-129-9080
LG-6
790-129-9020
LG-7
790-129-9070
Three bond
1211
790-129-9090
Three bond
1207B
419-15-18131
Adhesives
Gasket
sealant
00-10
Qty
Container
Main applications, features
Used to prevent rubber gaskets, rubber

cushions, and cock plug from coming out.
Used in places requiring an immediately
effective, strong adhesive.
Used for plastics (except polyethylene,
20 g
Polyethylene
polyprophylene, tetrafluoroethlene and
(2 pcs.)
container
vinyl chloride), rubber, metal and nonmetal.
Features:
Polyethylene
Resistance to heat and chemicals
50 g
container
Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive:
Used as adhesive or sealant for metal,
1 kg
glass and plastic.
Hardening
Can
agent:
500 g
Polyethylene Used as sealant for machined holes.
250 g
container
Used as heat-resisting sealant for
75 g
Tube
repairing engine.
Quick hardening type adhesive
Polyethylene Cure time: within 5 sec. to 3 min.
50 g
container
Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Quick cure type
Polyethylene
(max. strength after 30 minutes)
2g
container
Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Polyethylene
Used at joint portions subject to high
50 cc
container
temperatures.
Used as adhesive or sealant for gaskets
200 g
Tube
and packing of power train case, etc.
Used as sealant for various threads, pipe
joints, flanges.
1 kg
Can
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance to
heat, cold
200 g
Tube
Used as sealant for flange surface, tread.
Used as sealant for oil pan, final drive
case, etc.
Features: Silicon based, quick hardening
type
Used as sealant for flywheel housing,
1 kg
Tube
intake manifold, oil pan, thermostat
housing, etc.
Used as heat-resisting sealant for
100 g
Tube
repairing engine.
Features: Silicone type, heat resistant,
vibration resistant, and impact resistant
100 g
Tube
sealing material
Used as sealing material for transfer case
150 g
Tube
FOREWORD
Molybdenum
disulphide
lubricant
Komatsu code
Part No.
Qty
Container
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
Various
Various
G2-LI
G2-CA
Grease
Primer
Adhesive
Caulking
material
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Molybdenum
disulphide
grease
LM-G (G2-M)
Hyper White
Grease G2-T
G0-T (*)
*: For use in
cold district
Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
GLASS PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)
SUNSTAR
GLASS PRIMER
435-41
SUNSTAR
SASH PRIMER
GP-402
SUNSTAR
PENGUINE
SUPER 560
SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
Sika Japan,
Sikaflex 256HV
SUNSTAR
PENGUINE
SEAL No. 2505
SEKISUI
SILICONE
SEALANT
GE TOSHIBA
SILICONES
TOSSEAL 381
SYG2-400M
SYG2-400M-A
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
Various
Various
400 g 10 Bellows type

400 g 20 Bellows type
16 kg
Can
400 g
16 kg
400 g
16 kg
Main applications, features

Used as lubricant for sliding portion (to
prevent from squeaking).
Used to prevent seizure or scuffling of the
thread when press fitting or shrink fitting.
Used as lubricant for linkage, bearings,
etc.
General purpose type
Used for normal temperature, light load

bearing at places in contact with water or
steam.
Used for heavy load portion
Seizure resistance and heat resistance

higher than molybdenum disulfide grease
Bellows type
Since this grease is white, it does not
Can
stand out against machine body.
Since this grease is decomposed by
bacteria in short period, it has less effects
Bellows type
on microorganisms, animals, and plants.
Can
20 ml
Glass
container
20 ml
Glass
container
22M-54-27230
20 ml
Glass
container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass
container
22M-54-27210
320 ml
Ecocart
(Special
container)
Used as primer for cab side

(Using limit: 4 months)
417-926-3910
417-926-3910
320 ml
Polyethylene
container
20Y-54-39850
310 ml
Polyethylene
container
417-926-3920
320 ml
Polyethylene
container
20Y-54-55130
333 ml
Polyethylene
container
22M-54-27220
333 ml
Cartridge
Used as primer for glass side

Adhesive for cab glass
Category
COATING MATERIALS
Used as primer for painted surface on

cab side
Used as primer for black ceramiccoated surface on glass side and for
hard polycarbonate-coated surface
Used as primer for sash (Alumite).
Used as adhesive for glass.
S is used for high-temperature
season (April - October) and W for
low-temperature season (November April) as adhesive for glass.
Used as adhesive for glass.
Used to seal joints of glass parts.
Used to seal front window.
Used to seal joint of glasses.
Translucent white seal.
00-11
FOREWORD
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
of bolt
Width across
flats
mm
mm
Nm
kgm
6
8
10
12
14
10
13
17
19
22
11.8 14.7
27 34
59 74
98 123
153 190
1.2 1.5
2.8 3.5
6 7.5
10 12.5
15.5 19.5
16
18
20
22
24
24
27
30
32
36
235 285
320 400
455 565
610 765
785 980
23.5 29.5
33 41
46.5 58
62.5 78
80 100
27
30
33
36
39
41
46
50
55
60
1150 1440
1520 1910
1960 2450
2450 3040
2890 3630
118 147
155 195
200 250
250 310
295 370
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
kgm
6
8
10
12
10
13
14
27
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
Tightening torque
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
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
52
82
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
FOREWORD
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
12
16
14
17
22
59 74
98 123
235 285
6 7.5
10 12.5
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
mm
mm
14
20
24
33
42
Varies depending
on type of
connector.
Tightening torque (Nm {kgm})
Norminal No.
02
03, 04
05, 06
10, 12
14
Range
35 63
84 132
128 186
363 480
746 1010
{3.5 6.5}
{8.5 13.5}
{13.0 19.0}
{37.0 49.0}
{76.0 103}
Target
44 {4.5}
103 {10.5}
157 {16.0}
422 {43.0}
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
mm
mm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
36
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Range
5.88 8.82
9.8 12.74
14.7 19.6
19.6 24.5
24.5 34.3
34.3 44.1
44.1 53.9
58.8 78.4
93.1 122.5
107.8 147.0
127.4 176.4
181.3 240.1
274.4 367.5
{0.6 0.9}
{1.0 1.3}
{1.5 2.0}
{2.0 2.5}
{2.5 3.5}
{3.5 4.5}
{4.5 5.5}
{6.0 8.0}
{9.5 12.5}
{11.0 15.0}
{13.0 18.0}
{18.5 24.5}
{28.0 37.5}
Target
7.35 {0.75}
11.27 {1.15}
17.64 {1.8}
22.54 {2.3}
29.4 {3.0}
39.2 {4.0}
49.0 {5.0}
68.6 {7.0}
107.8 {11.0}
124.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}
00-13
FOREWORD
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
24 0 4
43 0 6
77 0 12
6
8
10
12
1.02 0 0.20
2.45 0 0.41
4.38 0 0.61
7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
kgm
0.81 0 0.20
1.02 0 0.20
1.22 0 0.20
2.45 0 0.41
3.67 0 0.51
802
10 0 2
12 0 2
24 0 4
36 0 5
6
8
10
12
14
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
Tightening torque
inch
Nm
kgm
301
802
12 0 2
15 0 2
24 0 4
36 0 5
60 0 9
1 / 16
1/8
1/4
3/8
1/2
3/4
1
0.31 0 0.10
0.81 0 0.20
1.22 0 0.20
1.53 0 0.20
2.45 0 0.41
3.67 0 0.51
6.12 0 0.92
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.
Nominal size Width across
of hose
flats
Taper seal
type
Face seal type
Nominal thread
Thread size size
Root diameter
- Threads per
(mm)
inch, Thread series (mm) (Reference)
Range
Target
34 54 {3.5 5.5}
44 {4.5}
9
18UN
16
14.3
34 63 {3.5 6.5}
44 {4.5}
14
22
54 93 {5.5 9.5}
74 {7.5}
11
16UN
16
17.5
24
59 98 {6.0 10.0}
78 {8.0}
18
04
27
84 132 {8.5 13.5}
103 {10.5}
22
13
16UN
16
20.6
05
32
128 186 {13.0 19.0}
157 {16.0}
24
1 14UNS
25.4
06
36
177 245 {18.0 25.0}
216 {22.0}
30
3
1 12UN
16
30.2
(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
02
03
00-14
19
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
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal

etc.
0.32
2.09
3.1
20
Lighting, signal etc.
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
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority
Classification
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2
Color White & Red
Code
WB
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Auxiliary
Color White & Black
Code
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
Color White & Blue
Code
Color White & Green
Code
Color
WG
RY
Black & Red Red & Yellow

RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
5
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
6
Red & Blue Yellow & White Green & Blue
n
n
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
(A)
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
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
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
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
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
0.220
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
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
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
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
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
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column 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.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
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
HM300-1 E-SPEC
Serial Numbers
1001 and up
1001 and up
23,545
Max. payload
kg
27,300
Overall weight
kg
50,920
Unloaded (front wheel)
kg
13,125
(center wheel)
kg
5,345
(rear wheel)
kg
5,075
Fully loaded (front wheel)
kg
15,220
(center wheel)
kg
18,125
(rear wheel)
kg
17,575
Struck
m3
12.9
16.6
km/h
59
Weight
kg
Dump body capacity

Performance
HM300-1
Unloaded
Weight
Dimensions
Machine model
Heaped (2:1)
Max. travel speed

Gradeability (sin )
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
Wheelbase (center wheel - rear wheel)
mm
1,710
Front tires
mm
2,435
Center tires
mm
2,435
Rear tires
mm
2,435
mm
510
Tread
Ground Clearance
Model
Komatsu SAA6D125E-3
Type
4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
after-cooler
Engine
No. of cylinders - Bore x stroke
mm
Piston displacement
l {cc}
11.04{11,040}
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}
g/kWh{g/HPh}
194 {145}
Fuel consumption (rated)

Starting motor
Alternator
Battery
HM300-1
6-125 x 150
7.5kW
24V 50A
12V 112Ah x 2
01-3
4
(9)
GENERAL
Power train
Torque converter
Transmission
Machine model
HM300-1
HM300-1 E-SPEC
Serial Numbers
1001 and up
1001 and up
3-element, 1-stage, 2-phase
Type
Lock-up clutch
Hydraulically-actuated, wet-type, single-disc

clutch
Type
TORQFLOW multiple-axle transmission, fully

automatic, electrically-hydraulically actuated,
force-feed type pump lubrication type
No. of speeds
F6, R2
Type
Reduction gear
Final drive
Travel system
SPECIFICATIONS
Spiral bevel gear, splash lubrication
Reduction ratio
3.154
Differential type
Straight bevel gear, splash lubrication
Type
Planetary gear, splash lubrication
Reduction ratio
4.667
Type
Fully hydraulic
Suspension
Front axle
Axle type
Suspension method
Tires
Size and no.
Full floating suspension (De Dion type)
Center axle
Full floating suspension
Rear axle
Full floating suspension
Front axle
Hydropneumatic type
Rear axle
Hydropneumatic type
Front tire
23.5 R25 x 2
Center tire
23.5 R25 x 2
Rear tire
23.5 R25 x 2
kPa
Tire inflation pressure
Brakes
Main brake
Parking brake
Retarder
01-4
4
{kg/cm2}
Front wheel
Center wheel
440 {4.5}
Independent front and center system brake, sealed,
wet- type, multiple disc, hydraulically operated type
Independent front and center system brake, sealed,
wet- type, multiple disc, hydraulically operated type
Spring-boosted, caliper disc type
Independent front and
center system brake,
sealed, wet- type, multiple disc, hydraulically
operated type
HM300-1
GENERAL
SPECIFICATIONS
Machine model
HM300-1
HM300-1 E-SPEC
Serial Numbers
1001 and up
1001 and up
For steering, hoist

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

Type
Gear pump
14.1

For transmission, brake cooling
Type
Gear pump
204

For brake cooling
Type
Gear pump
180

For brake
Type
Gear pump
40
Hoist cylinder
Cylinders
Type
HM300-1
2-stage piston type

(only 2nd stage double-acting)
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
01-5
4
(9)
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model
HM300-1
HM300-1 E-SPEC
Serial Numbers
1001 and up
1001 and up
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
Operators 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
(12)
HM300-1
GENERAL
FUEL, COOLANT AND LUBRICANTS
ASTM: American Society of Testing and Material
HM300-1
01-7
(11)
GENERAL
Reservoir
Engine oil
pan
Transmission
case
(Incl. brake
oil tank)
Hydraulic
tank
Front
suspension
(each)
Rear
suspension
(each)
Front
differential
Case
Capacity
Specified
Liters
45
165
171
2.2
14
Refill
Liters
35
77.5
120
2.2
14
Reservoir
Capacity
Front final
drive case
(each)
Center
differential
case
Center final
drive case
(each)
Rear
differential
case
Rear final
drive case
(each)
Fuel tank
Cooling
system
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 150C), 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 45C (113F) 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 Supercoolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10C (14F). (never
dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%.
01-8
(11)
HM300-1
GENERAL
Mixing rate of water and antifreeze

Min. atmospheric
temperature
-10
-15
-20
-25
-30
14
-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

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,

AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
1. Reservoir tank
2. Radiator
3. Aftercooler
4. Torque converter oil cooler
5. Steering oil cooler
6. Upper tank
7. Lower tank
A. To intake manifold
B. From turbocharger
C. From thermostat
D. To water pump
10-2
(9)
Specifications
Radiator
Core type: CF4-4
Total heat dissipation area: 50.61m2
Torque converter oil cooler
Core type: PTO-LS
Steering oil cooler
Core type: PTO-LS
HM300-1
POWER TRAIN SKELETON
10-4
(4
9)
HM300-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Engine
Output shaft
Front drive shaft
Brake cooling and brake system pump (SAR(3)80+(1)18)
Torque converter, transmission, front brake cooling pump (SAR(3)90)
PTO
Torque converter
Steering, hoist control pump (SAR(3)63+63+(1)6)
Transmission
Front drive shaft
Oscillation hitch
Center drive shaft
Front differential
Front limited slip differential
Front drive shaft
Tire
Final drive (front)
Brake (front)
Rear drive shaft (front)
Center differential
Center limited slip differential
Tire
Final drive (center)
Brake (center)
Rear drive shaft (rear)
Rear differential
Rear limited slip differential
Tire
Final drive (rear)
Interaxle differential lock
HM300-1
10-5
4
(9)
OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion
2. Outer body
3. Inner body
4. Breather
5. Coupling shaft
6. Flange
7. Cover
10-6
FUNCTION
The output shaft is installed to the engine flywheel,and absorbs the twisting vibration caused by
changes in the engine torque.
HM300-1
OUTPUT SHAFT
Unit: mm
No.
Check item
Clearance between bearing

and inner body
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
85
+0.025
+0.003
0
-0.020
-0.045
-0.013

and flange
130
0
-0.018
-0.020
-0.045
-0.045
-0.002
Clearance between retainer

and flange
130
+0.006
-0.034
+0.060
+0.020
-0.014
-0.094
Wear of shaft and oil seal contact surface
Backlash at spline
portion
Deterioration and cracks in
rubber
Deterioration and cracks in
rubber
HM300-1
Standard size
Tolerance
Repair limit
70
0
-0.074
-0.12
Replace
Standard backlash
Clearance limit
0.071 0.177
0.35
Standard clearance
Clearance limit
70
At min. width: Min. 63 mm

There must be no cracks
50
At min. width: Min. 48 mm

There must be no cracks
10-7
(9)
TORQUE CONVERTER AND TRANSMISSION

HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC

PIPING
10-8
HM300-1
TORQUE CONVERTER AND TRANSMISSION 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)
TORQUE CONVERTER
TORQUE CONVERTER
1. PTO gear (No. of teeth: 66)

Unit: mm
No.
Check item
Clearance between PTO gear

and bearing

and case
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
50
+0.018
+0.002
0
-0.012
-0.030
-0.002
90
0
-0.015
+0.016
-0.006
-0.006
0.031
Replace
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
(9)
HM300-1
1. Coupling
2. Input shaft
(No. of teeth: 78)
3. Case
4. Drive case
5. Turbine
6. Race
7. Pump
HM300-1
8.
9.
10.
11.
12.
13.
14.
TORQUE CONVERTER
Stator shaft
One way clutch
Stator
Disc
Piston
Clutch housing
Retainer
10-11
(9)
10-12
TORQUE CONVERTER
HM300-1
TORQUE CONVERTER
Unit: mm
No.
Check item
Outside diameter of coupling
and oil seal sliding portion
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0
-0.087
94.8
Inside diameter of seal ring

sliding portion of input shaft
sliding portion
35
+0.025
0
35.1

sliding portion of clutch housing
365
+0.089
0
365.5

sliding portion of clutch piston
260
+0.081
0
260.1

sliding portion of pump housing
140
+0.040
0
140.5

sliding portion of input shaft
60
+0.030
0
60.1
Width
-0.01
-0.04
4.5
Wear of clutch
housing seal ring
Thickness
0.15
5.85
4.45
0
-0.1
4.05
5.2
0.1
4.7
102.555
0.008
102.585
Wear of stator shaft Width

seal ring
Thickness
Inside diameter of outer race

one-way clutch transmission
surface
10
Outside diameter of inner race

one-way clutch transmission
surface
83.6
+ 0.004
- 0.009
83.57
11
Inside diameter of sliding portion of bushing
83.71
+0.015
0
83.79
12
Thickness of sliding portion of

bushing
0.05
5.5
13
Thickness of clutch disc
0.1
4.4
14
Backlash between input shaft

and PTO gear
HM300-1
Replace
0.18 0.46
10-13
(9)
PATH FOR TRANSMISSION OF POWER

1. When lock-up clutch is disengaged
When the lock-up clutch is disengaged, drive
case (1) and turbine (2) are separated, and the
torque converter functions as normal.
The power generated by the engine goes from
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
housing (5), and rotates drive case (1) and pump
(6) as one unit.
The power from pump (6) uses oil as a medium,
rotates turbine (2), and is transmitted from turbine (2) to transmission input shaft (7).
10-14
(9)
TORQUE CONVERTER
2. When lock-up clutch is engaged

When the lock-up clutch is engaged, drive case
(1) and turbine (2) are engaged and form one
unit. Stator (8) is rotated by the rotation of pump
(6) and turbine (2).
The power generated by the engine goes from
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
housing (5), and rotates drive case (1) and pump
(6) as one unit.
In addition, drive case (1) and turbine (2) are engaged by the clutch, so the power is transmitted
directly from turbine (2) to transmission input
shaft (7) without using oil as a medium.
HM300-1
TORQUE CONVERTER
FLOW OF OIL
The oil passes through the main relief valve, is adjusted by the torque converter relief valve to a pressure 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 stator (3) to pump (2). The oil is given centrifugal force
by pump (2), enters turbine (4), and transmits the energy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and enters 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)
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
2. Idler gear (No. of teeth: 53)
3. 1st clutch
4. 2nd clutch
5. Differential lock clutch
6. Rear output shaft
7. Rear coupling
8. Front output shaft
HM300-1
TRANSMISSION
9. Lower shaft
10. 3rd clutch
11. Upper shaft
12. FH clutch
13. Input shaft
14. FL clutch
15. Torque converter
10-17
10-18
TRANSMISSION
HM300-1
TRANSMISSION
Unit: mm
No.
Check item
Criteria
Clearance (F) between FL, R clutch

bearing and case
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.026
-0.014
-0.014
0.044
Shaft
Hole
130
0
-0.018
Clearance (R) between FL, R clutch

bearing and case
130
0
-0.018
-0.012
-0.052
-0.052
0.006
Clearance (F) between FH, 1st clutch

bearing and case
130
0
-0.018
+0.026
-0.014
-0.014
0.044
Clearance (R) between FH, 1st clutch

bearing and case
130
0
-0.018
-0.012
-0.052
-0.052
0.006
Clearance (R) between FH. 1st clutch

bearing and upper shaft
60
+0.054
+0.044
0
-0.015
-0.069
0.044
Clearance (F) between 2nd, 3rd

clutch bearing and case
120
0
-0.015
-0.010
-0.045
-0.045
0.005
Clearance (R) between 2nd, 3rd

clutch bearing and case
125
0
-0.018
-0.012
-0.052
-0.052
0.006
Clearance (F) between differential

lock clutch bearing and case
230
0
-0.030
-0.014
-0.060
-0.060
0.016
Clearance (R) between differential

lock clutch bearing and case
205.583
+0.025
0
+ 0.013
-0.033
-0.058
-0.013
Standard size
Tolerance
Repair limit
2.5
+0.18
+0.10
2.7
Width
2.4
0.05
2.2
Thickness
1.7
0
-0.10
1.5
3.2
+0.076
0
3.5
Width
3.1
0
- 0.05
2.8
Thickness
2.05
0.10
1.8
Inside diameter of seal ring sliding

portions of input and upper shafts
(Rear side)
60
+0.050
0
60.1
Width of seal ring grooves of input

and upper shafts (Rear side)
3.2
+0.076
0
3.5
Wear of seal ring

grooves of input and
upper shafts (Rear
side)
Width
3.1
0
-0.05
2.8
Thickness
Width of input shaft seal ring groove

10
Wear of input shaft
seal ring
Width of input shaft seal ring groove

11
Wear of input shaft
seal ring
12
13
2.05
0.10
1.8

portion of lower shaft (Rear side)
50
+0.050
0
50.1
Width of seal ring groove of lower

shaft (Rear side)
3.2
+0.076
0
3.5
Width
3.1
0
-0.05
2.8
Thickness
2.05
0.10
1.8

portion of front output shaft
80
+0.030
0
80.1
Width of seal ring groove of front output shaft
3.2
+0.076
0
3.5
Width
3.1
0.05
2.8
Thickness
2.29
0
-0.1
2.1
95
0
-0.087
94.8
Wear of seal ring

groove of lower shaft
(Rear side)
14
Wear of seal ring of

front output shaft
15
Outside diameter of rear coupling oil

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

2. Strainer
3. Lubrication oil relief valve
Unit: mm
No.
Check item

and case
Clearance between R idler gear

and bearing
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
70
+0.032
+0.002
0
-0.015
-0.047
-0.002
100
0
-0.015
-0.038
-0.073
-0.073
-0.023
Outline
The transmission is installed to the rear of the
torque converter. The power from the torque
converter passes through the transmission input
shaft and enters the transmission.
The transmission uses combinations of the FL,
FH, and R clutches and the three speed clutches
to shift the power from the input shaft and selects a speed range from FORWARD 1st - 6th or
REVERSE 1st - 2nd. This is then transmitted to
the output shaft.
Gearshifting is carried out automatically by the
automatic transmission according to the changes in the engine speed.
10-20
(9)
Remedy
Replace
Clutch combination and reduction ratio

Speed range
Clutch used
Reduction ratio
F1
FL x 1st
6.522
F2
FH x 1st
4.243
F3
FL x 2nd
2.717
F4
FH x 2nd
1.768
F5
FL x 3rd
1.130
F6
FH x 3rd
0.735
R1
R x 1st
5.829
R2
R x 2nd
2.429
HM300-1
TRANSMISSION
FL - R CLUTCH
A: R clutch oil port

B: FL clutch oil port
C: Lubricating oil port

D: Lock-up clutch oil port
1. Input shaft
2. Idler gear (No. of teeth: 45)
3. FL gear (No. of teeth: 34)
4. FL clutch
5. FL, R cylinder (No. of teeth: 78)

6. R clutch
7. R gear (No. of teeth: 28)
Unit: mm
No.
Check item
Clearance (F) between FL, R

shaft and bearing
Clearance (R) between FL, R

shaft and bearing
10
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
60
+0.033
+0.022
0
-0.015
-0.048
-0.022
60
+0.033
+0.022
0
-0.015
-0.048
-0.022
Standard
size
Clearance
limit
Standard size
Tolerance
Repair limit
Thickness
1.7
0.05
1.5
Distortion
0.05
0.15
Thickness
2.2
0.08
1.75
Distortion
0.10
0.25
Separator plate
11
Replace
Friction plate
12
Load of wave spring (height:

2.2 mm)
712 N
{72.6 kg}
101 N
{10.3 kg}
605 N
{61.7 kg}
13
Thickness of FL clutch thrust

washer
0.1
2.7
14
Thickness of R clutch thrust

washer
0.1
2.7
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)
TRANSMISSION
FH - 1ST CLUTCH
A: 1st clutch oil port

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

2. FH clutch
3. FH, 1st cylinder, idler gear (No. of teeth: 72)
4. 1st clutch
5. 1st gear (No. of teeth: 24)
6. Upper shaft
Unit: mm
No.
Check item
Clearance (F) between FH, 1st

shaft and bearing
Criteria
Tolerance
Standard
size
60
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
+0.030
+0.011
0
-0.015
-0.045
-0.011
Standard size
Tolerance
Repair limit
Thickness
1.7
0.05
1.5
Distortion
0.05
0.15
Friction plate
(FH clutch)
Thickness
2.2
0.08
1.75
Distortion
0.10
0.25
Friction plate
(1st clutch)
Thickness
2.2
0.08
1.8
Distortion
0.10
0.25
8
Separator plate
10
11

2.2 mm)
712 N
{72.6 kg}
101 N
{10.3 kg}
605 N
{61.7 kg}
12
Thickness of FH clutch thrust

washer
0.1
2.7
13
Thickness of 1st clutch thrust

washer
0.1
2.7
14
End play of FH gear
0.07 0.93
15
End play of 1st gear
0.23 1.37
10-22
(9)
Replace
HM300-1
TRANSMISSION
2ND - 3RD CLUTCH
A: 2nd clutch oil port

B: 3rd clutch oil port
1. 3rd gear (No. of teeth: 26)

2. 3rd clutch
3. 2nd, 3rd cylinder, idler gear (No. of teeth: 50, 46)
4. 2nd clutch
5. 2nd gear (No. of teeth: 46)

6. Lower shaft
10-24
HM300-1
TRANSMISSION
Unit: mm
No.
Check item
Clearance (F) between 2nd,

3rd shaft and bearing
Clearance (R) between 2nd,

3rd shaft and bearing
Separator plate
(3rd clutch)
10
11
12
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
55
+0.030
+0.011
0
-0.015
-0.045
-0.011
70
+0.030
+0.011
0
-0.015
-0.045
-0.011
Standard size
Tolerance
Repair limit
Thickness
1.7
0.05
1.5
Distortion
0.05
0.15
Thickness
2.0
0.05
1.8
Distortion
0.05
0.15
Friction plate
(3rd Clutch)
Thickness
2.2
0.08
1.75
Distortion
0.10
0.25
Friction plate
(2nd Clutch)
Thickness
3.2
0.08
2.75
Distortion
0.10
0.25
Friction plate
(2nd Clutch)
13

2.2 mm) (3rd clutch)
712 N
{72.6 kg}
101 N
{10.3 kg}
605 N
{61.7 kg}
14

3.8 mm) (2nd clutch)
1,274 N
{130 kg}
115 N
{11.7 kg}
1,088 N
{111 kg}
15
Thickness of 3rd clutch thrust

washer
0.1
2.7
16
Thickness of 2nd clutch thrust

washer
0.1
3.6
17
End play of 3rd gear
0.07 0.93
18
End play of 2nd gear
0.07 0.93
HM300-1
Replace
10-25
TRANSMISSION
DIFFERENTIAL LOCK CLUTCH
A: Lubricating oil port

B: Differential lock clutch oil port
1. Front output shaft
2. Front housing
3. Clutch hub (No. of teeth: 38)
4. Differential lock clutch
5. Carrier
6. Output gear (No. of teeth: 68)
10-26
(9)
7. Planetary gear (No. of teeth: 22)

8. Sun gear (No. of teeth: 44)
9. Ring gear (No. of teeth: 88)
10. Rear housing
11. Rear output shaft
HM300-1
TRANSMISSION
Unit: mm
No.
12
Check item
Clearance between front

housing and bearing
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
170
+0.040
+0.015
0
-0.025
-0.065
-0.015
13
Clearance between rear

housing and bearing
158.750
+0.068
+0.043
+0.025
0
-0.068
-0.018
14
Clearance between front

housing and bearing
140
0
-0.018
-0.020
-0.045
-0.045
-0.002
15
Clearance (F) between front

output shaft and bearing
80
+0.030
+0.011
0
-0.015
-0.045
-0.011
16
Clearance between carrier and

bearing
115
0
-0.015
-0.024
-0.059
-0.059
-0.009
17
Clearance (R) between front

75
+0.030
+0.011
0
-0.015
-0.045
-0.011
18

housing and bearing
140
0
-0.018
-0.036
-0.061
-0.061
-0.018
19

80
+0.030
+0.011
0
-0.015
-0.045
-0.011
Replace
Standard size
Tolerance
Repair limit
Thickness
2.0
0.05
1.8
Distortion
0.05
0.15
Thickness
3.2
0.10
2.75
Distortion
0.20
0.35
1,480 N
{151 kg}
440 N
{45 kg}
1,255 N
{128 kg}

sliding portion of front housing
90
+0.035
0
90.1
Width of seal ring groove of

front output shaft
3.0
+0.15
+0.10
2.3
Width
3.0
-0.01
-0.03
2.7
Thickness
3.7
0.12
3.3
20
Separator plate
21
22
23
Friction plate
3.2 mm)
Wear of seal ring

of front output
shaft
HM300-1
10-27
(9)
TRANSMISSION
OPERATION OF CLUTCHES
Clutch engaged (fixed)
The oil sent from the transmission valve passes
through the oil passage inside shaft (1), reaches
the back face of piston (6) and acts on piston (6).
When piston (6) is actuated, separator plate (2)
and friction plate (3) are pressed together, shaft
(1) and clutch gear (4) form one unit, and the
power is transmitted.
When this happens, the oil is drained from oil
drain hole (5), but the drain amount is less than
the amount of oil supplied, so there is no influence on the actuation of the clutch.
Clutch disengaged (free)

The oil sent from the transmission valve is shut
off, so the pressure of the oil acting on the back
face of piston (6) goes down.
Piston (6) is returned to its original position by
wave spring (7), and shaft (1) and clutch gear (4)
are separated.
When the clutch is disengaged, centrifugal force
is used to drain the oil at the back face of the piston through oil drain hole (5). This acts to prevent the clutch from being partially applied.
Oil drain hole (5) forms part of the structure

of only the 2nd and differential lock clutches.
10-28
HM300-1
TRANSMISSION
FORWARD 1ST
Operation
In the case of FORWARD 1st, FL clutch (3) and

1st clutch (11) are engaged. The power from the
torque converter is transmitted to input shaft (1),
and then transmitted to front and rear output
shafts (27) and (28).
FL clutch (3) and 1st clutch (11) hold each clutch
disc in position with the oil pressure applied to
the piston.
The power from the torque converter is transmitted from input shaft (1) through FL clutch (3),
goes to FL gear (5), and is then transmitted to
FH, 1st cylinder gear (8).
HM300-1
1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes
through 1st clutch (11), and goes from 1st gear
(12) to 2nd, 3rd cylinder gear (14). It then goes
through output gear (19), and is transmitted to
differential lock carrier (20).
When the differential lock switch is OFF, the
front output force passes from planet gear (24)
through sun gear (25), and is transmitted to front
output shaft (27). The rear output force passes
from planet gear (24) through ring gear (26),
and is transmitted to rear output shaft (28).
If the differential lock is ON, see FORWARD
2ND.
10-29
(9)
TRANSMISSION
FORWARD 2ND
Operation
In the case of FORWARD 2nd, FH clutch (10)
and 1st clutch (11) are engaged. The power
from the torque converter is transmitted to input
shaft (1), and then transmitted to front and rear
output shafts (27) and (28).
FH clutch (10) and 1st clutch (11) hold each
clutch disc in position with the oil pressure applied to the piston.
The power from the torque converter is transmitted from input shaft (1) to idler gear (2) and goes
to FH gear (9), passes through FH clutch (10),
and is then transmitted to FH, 1st cylinder gear
(8).
10-30
When the differential lock switch is ON, the
front output force passes from front housing (21)
through differential lock clutch (22) and clutch
hub (23), and is transmitted to front output shaft
(27). The rear output force passes from planet
gear (24) through ring gear (26), and is transmitted to rear output shaft (28).
If the differential lock is OFF, see FORWARD
1ST.
HM300-1
TRANSMISSION
FORWARD 3RD
Operation
In the case of FORWARD 3rd, FL clutch (3) and
2nd clutch (17) are engaged. The power from
the torque converter is transmitted to input shaft
(1), and then transmitted to front and rear output
FL clutch (3) and 2nd clutch (17) hold each
goes to FL gear (5), and is then transmitted
through FH, 1st cylinder gear (8) and idler gear
(13), and goes to 2nd gear (15).
HM300-1
2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd
clutch (17), and goes to 2nd, 3rd cylinder gear
(14). It then goes through output gear (19), and
is transmitted to differential lock carrier (20).
The diagram above shows the situation when
the differential lock is OFF.
For details of the actuation when the differential
lock is OFF, see FORWARD 1ST; for details of
the actuation when the differential lock is ON,
see FORWARD 2ND.
10-31
TRANSMISSION
FORWARD 4TH
Operation
In the case of FORWARD 4th, FH clutch (10)
and 2nd clutch (17) are engaged. The power
FH clutch (10) and 2nd clutch (17) hold each
The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2)
and FH gear (9), passes through FH clutch (10),
and is then transmitted through FH, 1st cylinder
gear (8) and idler gear (13), and is transmitted
to 2nd gear (15).
10-32
2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd
clutch (17), and goes to 2nd, 3rd cylinder gear
(14). It then goes through output gear (19), and
is transmitted to differential lock carrier (20).
the differential lock is ON.
see FORWARD 2ND.
HM300-1
TRANSMISSION
FORWARD 5TH
Operation
In the case of FORWARD 5th, FL clutch (3) and
3rd clutch (18) are engaged. The power from
the torque converter is transmitted to input shaft
(1), and then transmitted to front and rear output
FL clutch (3) and 3rd clutch (18) hold each clutch
the piston.
goes to FL gear (5), and is then transmitted
through FH, 1st cylinder gear (8) to 3rd gear
(16).
HM300-1
3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch
(18), and goes to 2nd, 3rd cylinder gear (14). It
then goes through output gear (19), and is transmitted to differential lock carrier (20).
see FORWARD 2ND.
10-33
TRANSMISSION
FORWARD 6TH
Operation
In the case of FORWARD 6th, FH clutch (10)
and 3rd clutch (18) are engaged. The power
FH clutch (10) and 3rd clutch (18) hold each
The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2)
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
3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch
(18), and goes to 2nd, 3rd cylinder gear (14). It
then goes through output gear (19), and is
transmitted to differential lock carrier (20).
the differential lock is ON.
see FORWARD 2ND.
HM300-1
TRANSMISSION
REVERSE 1ST
Operation
In the case of REVERSE 1st, R clutch (4) and
1st clutch (11) are engaged. The power from the
torque converter is transmitted to input shaft (1),
and then transmitted to front and rear output
R clutch (4) and 1st clutch (11) hold each clutch
the piston.
The power from the torque converter is transmitted from input shaft (1) through R clutch (4),
goes to R gear (6), is rotated in the opposite direction by R idler gear (7), passes through idler
gear (13), and is then transmitted to FH, 1st
cylinder gear (8).
HM300-1
see FORWARD 2ND.
10-35
TRANSMISSION VALVE
TRANSMISSION VALVE
ECMV clutch operation table

A.
B.
C.
D.
E.
F.
G.
H.
Differential lock clutch oil pressure detection port

FH clutch oil pressure detection port
1st clutch oil pressure detection port
FL clutch oil pressure detection port
R clutch oil pressure detection port
3rd clutch oil pressure detection port
2nd clutch oil pressure detection port
Lock-up clutch oil pressure detection port
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ECMV (for differential lock clutch)

ECMV (for FH clutch)
ECMV (for 1st clutch)
ECMV (for FL clutch)
ECMV (for R clutch)
ECMV (for 3rd clutch)
ECMV (for 2nd clutch)
ECMV (for lock-up clutch)
Seat
Last chance filter
ECMV
Speed
Range
F1
FL
F6
1st
2nd
3rd
O
O
O
O
F4
F5
F2
F3
FH
O
O
R1
R2
O
O
10-36
HM300-1
STRUCTURE, FUNCTION AND

ECMV (Electronic Control Modulation Valve)
A:
P:
T:
Dr:
P1:
P2:
To clutch
From pump
Drain
Drain
Clutch oil pressure detection port
Pilot oil pressure detection port
HM300-1
1. Connector for fill switch

2. Connector for proportional solenoid
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
10-37

ECMV FOR LOCK-UP CLUTCH

Outline
This valve acts to set the lock-up clutch oil pressure to the set pressure, and also to switch the
lock-up clutch.
It forms a modulation wave pattern, so the lockup clutch is engaged smoothly to reduce the
shock when shifting gear. In addition, it prevents
generation of peak torque in the power train. As
a result, it provides a comfortable ride for the operator and greatly increases the durability of the
power train.
10-38
(9)
Operation
During torque converter travel
When the transmission is in torque converter
travel, no current flows to proportional solenoid
(1).
Pressure control valve (3) drains the oil at clutch
port A through drain port Dr and cancels the
lock-up clutch.
When this happens, there is no oil pressure acting on oil pressure detection valve (4), so fill
switch (6) is OFF.
HM300-1

DURING DIRECT TRAVEL

(torque converter travel direct travel)
1. When filling
When the transmission is in direct travel (lockup), if electric current is applied to proportional
solenoid (1) by the electric signal, a hydraulic
force balancing with the force of the solenoid
acts on chamber B, and pressure control valve
spool (3) moves to the left. As a result, the
circuit between pump port P and clutch port A
opens, and oil starts to fill the clutch. When the
clutch is filled with oil, fill switch (6) is turned
ON.
HM300-1
2. Adjusting pressure
When electric current flows to proportional solenoid (1), the solenoid generates a propulsion
force proportional to the current. The pressure
is adjusted so that the total of this propulsion
force of the solenoid, the propulsion force of the
oil pressure at the clutch port, and the reaction
force of pressure control valve spring (2) is balanced.
To reduce the shock when shifting gear, the oil
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 converter.
10-39
(9)

ECMV FOR SPEED CLUTCH

Outline of ECMV
The ECMV (Electronic Control Modulation
Valve) consists of two components: the pressure
control valve and the fill switch.
Pressure control valve
The proportional solenoid receives the flow of
electricity sent from the transmission controller,
and the pressure control valve converts this into
hydraulic pressure.
Fill switch
This detects when oil has filled the clutch. It
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.
ECMV and proportional solenoid

There is one proportional solenoid installed to
each ECMV.
It generates propulsion as shown in the diagram below according to the command current
from the controller.
The propulsion generated by the proportional
solenoid acts on the pressure control valve
spool and generates oil pressure as shown in
the diagram below. In this way, the command
current is controlled and the propulsion force
varies to actuate the pressure control valve
and control the oil flow and 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
(9)
HM300-1

OPERATION OF ECMV
The ECMV is controlled by the command current
from the transmission controller to the proportional solenoid and the fill switch output signal.
The relationship between the ECMV proportional solenoid command current and the clutch
input pressure and fill switch output signal is as
shown in the diagram below.
1. When gear shifting (during draining)

(Range A in graph)
When no current is flowing to proportional solenoid (1), pressure control valve spool (3) drains
the oil at clutch port A through drain port Dr.
When this happens, there is no hydraulic force
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

to pressure control valve)
(Ranges B and C in graph)
When there is no oil inside the clutch, if electric
current is applied to proportional solenoid (1), a
hydraulic force balancing the force of the solenoid acts on chamber B, and pressure control
valve spool (3) moves to the left. As a result,
the circuit between pump port P and clutch port
A opens, and oil starts to fill the clutch. When
the clutch is filled with oil, fill switch (6) is turned
ON.
10-42
(9)
3. Adjusting pressure (Range D in graph)

When electric current flows to proportional solenoid (1), the solenoid generates a propulsion
force proportional to the current. The pressure
is adjusted so that the total of this propulsion
force of the solenoid, the propulsion force of the
oil pressure at the clutch port, and the reaction
force of pressure control valve spring (2) is balanced.
HM300-1

ECMV (Electronic Control

ECMV (Electronic
ModulationControl
Valve)
ECMV FOR DIFFERENTIAL LOCK

Operation
1. When differential lock switch is turned ON
OFF
When the differential lock switch is turned OFF,
there is no electric current flowing from the
controller to proportional solenoid (1) of the
ECMV, so the oil at clutch port A passes through
drain port Dr and is drained. As a result, the
force of the oil pressure at clutch port A goes
down and piston (2) is returned to its original
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
follows:
Front 1: Rear 2
HM300-1
2. When differential lock switch is turned OFF

ON
When the differential lock switch is turned ON, and
electric signal is sent from the controller to
proportional solenoid (1) of the ECMV, and oil starts
to fill clutch port A. As a result, piston (2) is actuated,
presses separator plate (3) and friction plate (4)
together, so carrier (6) and front output shaft (7) form
one unit and transmit the power.
The proportion of the torque at this point is as

follows:
Front 1: Rear 1
10-43
(9)

MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A: Drain (torque converter relief)

B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief oil pressure detection port
P2: Torque converter relief oil pressure detection
port
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
Unit: mm
No.
Check item
Clearance between main relief

valve and valve body
Clearance between torque converter relief valve and valve

body
Criteria
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
28
-0.035
-0.045
+0.013
0
0.035
0.058
0.078
22
-0.035
-0.045
+0.013
0
0.035
0.058
0.078
Standard size
8
Main relief valve spring (outside)
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
108
79.5
275 N
{28.0 kg}
104.8
261 N
{26.6 kg}
Main relief valve spring (inside)
108
79.5
326 N
{33.2 kg}
104.8
309 N
{31.5 kg}
10
Torque converter relief valve

spring
50
41
173 N
{17.6 kg}
48.5
164 N
{16.7 kg}
10-44
(9)
Replace
HM300-1

OUTLINE
Torque converter relief valve
The torque converter relief valve protects the torque
converter from abnormally high pressure. It is installed in the torque converter inlet port circuit to hold
the oil pressure in the torque converter inlet port circuit below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Operation of main relief valve

The oil from the hydraulic pump passes through
the filter and enters port A of the relief valve. It
then passes through orifice a of spool (6) and
enters chamber B.
When the oil from the pump fills the circuit, the
oil pressure starts to rise.
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
The oil relieved by the main relief valve flows
from port C into the torque converter, and at the
same time, passes through orifice b of spool (2)
and enters chamber D.
When the circuit leading to the torque converter
becomes filled with oil, the oil pressure starts to
rise.
As the oil pressure going to the torque converter

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
As the oil pressure in the circuit rises, the oil entering chamber B pushes piston (4). The reaction force compresses valve spring (7) and
moves spool (6) to the left to open the circuit between port A and port C.
When this happens, the oil at port A is relieved
to port C and flows from port C to the torque
converter.
The oil pressure at port A at this point is 2.55
MPa {26.0 kg/cm2} (engine at rated speed).
10-45
(9)
DRIVE SHAFT
DRIVE SHAFT
1. Drive shaft (right)

2. Front drive shaft
3. Drive shaft (left)
4. Center drive shaft
5. Rear drive shaft (front)
6. Rear drive shaft (rear)
10-46
(9)
Outline
The power from the engine goes from the output
shaft through front drive shaft (2), the transmission, and the front axle, and is transmitted by
right and left drive shafts (1) and (3).
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 sliding joints to absorb the change of angles and
lengths and transmit the power without damaging the parts even when the positions of the components change and impacts are given to the
machine.
HM300-1
AXLE
AXLE
FRONT
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
HM300-1
10-47
AXLE
CENTER
1. Center differential
2. Center axle housing
3. Brake
4. Final drive
5. Drain plug
10-48
HM300-1
AXLE
REAR
1. Drain plug
2. Rear differential
3. Rear axle housing
4. Final drive
HM300-1
10-49
DIFFERENTIAL
DIFFERENTIAL
FRONT
1.
2.
3.
4.
5.
Bevel gear (No. of teeth: 41)

Bevel pinion (No. of teeth: 13)
Limited slip differential
Side gear (No. of teeth: 24)
Pinion gear (No. of teeth: 12)
10-50
(9)
6.
7.
8.
9.
Shaft
Shaft
Disc
Plate
HM300-1
DIFFERENTIAL
Unit: mm
No.
10
Check item
Wear of coupling oil seal contact surface
11
12
Backlash between bevel gear

and pinion
HM300-1
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0
-0.087
94.9
90
0
-0.087
89.9
0.36 0.55 (in circumferential direction at outside diameter)
Repair or
replace
Adjust
10-51
DIFFERENTIAL
CENTER
1.
2.
3.
4.
5.
6.
7.

Disc
Plate
10-52
8.
9.
10.
11.
12.
13.
Shaft
Gear (No. of teeth: 27)
Shaft
Coupling
Shaft
Gear (No. of teeth: 27)
HM300-1
DIFFERENTIAL
Unit: mm
No.
14
Check item
15
Wear of coupling oil seal

contact surface
16

and pinion
HM300-1
Criteria
Remedy
Standard size
Tolerance
Repair limit
95
0
-0.087
94.9
90
0
-0.087
89.9
Repair or
replace
Repair or
replace
Adjust
10-53
DIFFERENTIAL
REAR
1.
2.
3.
4.
5.
6.
7.
8.

Plate
Disc
Shaft
10-54
HM300-1
DIFFERENTIAL
Unit: mm
No.
10
Check item
and pinion
HM300-1
Criteria
Standard size
Tolerance
90
0
-0.087
Remedy
Repair limit
89.9
Repair or
replace
Adjust
10-55
LIMITED SLIP DIFFERENTIAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Washer
Disc
Plate
Pressure ring
Bevel gear
Side gear
Pinion gear
Shaft
Case
Cover
Shaft
10-56
(9)
Operation of limited slip differential

The power transmitted from the transmission goes
from bevel gear (5) to case (9), pressure ring (4),
shaft (8), pinion gear (7), side gear (6), and is then
divided and sent to left and right shafts (11). A brake
mechanism consisting of disc (2) and plate (3) is assembled at the rear face of side gear (6), and the
brake torque is generated in proportion to the torque
transmitted from pressure ring (4) to shaft (8).
In order for this brake torque to act to suppress the
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 suppressed.
HM300-1
Unit: mm
No.
Check item
Criteria
Standard size
Plate thickness
Remedy
Tolerance
Repair limit
0.02
2.9
+0.04
-0.03
2.95
3
3.1
Disc thickness
Clearance between disc and

plate (Total on both sides)
Washer thickness
0.2 - 0.75
Replace
4
0.05
3.8
4.1
5
End play of side gear in axial

direction (Each side)
0.15 - 0.35
Backlash between case and

plate
0.4
Backlash between side gear

and disc
0.13 0.36
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 uniformly to the left and right by the side gear. Under 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 surface of the side gear.
10-58
(9)
HM300-1
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 surface.
The power from the transmission is divided uniformly 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 supplied 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 actuated.
Difference in wheel drive force for each type of differential when wheel on one side is slipping
Wheel drive force (taken as 1 for wheel
that is slipping)
Slipping
wheel
Locked
wheel
Total
(proportional)
Limited slip
differential
2.64
3.64 (1.82)
Normal
differential
2 (1)
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)
FINAL DRIVE
FINAL DRIVE
FRONT
1.
2.
3.
4.
5.
6.
7.
Axle shaft
Ring gear (No. of teeth: 66)
Planetary gear (No. of teeth: 23)
Planetary carrier
Sun gear (No. of teeth: 18)
Drain plug
Brake
10-62
(9)
HM300-1
FINAL DRIVE
Unit: mm
No.
Check item
Backlash between planetary

gear and sun gear

gear and ring gear
10
Curvature of drive shaft
11
Thickness of spacer
Criteria
Remedy
0.17 0.41
Replace
12
Wear of outside diameter of

portion of ring gear hub
inserted into bearing
13

portion of axle tube inserted
into bearing
0.20 0.55
Repair limit: 0.7TIR
Repair or replace
Standard size
Tolerance
Repair limit
14
0.1
13.5
170
+0.040
+0.015
170
Replace
Repair
14
Clearance between shaft (outside diameter) and bushing
Standard
size
65
HM300-1
-0.030
-0.055
140
Tolerance
139.83
Shaft
Hole
Standard
clearance
0
-0.013
+0.337
+0.251
0.251
0.350
Clearance
limit
Replace
0.4
10-63
(9)
FINAL DRIVE
CENTER
1.
2.
3.
4.

6. Drain plug
7. Brake
Axle shaft
Ring gear (No. of teeth: 66)
Planetary gear (No. of teeth: 23)
Planetary carrier
Unit: mm
No.
Check item
Criteria

gear and sun gear
0.17 0.41

gear and ring gear
0.20 0.55
10
11
Thickness of spacer
Remedy
Replace
12

13

into bearing
Repair or replace
Standard size
Tolerance
Repair limit
28
0.1
27.5
170
+0.040
+0.015
170
Replace
Repair
10-64
(9)
140
-0.030
-0.055
139.83
HM300-1
FINAL DRIVE
REAR
1. Axle shaft
2. Ring gear (No. of teeth: 66)
3. Planetary gear (No. of teeth: 23)
4. Planetary carrier
6. Drain plug
Unit: mm
No.
Check item
Criteria

gear and sun gear
0.17 0.41

gear and ring gear
0.20 0.55
10
Thickness of spacer
Remedy
Replace
11

12

into bearing
Repair or replace
Standard size
Tolerance
Repair limit
28
0.1
27.5
170
+0.040
+0.015
170
Replace
Repair
HM300-1
140
-0.030
-0.055
139.83
10-65
(9)
FINAL DRIVE
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
(9)
HM300-1
STEERING COLUMN
STEERING COLUMN
1.
2.
3.
4.
5.
6.
Steering shaft
Steering column
Lock lever
Yoke
Join shaft
Steering valve
HM300-1
10-67
BRAKE PIPING
BRAKE PIPING
10-68
HM300-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
BRAKE PIPING
Slack adjuster (Front)

Shuttle valve
Slack adjuster (center)
Proportional reducing valve
Accumulator (for center)
Accumulator (for front)
Parking brake solenoid
Brake system tank
Accumulator charge valve
Brake valve
Brake filter
HM300-1
10-69
4
BRAKE VALVE
BRAKE VALVE
1.
2.
3.
4.
5.
6.
Pilot piston
Rod
Lower cylinder
Spool
Upper cylinder
Spool
10-70
A.
B.
C.
D.
E.
To center brake
To front brake
To brake system tank
From front accumulator
From center accumulator
HM300-1
OPERATION
Upper portion
When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and
actuates the center brake cylinder.
BRAKE VALVE
Applying brake when upper valve fails

Even if there is leakage of oil in the upper piping,
spool (5) is moved down mechanically when
pedal (1) is depressed, and the lower portion is
actuated normally.
The upper portion brake is not actuated.
Applying brake when lower valve fails
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 operating 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 cylinder is held and the brake remains applied.
HM300-1
10-71
(9)
Lower portion
When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the front brake cylinder at the
same time, so the pressure in the circuit
between port B and port D rises. The oil entering
port J from orifice f of spool (5) pushes up spool
(5) by the same amount that spool (3) moves,
and shuts off port B and port D. Drain port b is
closed, so the oil entering the brake cylinder is
held, and the brake is applied.
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
portion is balanced with the pressure in the
space in the upper portion. When spools (3) and
(5) move to the end of their stroke, the circuits
between ports A and C and between ports B and
D are fully opened, so the pressure in the space
in the upper and lower portions and the pressure
in the left and right brake cylinders is the same
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
4
BRAKE VALVE
Brake released
Upper portion
When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the brake system tank
return circuit to release the center and rear
brakes.
Lower portion
When the pedal is released, spool (3) in the
upper portion moves up. At the same time, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5)
up. Drain port b is opened and the oil from the
brake cylinder flows to the brake system tank
return circuit to release the front brake.
HM300-1
ACCUMULATOR CHARGE VALVE
ACC.
P.
PP.
T.
To accumulator
From hydraulic pump
To accumulator
To brake system tank
HM300-1
Function
The accumulator charge valve is actuated to
maintain the oil pressure from the pump at the
specified pressure and to store it in the accumulator.
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.
10-73
4
(9)
1. \Main relief valve (R3)

2. Valve body
3. Relief valve (R1)
10-74
4. Relief valve (H1)

5. Filter
6. Filter
HM300-1
OPERATION
1. When no oil is being supplied to accumulator
(cut-out condition)
The pressure at port B is higher than the set
pressure of the relief valve (R1), so piston (8) is
forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so 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 oil tank pressure. The
oil from the pump enters port P, pushes spool
(15) to the right at a low pressure equivalent to
the load on spring (14).
It also passes through orifices (17), (18) and
(16), and flows to the oil tank.
HM300-1
2. When oil supplied to accumulator

1) Cut-in condition
When the pressure at port B is lower than the set
pressure of the relief valve (R1), piston (8) is
pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into
tight contact, and port C and port T are shut off.
is also shut off from port T, so the pressure rises,
and the pressure at port P also rises in the same
way.
When the pressure at port P goes above the
pressure at port B (accumulator pressure), the
supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area)
of orifice (17) and the pressure difference
(equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
10-75
(9)
2) When cut-out pressure is reached

When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve
(R1), poppet (6) separates from valve seat (7),
so an oil flow is generated and the circuit is relieved.
When the circuit is relieved, a pressure difference 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.
is connected to port C of the relief valve (R1), so
the pressure becomes the brake oil tank pressure.
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
3. Main relief valve (R3)

If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball (11)
is pushed up and the oil flows to the brake oil
tank circuit, so this set the maximum pressure in
the brake circuit and protects the circuit.
HM300-1
ACCUMULATOR
ACCUMULATOR
1.
2.
3.
4.
Valve
Top cover
Cylinder
Piston
Function
The accumulator is installed between the accumulator 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)
SLACK ADJUSTER
SLACK ADJUSTER
1.
2.
3.
4.
5.
Breather
Cylinder
Check valve
Spring
Piston
A. Inlet port
B. Outlet port
Unit: mm
No.
Check item
Clearance
between body and
piston
Front
Center
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
55
-0.030
-0.076
+0.074
0
0.030
0.150
0.25
55
-0.030
-0.076
+0.074
0
0.030
0.150
0.25
Standard size
Slack adjuster
spring
Front
Center
10-78
(9)
Replace
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
230
88
118 N
{12 kg}
198
60
39.2 N
{4.0 kg}
HM300-1
Specifications
Piston actuation oil pressure:
0.01 + 0.01 MPa {0.1 + 0.1 kg/cm2}
Check valve cracking pressure:
0.93 0.05 MPa {9.5 0.5 kg/cm2}
Check valve closing pressure:
0.6 0.05 MPa {6.0 0.5 kg/cm2}
SLACK ADJUSTER
If the brake pedal is depressed further, and the

oil pressure discharged from the brake valve
goes above to set pressure, check valve (3)
opens and the pressure is applied to port C to
act as the braking force.
Therefore, when the brake is applied, the time
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 returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil discharged from the brake valve flows from port P
of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
2. When brake pedal is released

When the brake is released, piston (4) returns
because of lowering of the brake oil pressure by
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)
BRAKE
BRAKE
FRONT
1.
2.
3.
4.
5.
6.
7.
Stud bolt
Cylinder
Brake piston
Disc
Plate
Hub gear (No. of teeth: 96)
Outer gear (No. of teeth: 148)
10-80
(9)
HM300-1
BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard backlash
0.22 0.56
Repair limit
1.1
0.17 0.52
1.1
Standard size
2.4
5.2
6.9
Standard distortion
Max 0.45
Repair limit
2.15
4.7
5.1
Repair limit
0.7
Max 0.50
0.7
Assemble thickness of plate

and disc
Standard size
61.2
Repair limit
56.7
Wear of lip contact surface of

oil seal ring
401
400.9
Backlash between outer gear

and plate
Backlash between hub gear

and plate
Thickness of plate
4
5
Thickness of disc
Thickness of damper
Distortion of disc friction surface
Distortion of plate and damper

friction surface
8
9
HM300-1
Replace
Correct or
replace
10-81
(9)
BRAKE
CENTER
1.
2.
3.
4.
5.
6.
7.
Bolt
Cylinder
Brake piston
Disc
Plate
Hub gear (No. of teeth: 96)
Outer gear (No. of teeth: 148)
10-82
HM300-1
BRAKE
Unit: mm
No.
Check item
Backlash between outer gear

and plate
Backlash between hub gear

and plate
Thickness of plate
Criteria
Remedy
Standard backlash
Repair limit
0.22 0.56
1.1
0.17 0.52
1.1
Standard size
Repair limit
2.4
2.15
Thickness of disc
5.2
4.7
Thickness of damper
6.9
5.1
Distortion of disc friction surface
Standard distortion
Repair limit
Max 0.45
0.7
Distortion of plate and damper

friction surface
Max 0.50
0.7
Assemble thickness of plate

and disc
Standard size
Repair limit
76.4
70.9
Wear of lip contact surface of

oil seal ring
401
400.9
HM300-1
Replace
10-83
(9)
BRAKE
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 presses 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 reduces 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 releases the brake.
10-84
(9)
HM300-1
PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter
2. Connector
3. Solenoid assembly
A. To brake valve
P. From accumulator
T. To brake system tank
HM300-1
Function
The proportional reducing valve is a valve used
for retarder control. It is installed between the
brake valve and the system tank in the brake circuit.
It varies the discharge pressure of the pressure
oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
10-85
4
(9)
BRAKE SYSTEM TANK
BRAKE SYSTEM TANK
1.
2.
3.
4.
Plug
Return tube
Valve
Suction tube
A. From accumulator charge valve, brake valve

B. To transmission
C. To hydraulic pump
10-86
4
HM300-1
PARKING BRAKE
PARKING BRAKE
1. Spring cylinder
2. Parking brake disc
3. Parking brake caliper
10-88
Function
The parking brake is the disc type and installed
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 oscillation hitch.
The disc is installed to the oscillation hitch shaft
output coupling and rotates together with the
coupling.
HM300-1
PARKING BRAKE
Unit: mm
No.
4
Check item
Criteria
Remedy
Standard size
Repair limit
0.4
0.8
Repair or
replace
Face runout of disc
Rebuid
(Thickness of
disc must not be
under 20 mm)
Min. 20
5
Thickness of disc
25
Max. 20
Replace
Thickness of pad (including

thickness of plate)
Clearance between blade and

brake assembly
20
Standard dimension of blade
Tolerance
22.3
0
-0.3
Standard
dimension of
brake assembly
23
HM300-1
10
Tolerance
Standard
clearance
Clearance
limit
Repair or
replace
1.0 0.4
1.5
+0.4
-0.1
10-89
(9)
PARKING BRAKE CALIPER
PARKING BRAKE CALIPER
1.
2.
3.
4.
5.
Adjuster
Piston
Piston shaft
Pad
Caliper
10-90
Outline
A piston guide is installed to caliper (5). Piston
(2) and piston shaft (3) are inserted, and the rotation of piston shaft (3) moves piston (2) in the
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 position.
HM300-1
SPRING CYLINDER
SPRING CYLINDER
1.
2.
3.
4.
5.
6.
Outer spring
Inner spring
Piston
Cylinder
Boot
Rod
HM300-1
OUTLINE
The oil pressure from the parking brake solenoid
valve pushes the spring and releases the parking brake.
When the engine is stopped, the parking brake
is applied by springs (1) and (2), so the machine
is prevented from moving.
10-91
PARKING BRAKE SOLENOID
PARKING BRAKE SOLENOID
1. Solenoid valve assembly

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

Arm
Lateral rod
Dust cover
Unit: mm
No.
Check item
Clearance between pin and

bushing

bushing
HM300-1
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
45
-0.025
-0.064
+0.039
0
0.025
0.103
0.3
45
-0.025
-0.064
+0.039
0
0.025
0.103
0.3
Replace
10-95
SUSPENSION
REAR
10-96
HM300-1
1.
2.
3.
4.
5.
6.
SUSPENSHION
Arm
Equalizer bar
Lateral rod (center)
Spring
Rear suspension
Lateral rod (rear)
10-98
HM300-1
SUSPENSHION
Unit: mm
No.
Check item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
60
-0.030
-0.076
+0.046
0
0.030
0.122
0.3

bushing
Standard
size
Remedy
Outline
The suspension supports the weight of the machine. It also reduces any impact caused by unevenness in the road surface and provides a
comfortable ride for the operator. By ensuring
that all the tires are always in contact with the
road surface, it maintains the stability of the machine, and also fulfills the operating performance by ensuring that the machine can carry out
acceleration, braking, and turning.
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.
Replace
2. Center, rear suspension

The center axle and rear axle are both fixed to arms.
The center axle is joined to the equalizer bar through
a spring, and the rear axle is joined through the rear
suspension cylinder. The arm and equalizer bar oscillate in accordance with the condition
of the road surface to keep the wheels in contact with
the road surface.
The main frame and arm are connected by a lateral
rod and receive the lateral load.
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
SUSPENSION CYLINDER
SUSPENSION CYLINDER
1.
2.
3.
4.
5.
6.
Feed valve
Oil level valve
Flange
Rod
Cylinder
Piston
10-100
HM300-1
SUSPENSION CYLINDER
Unit: mm
No.
Check item
Clearance between piston rod

and bushing
Clearance between cylinder

and wear ring
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
110
-0.036
-0.090
+0.235
+0.060
0.096
0.325
0.4
150
0
-0.21
+0.100
0
0 0.22
0.8
Replace
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
ball (6), and is sent to chamber (1) through only
orifice (5), so the flow of oil passing through the
orifice is controlled so that it is less than during
retraction.
In this way, the amount of oil returning to chamber (1) is restricted to provide a shock absorbing effect.
HM300-1
1.
2.
3.
4.
5.
6.
Oil chamber
Nitrogen gas chamber
Cavity
Orifice
Orifice
Check ball
10-101
(9)
OSCILLATION HITCH
OSCILLATION HITCH
1.
2.
3.
4.
5.
6.
Steering cylinder
Front frame
Center drive shaft
Rear frame
Pin
Hitch frame
10-102
7.
8.
9.
10.
11.
Disc
Coupling
Shaft
Coupling
Pin
HM300-1
10-104
OSCILLATION HITCH
HM300-1
OSCILLATION HITCH
Unit: mm
No.
12
Check item
Criteria
Standard shim thickness
Remedy
2
1
13
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
14
Clearance between bushing

and front frame
110
-0.036
-0.090
+0.054
0
0.036
0.144
15
Clearance between shaft and

bushing
80
-0.030
-0.049
+0.046
0
0.030
0.095
0.5
16

bearing
80
-0.030
-0.049
0
-0.015
0.015
0.049
0.5
17

bushing
80
-0.030
-0.049
+0.046
0
0.030
0.095
0.5
18
Clearance between front frame

and shaft
80
-0.030
-0.049
+0.046
0
0.030
0.095
19
20
Clearance between bushing

and pin
80
-0.030
-0.049
+0.046
0
0.030
0.095
0.5
21

bearing
80
-0.030
-0.049
0
-0.015
0.015
0.049
0.5
22
Clearance between front frame

and bushing
95
+0.089
+0.054
+0.054
0
-0.089
0
23
Clearance between hitch frame

and bearing
120
0
-0.015
0
-0.035
-0.035
0.015
24

and bearing
300
0
-0.052
0
-0.035
-0.035
0.052
25
Clearance between rear frame

and bearing
420
0
-0.045
-0.017
-0.080
-0.080
0.028
26

and retainer
400
-0.018
-0.075
+0.057
0
0.018
0.122
27

and bearing
380
0
-0.040
-0.016
-0.073
-0.073
0.024
28

and hitch frame
280
-0.056
-0.108
0
-0.035
0.031
0.108
29

and bearing
150
0
-0.018
-0.012
-0.052
-0.006
0.013
30
Outline
The front frame and the rear frame are connected by the oscillation hitch.
Front frame (2) is connected with bearings and
pins (5) and (11); rear frame (4) is connected
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articulate and oscillate.
HM300-1
Replace
In addition, the output from the transmission is

transmitted from center drive shaft (3) to coupling (10). It is then transmitted from coupling
(8) through the rear drive shaft to the rear axle.
10-105
(9)
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
DUMP BODY CONTROL
DUMP BODY CONTROL
1.
2.
3.
4.
Dump control lever

Hoist valve
EPC valve
Steering, hoist control pump
(SAR(3)63+63+(1)6)
5. Hoist cylinder
6. Body positioner sensor
7. Pilot check valve
HM300-1
Function
This control is carried out by the body position
sensors. The body position sensor senses the
position of the dump body and the retarder controller (brake controller: E-SPEC) controls it.
The signal from the dump control lever is controlled by the retarder controller (Brake controller: 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.
10-107
4
HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1.
2.
3.
4.
5.
6.
7.
Hydraulic oil filter

Breather
Oil level gauge
Drain plug
Bypass valve
Element
Strainer
10-108
4
HM300-1
FLOW AMP VALVE
FLOW AMP VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Valve
Relief Valve
Orifice
Spring
Pin
Valve
Valve
Plug
Valve
Spool
Valve body
Stopper
HM300-1
CL.
L.
P.
PP.
HP.
LS.
HT.
T.
EF.
R.
CR.
To steering cylinder
To steering valve
To steering valve
From steering valve
From hydraulic pump
From steering valve
From hoist valve
To steering valve
To hoist valve
From steering valve
To steering cylinder
Outline
The flow amp valve consists of the directional
valve, amplifying stage, priority valve, relief
valve, pressure control valve, and suction valve.
It amplifies the oil flow sent from ports L and R of
the steering unit by the specified ratio. The amplified oil then goes from ports CL and CR of the
flow amp valve and flows to the steering cylinder.
The amplified oil flow is proportional to the
amount the steering wheel is turned.
10-109
FLOW AMP VALVE
Operation
Operation
1. At neutral
Port P of steering unit (7) is closed and the flow
amp valve is closed at chamber M of pressure
control valve (3).
Ports L, R, and T of steering unit (7) are connected to each other, so the oil passes through port
T of the flow amp valve and is drained to the hydraulic tank.
By connecting in this way, directional valve (6)
is always held at the neutral position by the
springs on both sides. For this reason, at the
neutral position, the reaction or impact from the
steering cylinder is not transmitted to steering
unit (7).
10-110
For priority valve (2) also, the oil is drained from

relief valve (1).
Before starting, priority valve (2) is pushed
strongly to the left by the spring, so in reality,
port EF of the flow amp valve is almost closed.
At the same time as the engine starts, oil flows
to port HP of the flow amp valve and then flows
to port P of steering unit (7). At the same time,
the pilot pressure that is connected to port PP
suddenly rises. As a result of balancing with
the spring and moving to the right, port EF opens
and the oil flows to the hoist piping.
HM300-1
2. When turning
When steering unit (7) is actuated, the oil sent
from port P of priority valve (2) passes through
ports P and L of steering unit (7) and enters port
L of directional valve (6).
At the same time, oil from priority valve (2) also
enters chamber M of pressure control valve (3).
When the oil entering directional valve (6) rises
to a pressure greater than the force of the
spring, it pushes the spool to the right, and enters chamber C of pressure control valve (3).
When it rises to a pressure greater than the
force of the spring in chamber C also, it pushes
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 steering 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
FLOW AMP VALVE
The oil at the steering cylinder head end goes

out from suction valve (5). It then goes from port
CR of directional valve (6) through check valve
(4) and is drained to the hydraulic tank from port
HT of the flow amp valve.
If there are rocks on the road or the the road surface is uneven, and any abnormal external force
is applied to the tires and steering cylinder, relief
valves (8) and (9) of suction valve (5) open at a
pressure of 29.1 MPa {285.5 kg/cm2}, so the oil
passes through directional valve (6) and is
drained to the hydraulic tank.
10-111
(9)
STEERING VALVE
STEERING VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cover
Drive shaft
Valve body
Center pin
Bearing
Spool
Centering spring
Sleeve
Stator
Rotor
Lower cover
10-112
(9)
L.
LS.
P.
R.
T.
To flow amp valve

To flow amp valve
From flow amp valve
To flow amp valve
To flow amp valve
HM300-1
Outline
The orbit-roll valve is connected directly to the
steering wheel shaft. If the steering wheel is operated, the orbit-roll valve operates the steering
valve by using the oil from the PPC pump as the
pilot pressure. Then, the oil from the steering
pump is sent to the right or left steering cylinder
through the steering valve to change the travel
direction of the machine.
The orbit-roll valve, broadly speaking, consists
of the following components: rotary type spool
(9) and sleeve (8), which have the function of selecting the direction, and the Girotor set (a combination of rotor (5) and stator (10)), which acts
as hydraulic motor during normal steering operations, and as a hand pump (in fact, the operating force of the steering wheel is too high, so it
cannot be operated) when the steering pump or
engine have failed and the supply of oil is
stopped.
HM300-1
STEERING VALVE
Structure
Spool (9) is connected to the drive shaft of the
steering wheel, and is connected to sleeve (8)
by center pin (7) (this is not touching the spool
when the steering wheel is at the neutral position) and centering spring (2).
Drive shaft (3) is meshed at the top with center

pin (7) and forms one unit with sleeve (8). The
bottom is meshed with the spline of rotor (5) of
the Gerotor set.
Valve body (4) has five ports. These are connected to the pump circuit, tank circuit, steering
cylinder head end, bottom end, and flow amp
valve pilot end. In addition, the port at the pump
end and the port at the tank end are connected
by the check valve inside the body. If there is
any failure in the pump or engine, this check
valve acts to suck in oil directly from the tank.
10-113
(9)
STEERING VALVE
CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with

the sleeve ports used to connect the suction and
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
oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90, the condition
changes to the condition shown in diagram
above right. In this case, ports 1, 2, and 3 are
the suction ports, and are connected to ports i,
k, and c. Ports 5, 6, and 7 are discharge ports,
and are connected to ports d, f, and h.
10-114
(9)
Suctiion /
discharge port
SBW00727
In this way, the ports of the Girotor acting as

delivery ports are connected to ports which are
connected to the end of the steering cylinder.
The ports acting as suction ports are connected
to the pump circuit.
Adjusting delivery in accordance with angle of
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.
HM300-1
STEERING VALVE
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 cylinder. 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 pressure 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 variation a) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
HM300-1
10-115
4
STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No.
Check item

and bushing
Criteria
Shaft
Hole
Standard
clearance
Clearance
limit
70
-0.030
-0.104
+0.271
+0.075
0.105
0.375
0.675
+0.174
+0.100
1.0
+0.174
+0.100

support shaft and bushing
65

bottom support shaft and
bushing
65
Replace
1.0
Standard size
Tolerance
Repair limit
110
+0.15
+0.05
Cylinder bore
10-116
Tolerance
Standard
size
Remedy
HM300-1
HOIST VALVE
HOIST VALVE
10-118
HM300-1
T:
P:
A1:
B1:
PA:
PB:
T2:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
HOIST VALVE
To tank
From flow amp
To hoist cylinder bottom
To hoist cylinder head
From EPC valve (Pressurized side for lowering and floating operation)
From EPC valve (Pressurized side for raising operation)
To tank (Via pilot check valve)
Body
Spool
Retainer
Spring (RAISE)
Relief valve
Spring (FLOAT)
Spring (LOWER)
Retainer
Retainer
Retainer
Check valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
x O.D.
Installed
length
Installed
load
Free
length
Installed
load
49.4 x 12.8
4.2
259 N
(26.4 kg)
233 N
{23.8 kg}
13 Check valve spring
32.7 x 10.9
24.5
44 N
{4.5 kg}
40 N
{4.1 kg}
14 Spool return spring
51.3 x 34.5
50
156 N
{15.9 kg}
140 N
{14.3 kg}
34.2 x 36.0
32
124 N
{12.7 kg}
112 N
{11.4 kg}
73.0 x 31.0
53
1005 N
{102.6 kg}
905 N
{92.3 kg}
12 Relief valve poppet spring
HM300-1
Replace spring
if damaged or
deformed
10-119
HOIST VALVE
OPERATION
1. Hoist valve at HOLD position
The oil from the flow amp enters port C. The passage to the hoist cylinder is blocked by hoist
spool (2), so the oil is drained from tank D to the
tank.
10-120
4
The ports to the hoist cylinder are blocked at

both the bottom end and head end, so the hoist
cylinder is held in position.
HM300-1
HOIST VALVE
2. Hoist valve at RAISE position
When the hoist lever inside the cab is operated

to the RAISE position, hoist spool (2) is moved
to the left by the solenoid valve.
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
At the same time, the return oil from the head

end flows from port B to port D, and flows to the
tank circuit.
10-121
4
(9)
HOIST VALVE
3. Hoist valve at FLOAT position

to the FLOAT position, hoist spool (2) is moved
to the right by the solenoid valve. As a result,
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 cylinder. Oil also flows from chamber C to chamber
D, and then flows to the brake oil cooler circuit.
10-122
4
The bottom end and head end of the hoist cylinder are connected inside the hoist valve, so the
hoist cylinder is placed in the free condition.
HM300-1
HOIST VALVE
4. Hoist valve at LOWER position

from the FLOAT position to the LOWER position,
hoist spool (2) is moved further to the right from
the FLOAT position by the solenoid valve. As a
result, the oil flows from chamber C, pushes
open check valve (11), and enters chamber B.
The oil from chamber B enters the head end of
the hoist cylinder, retracts the cylinder, and lowers the dump body.
HM300-1
At the same time, the return oil from the head

end of the hoist cylinder flows from chamber A to
chamber H.
When the dump body is lowered, the output
pressure of the solenoid valve rises and becomes greater than the cracking pressure of the
pilot check valve. As a result, the return oil from
chamber H returns to the tank through two lines:
one from chamber D to the tank, and the other
from chamber E to the tank.
10-123
4
(9)
EPC VALVE
EPC VALVE
1.
2.
3.
4.
A.
B.
P1.
T1.
T2.
Manual operation button

Solenoid assembly
Relief valve
Solenoid assembly (EPC)
To hoist valve
From hoist valve
From hydraulic pump
To hydraulic tank
To hydraulic tank
10-124
(4
9)
Function
With the EPC valve, the oil from the hydraulic
pump is controlled by the retarder controller
(Brake controller: E-SPEC). It is then sent to the
spool of the hoist valve, and switches the pilot
pressure to control the hoist valve.
HM300-1
PILOT CHECK VALVE
PILOT CHECK VALVE
1.
2.
3.
4.
5.
Body
Check valve
Retainer
Spring
Cover
A. From hoist valve

B. To hydraulic tank
P.P.From EPC valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
6
spring
HM300-1
Repair limit
Free length
x O.D.
Installed
length
Installed
load
Free length
Installed
load
126.3 x 48
62
619.8 N
{63.2 kg}
558 N
{56.9 kg}
Replace spring if
damaged or
deformed
10-124-1
4
HOIST CYLINDER
HOIST CYLINDER
Unit: mm
No.
Check item

and bushing
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
120
-0.036
-0.123
+0.277
+0.062
0.098
0.400
0.700

and bushing
80
-0.030
-0.104
+0.271
+0.061
0.091
0.375
0.675

support pin and bushing
60
+0.004
-0.019
1.0

support pin and bushing
60
+0.004
-0.019
1.0
HM300-1
Replace
10-125
(9)
HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING, HOIST AND PILOT PUMP
SAR(3) 63+63+(1)6
Unit: mm
No.
Check item
Criteria
Model
Side clearance
Standard clearance
Clearance limit
0.10 0.15
0.19
0.10 0.15
0.19
0.060 0.149
0.20
0.06 0.144
0.20
SAR(3)-63
SAR(3)-63
SAR(1)-6
Clearance between inside

diameter of plain bearing and
outside diameter of gear shaft
SAR(3)-63
SAR(3)-63
Model
Depth for knocking in pin
SAR(3)-63
SAR(1)-6
Rotating torque of spline shaft
Discharge amount
Oil: EO10-CD
Oil temperature: 4555C
SAR(1)-6
(9)
Tolerance
14
0
-0.5
10
0
-0.5
Delivery Standard
Rotating
pressure delivery
speed
{MPa
amount
(rpm)
(kg/cm2)} (l/min)
SAR(3)-63
SAR(3)-63
10-126
Standard size
Repair limit
8.7 20.7 Nm {0.9 2.1 kgm}
Model
Replace
SAR(1)-6
SAR(3)-63
Remedy
2,500
20.6
{210}
Delivery
amount limit
(l/min)
145.1
134.0
13.2
12.6
HM300-1
HYDRAULIC PUMP
TORQUE CONVERTER, TRANSMISSION AND FRONT BRAKE COOLING PUMP

SAR(3) 90
Unit: mm
No.
Check item
Side clearance

Discharge amount
Oil: EO10-CD
Criteria
Model
Standard clearance
Clearance limit
SAR(3)90
0.13 0.18
0.21
SAR(3)90
0.06 0.149
0.20
Standard size
Tolerance
Repair limit
14
0
-0.5
Replace
6.9 11.8 Nm {0.7 1.2 kgm}
Model
SAR(3)90
HM300-1
Remedy
Delivery Standard
Rotating
pressure delivery
speed
{MPa
amount
(rpm)
(kg/cm2)} (l/min)
Delivery
amount limit
(l/min)
2.9
{30}
192.7
2,500
208.6
10-127
(9)
HYDRAULIC PUMP
BRAKE COOLING AND BRAKE PUMP

SAR(3)80+(1)18
Unit: mm
No.
Check item
Criteria
Model
Side clearance
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
SAR(3)80
SAR(1)18

SAR(3)80
0.06 0.149
SAR(1)18
0.06 0.144
Standard size
Tolerance
Repair limit
14
0
-0.5
0.20
Replace
3
4
5
10
8.9 16.7 Nm {0.9 1.7 kgm}
Model
Discharge amount
Oil: EO10-CD
Delivery Standard
Rotating
pressure delivery
speed
{MPa
amount
(rpm)
(kg/cm2)} (l/min)
Delivery
amount limit
(l/min)
2.9
{30}
200
20.6
{210}
40.4
36.3
SAR(3)80
2,500
SAR(1)18
10-128
(9)
HM300-1
HYDRAULIC PUMP
EMERGENCY STEERING PUMP

SBL(1)26
Unit: mm
No.
1
Check item

Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
0.060 0.119
0.20
Side clearance
Criteria
Standard size
Tolerance
Repair limit
10
0
-0.5
Discharge amount
Oil: EO10-CD
HM300-1
Replace
2.0 4.9 Nm {0.2 0.5 kgm}

Rotating
speed
(rpm)
Delivery
pressure
{MPa
(kg/cm2)}
Standard
delivery
amount
(l/min)
Delivery
amount limit
(l/min)
3,500
20.6
{210}
67.6
62.4
10-129
(9)
CAB TILT
CAB TILT
1.
2.
3.
4.
5.
Tilt stopper bar

Tilt cylinder (if equipped)
Breather
Adapter
Pin
10-130
4
HM300-1
AIR CONDITIONER
AIR CONDITIONER
1.
2.
3.
4.
5.
6.
Air conditioner unit

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

Evaporator
Heater core
Blower motor
Hot water inlet port
Hot water outlet port
Refrigerant gas inlet port
Refrigerant gas outlet port
Dehumidified water drain port
10-132
HM300-1
AIR CONDITIONER
RECEIVER DRYER
1.
2.
3.
4.
Body
Sight glass
Dryer
Dryer
HM300-1
10-133
AIR CONDITIONER
CONDENSER
1. Fin
2. Tube
A. Refrigerant gas inlet port
B. Refrigerant gas outlet port
10-134
HM300-1
AIR CONDITIONER
COMPRESSOR
1. Case
2. Clutch
A. Suction service valve
B. Discharge service valve
HM300-1
10-135
HEARTER
HEARTER
10-135-1
(11)
HM300-1
HM300-1
HEARTER
10-135-2
(11)
1.
2.
3.
4.
5.
Engine oil pan heater

Transmission oil pan heater
Engine coolant heater
Junction box
Connector for external power supply
Specification
Engine oil pan heater: 0.6 kW (1 place)
Engine coolant heater: 1.5 kW (1 place)
Transmission oil pan heater: 0.6 kW (2 places)
10-135-3
(11)
HEARTER
Ourline
This device is a starting aid to heat the oil with
an external power supply so that the engine will
start easily.
If an external power supply is connected to
external power supply connector (5) of junction
box (4), the engine coolant and the oil in the
transmission oil pan and engine oil pan are
heated.
The source voltage is 230 V and the power consumption is 3.3 kW.
HM300-1
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
4
HM300-1
Outline
With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to
observe and control the condition of the machine
and transmit that data as network data to the
machine monitor.
The machine monitor is a system to display
these data and inform the operator of the condition of the machine.
There are two types of display on the machine
monitor: the normal mode and the service mode.
The items that are always displayed for the operator are the normal mode items. Their main
content is as follows.
1. Normal display items
Meters (speedometer, tachometer)
Gauges (engine coolant temperature,
torque converter oil temperature, retarder oil temperature, fuel level)
Pilot display
Service meter, odometer (character display)
2. Items displayed when there is abnormality
Caution, action code display (if an action
code is being displayed, press machine
monitor mode selector switch (2) (>), then
release it. A failure code (6-digit) is then displayed.)
3. When the filter, oil replacement interval is
reached, the item needing replacement is
displayed in the character display.
4. Other functions using the character display
and the machine monitor mode selector
switch to operate include the following: Total
reverse distance traveled display, filter, oil
replacement interval reset, telephone
number input, and language selection.
To make it easier to carry out troubleshooting of

the controllers (including the monitor panel itself), a service mode function is provided. Its
main content is as follows.
1. Displaying trouble data for electrical components, 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 monitor
3. Real-time monitor
Takes input and output signal values
recognized by each controller on network and displays in real time
HM300-1
4. Reduced cylinder mode

This function is used to stop the supply of
fuel sprayed from the fuel injector. This
makes it possible to determine the cylinder
where there is defective combustion.
5. ECMV compensation
This is used for the initial adjustment of the
transmission.
6. Changing replacement time for filter, oil
This changes the original setting for the
replacement interval.
7. Controller initialize
This function is used to set the machine
monitor when the machine is shipped from
the factory.
The service mode has the following functions.
1. Setting service meter
This can set service meter values recorded in machine monitor memory
However, values can only be increased
from present value (they cannot be decreased).
2. Setting total travel distance
This can set travel distance values recorded in machine monitor memory

3. Setting distance traveled in reverse
This can set values for distance traveled
in reverse recorded in machine monitor
memory.
The machine monitor system consists of the

monitor panel, buzzer, and switches, network,
controllers on the network, and the sensors inputting data to the monitor panel.
10-137
(9)
MACHINE MONITOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Speedometer
Engine tachometer
Retarder oil temperature gauge
Torque converter oil temperature gauge
Engine coolant temperature gauge
Fuel gauge
Character display
Turn signal pilot lamp (R.H.)
Turn signal pilot lamp (L.H.)
Front lamp high beam pilot lamp
Gearshift lever position pilot lamp
Shift indicator
Lock-up pilot lamp
Shift hold pilot lamp
Power mode pilot lamp (high power mode)
Power mode pilot lamp (economy mode)
Central warning lamp
Maintenance caution lamp
Battery charge circuit caution lamp
Steering oil temperature caution lamp
Engine oil pressure caution lamp
Brake oil pressure caution lamp
10-138
(9)(5)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Machine monitor, option system caution lamp

Engine system caution lamp
Transmission system caution lamp
Retarder system caution lamp
(Brake system caution lamp: E-SPEC)
Tilt caution lamp
Seat belt caution lamp
Parking brake pilot lamp
Retarder pilot lamp
(Overrun protection brake pilot lamp: E-SPEC)
Exhaust brake pilot lamp (option)
Inter-axle differential lock pilot lamp
Left and right differential lock pilot lamp
(if equipped)
Dump body pilot lamp
Emergency steering pilot lamp
Preheating pilot lamp
Retarder oil temperature caution lamp
Torque converter oil temperature caution lamp
Engine coolant temperature caution lamp
Fuel level caution lamp
HM300-1
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Travel speed compensation switch [SW1]

Rotary switch [SW2]
Rotary switch [SW3]
Switch for setting left and right differential lock [SW5-4]
Dipswitch [SW5-3]
Switch for setting exhaust brake [SW5-2]
Dipswitch [SW5-1]
Dipswitch [SW6-4]
Dipswitch [SW6-3]
Dipswitch [SW6-2]
Dipswitch [SW6-1]
HM300-1
10-139
OPTION SETTING CONNECTOR DIAGRAM
52.
53.
54.
55.
56.
57.
58.
Option setting connector [OP1]

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
(9)
HM300-1
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
No.
Display
item
Display
category
Meter
1
Travel
speed
Backlight
Meter
2
Engine
speed
Brake
3
cooling oil
37 temperature
Torque
converter
oil
temperature
Fuel level
gauge
LED
Amber
When side lamps light

up
Scale:
0 - 3400 rpm (red
Movement White, red zone: More than 2500
Background
rpm)
color: Black
Amber

up
Alarm
buzzer
Analog
display
(Note)
Lights up
when
actuated
Analog
display
(Note)
Lights up
when
actuated
Analog
display
(Note)
Movement
Caution
LED
Red
When temperature is
more than 120C
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
Analog
display
(Note)
Scale:
50 - 150C
White, red (red zone:
More than
Background
120C)
color: Black
Scale:
50 - 135C
Movement Background
More than
120C)
color: Black
Caution
LED
Red
When temperature is
more than 120C
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
Analog
display
(Note)
Scale:
50 - 135C
Movement Background
More than
102C)
color: Black
Caution
LED
Red
When temperature is
more than 102C
Lights up
when
abnormal
Backlight
LED
Amber

up
Lights up
when
actuated
EMPTY-FULL
Analog
display
(Note)
Scale:
White
Movement Background
color: Black
Remarks
Note: When machine monitor

check switch is operated, display
starts from present position,
completes one cycle, and
returns to the starting position





Caution
LED
Red
When below specified

level (amount of fuel
remaining in tank is
less than 75 l)
Lights up
when
actuated
Backlight
LED
Amber

up
Lights up
when
actuated
0 - 65535.0h
* Displayed on top
line of character
display
Actuated
when
engine is
running
Ratio of
movement
to time 1:1
When time exceeds 65535.0h,

stops at 65535.0h
0 - 999999.9km
* Displayed on bottom
line of character
display
Actuated
when
traveling
When distance exceeds

999999.9km, stops at
999999.9km
Service
meter
(normal
display
items)
Service
meter
Odometer
(normal
display
items)
Odometer
HM300-1
Scale:
0 - 80 km/h or 0 - 50
White
mph
Movement Background
(mph display is only
color: Black when non-SI is used)
Method of Central
display
warning
lamp
Gauge
Gauge
6
40
Display range/
conditions
LED
Gauge
Engine
5
coolant
39 temperature
Color
Backlight
Gauge
4
38
Device
2
1 When
machine Immediately
after
monitor
starting
check
switch is
switch is
operated turned ON
LCD
Display
letters:
Black
Background
color:
Green
10-141
4
(9)
Related actuation
No
Display item
Action code
Failure code
Display
category
Device
Color
Central
warning
lamp
Alarm
buzzer
Action code
Failure
code
Top line displays

failure code (6
digit) and
When there is
controller that
abnormality or failure,
press mode switch ">". detected problem;
bottom line
* Displayed on top
displays system
and bottom lines of
that is abnormal or
character display
nature of
abnormality
Reverse
travel
distance
meter, filter,
oil
Other displays replacement
time reset,
telephone
No. setting,
language
selection
Backlight
Right turn
signal
Method of display
When abnormality
When abnormality or or
failure occurs on
failure occurs on
machine, top line
machine
shows action
* Displayed on top and code;
bottom line
bottom lines of
displays
remedy or
character display
nature of failure
Night lighting
Display range/
conditions
When
machine
monitor
check
switch is
operated
Note 1
Immediately
after
starting
switch is
turned ON
Remarks
Note 2
Note 1: Top line displays

"HM300-1"
Note 2: Top line displays
"KOMATSU", bottom
displays "SYSTEM
CHECK"
See Operation &

Maintenance Manual for
details of failure display
Operate machine
Press machine monitor
monitor mode
mode selector switch selector switch ">"
"<>"
or "<" to switch
screen
See Operation &

Maintenance Manual for
details of failure display
LED
Green

up
Brightness
reduced one level
when side lamps
light up
LED
Green
When operated
When operated:
Lights up
When not
operated: Goes
out
Left turn signal
LED
Green
When operated
When operated:
Lights up
When not
operated: Goes
out
10
High beam
LED
Blue
When operated
When operated:
Lights up
When not
operated: Goes
out
11 Gearshift lever
(R2) position R2
LED
Green
When gearshift lever is

at R2
Lights up (*)
* Flashes when neutral

safety is actuated
11 Gearshift lever
(R1) position R1
LED
Green

at R1
Lights up (*)

safety is actuated
11 Gearshift lever
(N)
position N
LED
lever is
Orange When gearshift
at N
Lights up
LED
Green

at D
Lights up (*)

safety is actuated
11 Gearshift lever
(5)
position 5
LED
Green

at 5
Lights up (*)

safety is actuated
11 Gearshift lever
(4)
position 4
LED
Green

a4
Lights up (*)

safety is actuated
11 Gearshift lever
(3)
position 3
LED
Green

at 3
Lights up (*)

safety is actuated
11 Gearshift lever
(2)
position 2
LED
Green

at 2
Lights up (*)

safety is actuated
11 Gearshift lever
(1)
position 1
LED
Green

at 1
Lights up (*)

safety is actuated
Shift indicator
LED
F1,F2,F3,F4,F5,F6,N,R
1,R2,R3
* According to shift
range signal received
When shift range
Backfrom transmission
signal is received
ground
controller
from transmission
color:
* When alarm is
controller
Gray
actuated when making
emergency escape, "E-"
and "N" are displayed in
turn
c
All light up
c
All light up
Night lighting
LED
Amber
11 Gearshift lever
(D)
position D
Pilot
12
10-142
(9)
HM300-1
Related actuation
No
13
14
Display
item
Display
category
Lock-up
Device
LED
Shift hold
LED
Immediately
after
starting
switch is
turned ON
Color
Green
When torque
converter lock-up is
actuated and
transmission is set to
direct drive
When
operated:
Lights up
When not
operated:
Goes out
When shift hold

switch is operated
When
operated:
Lights up
When not
operated:
Goes out
High power mode
High power
mode:
Lights up
When not
actuated:
Goes out
Economy mode
Economy
mode:
Lights up
When not
actuated:
Goes out
Green
Method of Central
display
warning
lamp
When
machine
monitor
check
switch is
operated
Display range/
conditions
Alarm
buzzer
Remarks
Pilot
Output
mode
15 (high
power
mode)
LED
Green
16
Output
mode
(economy
mode)
LED
Green
17
Central
warning
lamp
LED
Red
Lights up
When there is
when
abnormality in system abnormal
LED
Red
When warning is
issued for
maintenance system, Lights up or
or when filter, oil
flashes
replacement interval
has passed
LED
Red
When there is
abnormality in charge
circuit
Lights up
when
abnormal
LED
Red
When steering oil

temperature rises
Lights up
when
abnormal
Note: Actuated only when

alternator R terminal = ON
Actually only used when failure

occurs in machine monitor
18 Maintenance
caution
19
Battery
charge
circuit
caution
Steering oil
20 temperature
caution
21
Engine oil
pressure
caution
LED
Red
When engine oil

pressure drops
Lights up
when
abnormal
22
Brake oil
pressure
caution
LED
Red
When brake oil

pressure drops
Lights up
when
abnormal
23
Machine
monitor or
option
system
caution
LED
Red
When there is
abnormality in
machine monitor or
option controller
system
Lights up
when
abnormal
24
Engine
system
caution
LED
Red
When there is
abnormality in engine
control system
Lights up
when
abnormal
25
Transmission
system
caution
LED
Red
When there is
abnormality in
transmission control
system
Lights up
when
abnormal
Lights up
when
abnormal
Caution
c(Note) U(Note)
Retarder
system
caution
26
(Brake
system
caution: ESPEC)
LED
Red
When there is
abnormality in
retarder control
system (When there
is abnormality in
brake control system:
E-SPEC)
27 Tilt caution
LED
Red
When dump body is

raised and there is
excessive tilt to left or
right
Lights up
when
abnormal
Red
When seat belt is not

fastened
When
actuated:
Lights up
When not
actuated:
Goes out
28
Seat belt
caution
HM300-1
LED
Note 1: Lamp lights up and at

same time action code E01 and
location for warning is displayed
on character display
Note 2: See Operation and
Maintenance Manual for details
of applicable item
10-143
(9)
Related actuation
No
Display
item
29
Immediately
after
starting
switch is
turned ON
Color
Parking
brake pilot
lamp
Red
When parking brake

is applied
Lights up
when
applied
30
Retarder
pilot lamp
(Overrun
protection
brake pilot
lamp: ESPEC)
Orange
When retarder brake

is applied (When
overrun protection
brake is applied: ESPEC)
Lights up
when
applied
31
Exhaust
brake
actuation
lamp
(option)
Orange
When exhaust brake

is actuated
Lights up
when
actuated
32
Inter-axle
differential
lock pilot
lamp
Orange
Lights up when interaxle differential lock is

operated
When
operated:
Lights up
When not
operated:
Goes out
33
Left and
right
differential
lock lamp
(if
equipped)
Orange
Lights up when left

and right differential
lock is actuated
When
actuated:
Lights up
When not
actuated:
Goes out
34
Body pilot
lamp
36 Preheating
pilot lamp
Device
LED
LED
Pilot
LED
LED
LED
LED
Red
Red
Red
For details, see

Operation and
Maintenance Manual
Method of Central
display
warning
lamp
When
machine
monitor
check
switch is
operated
Display range/
conditions
Emergency
35
steering
ready lamp
Display
category
Alarm
buzzer
c(Note) U(Note)
When
operated:
Lights up c(Note) U(Note)
When not
operated:
Goes out
When
operated:
Lights up when
Lights up
emergency steering is When not
actuated
operated:
Goes out
When
operated:
Lights up
When not
operated:
Goes out
Lights up when
electric heater for
engine preheating is
actuated
Remarks
Note: Actuated when parking

brake is applied and gearshift
lever is at position other than N
Note: Actuated when gearshift

lever is at position other than N
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
(4
9)
HM300-1
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 reading Service meter reading when problem first occurred = Time elapsed)
@@@@@ : Displays time that has elapsed since failure last occurred (Present service meter reading 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 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 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 failure 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 character 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
(9)
HM300-1
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 compensation.
6) Changing filter, oil replacement time
For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display 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
(7)
HM300-1
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
HM300-1
10-149
4
OUTLINE
The transmission controller receives the shift position signal for the gearshift lever, the accelerator signal for the accelerator pedal, the speed
signal for the transmission, and the other signals
from the switches and sensors. It then automatically 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 prevent overrun.
Each clutch pack of the each transmission
clutch and torque converter lock-up clutch is
equipped with an electronically controlled modulation valve, and each clutch pack is independently 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 signals from the switches and sensors to operate
the machine monitor displays and caution and
pilot lamps, and transmits these data to the network.
10-150
(9)
HM300-1
TRANSMISSION CONTROLLER
1.
2.
3.
4.
5.
6.
Self-diagnostic display window

Connector
Case
Motherboard
Model selector switch (rotary switch 1)
Model selector switch (rotary switch 2)
Outline
The transmission controller controls the transmission system.
It has the following features and functions.
1. It has a high power mode and economy
mode, and the gearshifting pattern can be
selected.
2. The braking mode is the mode when the
brake is used. By raising the gearshifting
point and increasing the speed of the brake
cooling pump it is possible to raise the cooling effect of the retarder and make effective
use of the engine brake.
3. It controls the torque converter lock-up solenoid valve, overrun prevention solenoid
valve, and exhaust brake solenoid valve.
4. It controls the inter-axle differential lock solenoid valve according to the output command from the retarder controller (Brake
controller: E-SPEC).
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
6. Speed sensors are installed at three places

(transmission input shaft, intermediate
shaft, and output shaft). This makes it possible to detect slippage of the transmission
clutches and to protect the transmission
when there is any abnormality in the hydraulic system.
7. It connects to the network and shares various data with other controllers.
8. It receives input of the model selection data
(what model it is mounted on), and uses the
network to contact other controllers. (For
details of the method of setting, see TESTING AND ADJUSTING.)
9. It has a self-diagnostic function which divides the input and output systems further
into small parts.
10. The self-diagnostic function is displayed in
two digits.
11. When an abnormality is detected, it transmits the details to the network and displays
it on the other displays.
12. It uses the machine monitor to display if the
failure is still existing.
13. It provides an escape function for use when
there is a failure in the electrical system.
14. It is separate from the gearshift lever.
10-151
4
(9)
ATC1
ATC3A
1
2
ATC4
1 Connector check
1 Connector check
Transmission input shaft speed

2
input
Power source input (24V) for

4 overrun prevention solenoid output
command
Power source input (24V) for
5 exhaust brake solenoid output
command
direct power source input

7 Battery
(24V)
8 GND
9 Power source input (24V)
10
11
12
prevention solenoid
13 Overrun
output command
Exhaust brake solenoid output
14 command (if equipped)
15 Transmission cut relay
16 GND
17 Power source input (24V)
Transmission output shaft speed

input
4 Engline load condition signal input

5
Throttle correction command

output
Potentiometer power source

output (5V)
Torque converter oil pressure

7
signal input
differential lock
8 Inter-axel
command input
10 Emergency escape switch input

11
Steering oil temperature signal

input
12
Transmission intermediate shaft

speed input
15
4 Fuel level signal input
ECMV output Rev (+)
16
17 ECMV output Low (-)

ECMV output inter-axel differential
18
lock (-)
19 ECMV output 2nd (-)
Hydraulic filter condition signal

input (if equipped)
10 Fill switch input Low

11 Fill switch input lock-up
12 Fill switch input High
13 Fill switch input 1st
16 Fill switch input Rev

Fill switch input inter-axel
differential lock
19
20
ATC5B
1
Emergency steering actuation

signal 2 input
Gearshift lever position R1 signal

input
Brake cooling oil temperature

(front wheel ) signal input
Gearshift lever position R2 signal

input
Gearshift lever position N signal

input
Gearshift lever position D signal

input
Torque converter oil temperature

signal input
Gearshift lever position 1 signal

input
Brake cooling oil temperature

(center wheel) signal input

input
Transmission oil temperature

signal input

input

input
10

input
9 ECMV output 2nd (+)
15 ECMV output High, Rev (-)
Speed range N action command 2

signal input
1 Alternator terminal R input
ECMV output High (+)
14 Sensor power source output (12V)
Air cleaner filter condition signal

input
13 ECMV output 1st, 3rd (-)
11
12 Network signal output
Speed range N action command 1

signal input
18 Start signal input
ECMV output 3rd (+)
Proportional solenoid power

12
source input 24V
10 Network signal GND
17
Transmission oil filter condition

6
signal input
GND input for torque converter oil

17
pressure
ECMV output 1st (+)
10 ECMV output lock-up (+)
16 GND (for sensor)
output inter-axle differential

8 ECMV
lock (+)
15 Fill switch input 3rd
ATC3B
7 ECMV output Low (+)
14 GND (for speed input)
20

1
source input 24V
3 Radiator coolant level signal input
14 Fill switch input 2nd
19
ATC2
6 Network signal output
Hydraulic tank level signal input (if

equipped)
13 Engine speed input
GND input for inter-axel differential

18
lock command input
11
ATC5A
Power source output (24V) for

3 torque converter oil pressure
sensor
10
11 Accelerator signal input

12
13
14
15
16 Machine inclination angle signal

input
11 Shift hold signal input

12
13
14 Model selection 1 input

20 ECMV output Lock-up (-)

21 GND
10-152
(4
9)
HM300-1
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
Shifting the transmission up and down is carried
out according to the shift map saved in the controller memory.
There are three types of shift map, depending
on the condition of the input signals.
The settings for each mode are as shown in the
table below.
Mode
Set conditions
Braking mode
When either of the following conditions is fulfilled

1. Brake signal ON
(footbrake, retarder brake operated)
2. Accelerator pedal released
High power
mode
When the following three conditions are fulfilled

1. Brake signal OFF
(footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at high power
Economy
mode
When the following three conditions are fulfilled

1. Brake signal OFF
(footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at economy
High power mode:

The high power mode uses the power of the machine to the maximum to provide the maximum payload. However, when the machine is unloaded or
has only a light load (high acceleration), an acceleration sensitive type variable shifting point is used.
This detects the acceleration of the machine and
shifts the transmission up sooner to provide better
acceleration and to improve the fuel consumption,
noise, and transmission shock.
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and transmission shock are improved. In this mode, the engine
output is limited to 90% of the maximum engine output.
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:
1. High power mode
For the shift-up point, the optimum point between 1,850 and 2,150 min-1 is selected according to the amount the accelerator pedal is
depressed, the acceleration of the machine, and
the speed range.
For the shift-down point also, the optimum point
between 1,120 and 1,350 min-1 is selected according to the amount the accelerator pedal is
depressed and the speed range.
2. Economy mode
For the shift-up point, the optimum point between 1,680 and 1,800 min-1 is selected according to the amount the accelerator pedal is
depressed, the acceleration of the machine, and
the speed range.
For the shift-down point also, the optimum point
between 1,060 and 1,100 min-1 is selected according to the amount the accelerator pedal is
depressed and the speed range.
3. Keeping gear speed in braking mode (foot

brake)
If the travel speed lowers below 10 km/h while
the foot brake is applied, the gear speed at that
time (F3, F4, F5) is held.
10-154
(9)
If the travel speed lowers below 4 km/h or the

foot brake is not applied or the lock-up is kept
turned on for a long period, the lock-up is turned
off and a gear speed proper for the travel speed
is selected.
Accordingly, if the machine travels downhill with
the foot brake applied and the engine speed
kept low by the lock-up, the brake cooling oil flow
becomes insufficient and the engine overheats
easily.
4. Lock-up
For the lock-up ON point, the optimum point between 1,050 and 1,350 min-1 is selected according to the torque converter input speed (engine
speed) and output speed (transmission input
shaft speed).
The lock-up OFF point when the foot brake or retarder brake are operated is 950 min-1.
When the foot brake or retarder brake are not
operated, it is 850 min-1.
When the machine moves off downhill with the
accelerator pedal released, the lock-up is not
engaged until the accelerator pedal is depressed or the foot brake is applied.
5. The auto brake ON point when traveling in F6 is
2,400 min- 1.
HM300-1
Gearshift lever positions and method of shifting

1) Gearshift lever position D
When shifting up (in high power mode)
I) When the gearshift lever is set at position D, the
transmission is set to F2 torque converter
range.
II) When the accelerator pedal is depressed, the
engine speed rises and accelerates. When the
transmission input shaft speed reaches 1050 1,350 min-1, the lock-up clutch is engaged, so
the torque converter is directly engaged and the
transmission is set to direct travel.
III) As the engine speed rises further and reaches
1,850 - 2,150 min-1, the transmission shifts up to
F3.
While the transmission is shifting up, the engine
speed is also lowered (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine
accelerates, it rises again and the transmission
shifts up in turn to F4 to F6 in the same way as
in III) above.
When shifting down (in high power mode)
When the load increases and the engine speed
drops to 1,060 - 1,100 min-1, the transmission
shifts down one speed.
(For example, when traveling in F6, the transmission shifts down to F5.)
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 converter drive.
I)
The safety functions related to travel in reverse

are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
4) Gearshift lever position N
At the neutral position, none of the transmission
clutches are actuated.
Shift hold function
If the hold switch on the gearshift lever is pushed
once, the current gear speed is held. If the hold
switch is pressed once again or the gearshift lever is operated, the gear speed can be changed.
If the travel speed lowers excessively while the
gear speed is held, the gear is shifted down.
When the travel speed rises again, however,
the original gear speed is held.
Time when gear cannot be shifted
In the automatic shift range, to prevent mistaken
operation caused by excessive variation in the
speed when shifting gear, a time delay is used to
prevent the gears from being shifted within the
set time.
The gearshifting time delay is controlled precisely by each gearshifting pattern through the
use of the all-range electronic modulation system.
The approximate values for the gearshifting pattern and gearshifting time delay are shown in
the diagram below.
In the above explanation, the set speed or actuation may differ according to the travel conditions. 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
1) Down-shift inhibitor function
If gearshift lever is operated D 5 - 1, 5 4 1, 4 3 - 1, 3 2 - 1, 2 1
For example, when traveling in D (F6), even if
the gearshift lever is operated to 4, the transmission does not shift directly F6 F4. It shifts
down F6 F5 F4 in turn according to the
engine speed.
(Even if the operator makes a mistake in operation of the gearshift lever, the transmission does
not skip a gear speed. This is to prevent overrunning of the engine.)
2) Neutral safety function
This circuit prevents the engine from starting if
the gearshift lever is not at the N position, even
if the starting switch is turned to the START
position.
(This is a safety circuit to prevent the machine
from moving unexpectedly when the engine is
started.)
3) Directional inhibit function
When traveling in reverse at a speed of more
than 3.8 km/h, even if the gearshift lever is
operated to D or positions 5 to 1, the transmission will not be shifted immediately to travel forward. The engine speed is lowered to reduce
the travel speed, and when the travel speed
goes below 3.8 km/h, the transmission is shifted
to FORWARD.
When traveling forward at a speed of more than
1.9 km/h, even if the gearshift lever is operated
to positions R1 or R2, the transmission will not
be shifted immediately to travel in reverse. The
speed range is shifted to N and the engine
speed is lowered to reduce the travel speed.
When the travel speed goes below 1.9 km/h,
the transmission is shifted to REVERSE.
When traveling in reverse at a speed of more
than 7.2 km/h with the gearshift lever at position
R2, even if the gearshift lever is operated from
R2 to R1, the transmission does not shift to R1.
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 gearshift 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
(9)
4) Power train overrun prevention rear brake function

If the engine speed rises to more than 2400
min-1 (more than 2350 min-1 in F6), the central
warning lamp flashes and the alarm buzzer
sounds.
If the engine speed rises to more than 2450
min-1 (more than 2400 min -1 in F6), the rear
brake is automatically actuated.
(To prevent overrun of engine, torque converter,
and transmission, to improve durability and reliability)
5) REVERSE safety
The machine will not travel in reverse if the
dump control lever is not at FLOAT and the
dump body is not completely lowered.
(Turnover prevention function)
However, if the gearshift lever is at the R1 position and the shift hold switch is pressed, it is
possible to travel in reverse while the switch is
being pressed, even if the dump body is not
fully lowered.
6) Speed range limit function when dump body is
raised
After dumping the load, if the body is not completely lowered, shifting up is limited.
If the gearshift lever is at D, the machine starts
in F2. If the former is at positions 5 to 1, the latter starts in F1. The gear is not shifted up until
the body is completely lowered.
Self-diagnostic function
The controller carries out self-diagnosis of the system and displays any abnormalities.
The details of the self-diagnosis are displayed as a
2-digit code with LEDs.
If any abnormality is detected by the self-diagnosis
function, the abnormality data is transmitted to the
network and is displayed as an action code on the
machine monitor. The transmission system caution,
warning lamp, or alarm buzzer may also be actuated.
HM300-1
AUTO EMERGENCY STEERING SYSTEM
AUTO EMERGENCY STEERING SYSTEM
1.
2.
3.
4.
5.
Hydraulic tank
Flow amp valve
Steering oil pressure sensor
Emergency steering pump
HM300-1
Outline
If the engine stops or an abnormality occurs in
the hydraulic pump when the machine is
traveling, and the oil in the steering circuit goes
below the specified oil pressure, the auto emergency 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 operate it manually.
10-157
4
SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
1.
2.
3.
4.
Magnet
Locknut
Wiring harness
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
SENSORS, SWITCHES
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
This is installed under the operators 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 potentiometer 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 corresponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the transmission controller.
Idle validation signal
This is installed under the operators 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 condition.
HM300-1
10-159
(9)
SENSORS, SWITCHES
ENGINE COOLANT TEMPERATURE SENSOR

BRAKE COOLING OIL TEMPERATURE SENSOR
1.
2.
3.
4.
Thermistor
Plug
Wiring harness
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 controller. 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 portion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is displayed on the character display of the monitor
panel.
10-160
(4
9)
HM300-1
SENSORS, SWITCHES
FUEL LEVEL SENSOR
1.
2.
3.
4.
Connector
Wire resistor
Arm
Float
HM300-1
Function
The fuel sensor is installed to the side face of the
fuel tank. The float moves up and down according 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 certain level, a warning lamp flashes.
10-161
(9)
SENSORS, SWITCHES
TILT SENSOR
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
The tilt sensor is installed to the rear of the chassis. A magnet supported by a leaf spring is installed to a case charged with damper oil. It uses
the position in relation to the magnetic resistance element to detect the tilt angle of the chassis.
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
SENSORS, SWITCHES
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 abnormality.
HM300-1
10-163
SENSORS, SWITCHES
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 maintenance caution lamp lights up to warn of the abnormality.
10-164
4
HM300-1
SENSORS, SWITCHES
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
RETARDER CONTROL SYSTEM
10-166
4
HM300-1
RETARDER CONTROLLER
1.
2.
3.
4.
5.

Rotary switch
Motherboard
Case
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
4
(12)
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 differential lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor 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
4
HM300-1
BRC1
BRC3A
Power source for +24V output

1
sensor
BRC4
BRC5A
1 Connector check 1
1 RS422 TX(+)
1 Connector check 2
2 RS422 RX(+)
2 Exhaust brake switch (if equipped)
3 RS232 TXD
3 Service brake switch
3 Exhaust brake solenoid
4 RS232C TXD
4 Retarder switch
4 Brake cut relay (+24V IN)
5 RS485 (+)
brake emergency brake

5 Parking
switch
Rear wheel differential lock

solenoid (if equipped)
power source +5V (hoist

6 Sensor
lever potentiometer, body position)
6 Neutral signal 1
7
7 Battery direct power source input

8 GND
9
10
11
9 Power source +24V

Front wheel differential lock
10 solenoid (if equipped)
11 Kick-out solenoid
12 Transmission rear axel speed
12 Hoist selector valve
13 Transmission ouput shaft speed
13 Brake cut relay
14 GND (pulse)
14
15 Neutral signal 2
15
17
17 Power source +24V
18
19
20
BRC3B
BRC2
source +24V
2
3
Inter-axel differential lock

command
Front wheel retarder

8 electromagnetic proportional
reducing valve (+)
Rear wheel retarder
reducing valve (+)
6 Accumulator oil pressure (REAR))

7
Accumulator gas pressure

(FRONT)
8 Accumulator gas pressure (REAR)

9
10
11
12 Hoist lever potentiometer 2

12
source +24V
13
7 Lever validation switch 2

8 FLASH SW. (ON/OFF)
9 RS422 RX(-)
system filter switch

8 Brake
(if equipped)
10 GND. (SERIAL)
9 Brake cooling filter switch
11 RS485(-)
10
12 S-NET (+)
Differential actuation switch (front)

11 (if equipped)
13
14
15
16
17
switch terminal C (engine

18 Starting
start signal)
19
20
BRC5B
1
3 Brake wear switch FR (if equipped)

4
Exhaust brake command (FRONT

TRANSMISSION)
Overrun command (FRONT

TRANSMISSION)
6 Brake wear switch RL (if equipped)

7
Brake wear switch RR

(if equipped)
Brake wear switch ML

(if equipped)
Brake wear switch MR

(if equipped)
13 Body position sensor

15 Steering angle potentiometer
16 Manual retarder lever
potentiometer
power source +5V

16 Sensor
(retarder lever potentiometer)
17
2 Brake wear switch FL (if equipped)
10
11
12
13
14
15
16
14 Sensor power source +12V (pulse)

15
actuation switch (rear)

12 Differential
(if equipped)
5 Accumulator oil pressure (FRONT)
10 Hoist EPC valve (+)

11

7 RS422 TX(-)
16 GND (analog)
16 GND
6 S-NET (+)
Front wheel retarder

reducing valve ()
Rear wheel retarder
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
4
HM300-1
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 output) 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 position.
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
(9)
HM300-1
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 - 90C)
(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 controller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
10-174
(9)
HM300-1
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 1 to line B and angle 2 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)
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
(4
9)
HM300-1
BRAKE CONTROLLER (E-SPEC)
1.
2.
3.
4.
5.

Rotary switch
Motherboard
Case
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 actuates the inter-axle differential lock.
HM300-1
10-175-2
4
(12)
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
(4
9)
HM300-1
BRC1
BRC3A
Power source for +24V output

1
sensor
BRC4
BRC5A
1 Connector check 1
1 RS422 TX(+)
1 Connector check 2
2 RS422 RX(+)
2 Exhaust brake switch (if equipped)
3 RS232 TXD
3 Brake switch
3 Exhaust brake solenoid
4 RS232C TXD
4 Overrun protection brake switch
4 Brake cut relay (+24V IN)
5 RS485 (+)
brake emergency brake

5 Parking
switch
Rear wheel differential lock

solenoid (if equipped)
5
6 Neutral signal 1
7 Battery direct power source input

8 GND
9 Power source +24V
Front wheel differential lock
10 solenoid (if equipped)
power source +5V (hoist

6 Sensor
lever potentiometer, body position)
7
10
11
11 Kick-out solenoid
12 Transmission rear axel speed
12 Hoist selector valve
13 Transmission ouput shaft speed
13 Brake cut relay
14 GND (pulse)
14
15
15 Neutral signal 2
16 GND (analog)
16 GND
17
17 Power source +24V
18
19
20
BRC3B
BRC2
1

source +24V
2
3
Inter-axel differential lock

command
wheel brake electromagnetic

8 Front
proportional reducing valve (+)
9 Rear
proportional reducing valve (+)
10 Hoist EPC valve (+)
11
12

source +24V
13
14 Sensor power source +12V (pulse)

15
16 Sensor power source +5V

(retarder lever potentiometer)
17
6 S-NET (+)
7 RS422 TX(-)
8 FLASH SW. (ON/OFF)

9 RS422 RX(-)
system filter switch

8 Brake
(if equipped)
10 GND. (SERIAL)
9 Brake cooling filter switch
11 RS485(-)
10
12 S-NET (+)
actuation switch (front)

11 Differential
(if equipped)
actuation switch (rear)
12 Differential
(if equipped)
13
14
15
16
17
switch terminal C (engine

18 Starting
start signal)
19
20
BRC5B
1
Accumulator gas pressure

(FRONT)
8 Accumulator gas pressure (REAR)

9
10
11
3 Brake wear switch FR (if equipped)

4
Exhaust brake command (FRONT

TRANSMISSION)
Overrun command (FRONT

TRANSMISSION)
6 Brake wear switch RL (if equipped)

7
Brake wear switch RR

(if equipped)
Brake wear switch ML

(if equipped)
Brake wear switch MR

(if equipped)
13 Body position sensor

15 Steering angle potentiometer
retarder lever
16 (Manual
potentiometer)
2 Brake wear switch FL (if equipped)
5 Accumulator oil pressure (FRONT)

6 Accumulator oil pressure (REAR))
10
11
12
13
14
15
16

18 Front
proportional reducing valve ()
19 Rear
proportional reducing valve ()
20 Hoist EPC valve ()
21 GND
HM300-1
10-175-4
4
(9)
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
(4
9)
HM300-1
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 position.
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
4
(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 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 - 90C)
(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
(4
9)
HM300-1
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 controller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
HM300-1
10-175-8
4
(9)
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 1 to line B and angle 2 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
(4
9)
HM300-1
DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-176
HM300-1
DUMP CONTROL LEVER
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
DUMP CONTROL LEVER
Function
When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is operated, and rotates potentiometer (16).
The amount the control lever is operated (travels) 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 actuation 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 protrusion b of rod (19), so the lever is held at the
FLOAT position.
10-178
HM300-1
2. Dump control lever FLOAT canceled

When lever (1) is returned from the FLOAT position, it is pushed down by a force greater than
the holding force of rod (19), detent spring (20),
retainer (13), and ball (14).
3. Dump control lever operated to LOWER
When lever (1) is operated further from the
FLOAT position, it moves to the LOWER position.
Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated.
Lever (17) and rod (19), which are installed to
the rotating shaft of potentiometer (16), are interconnected, so a voltage matching the up or
down movement of the rod is output from potentiometer (16).
HM300-1
DUMP CONTROL LEVER
4. Dump control lever operated to RAISE

When RAISE rod (18) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (19) during the stroke. (Before start of actuation of mechanical detent)
When rods (18) and (19) are pushed in further,
ball (14) pushes up retainer (13) which is held by
detent spring (20) and it escapes to the outside,
and rod (19) passes over protrusion a.
When this happens, rod (2) on the opposite side
is pushed up by spring (4).
When an electric current is flowing to solenoid
(9), if rod (2) is pushed up, nut (10) is held in contact with bushing (8).
As a result, rod (2) is held at the pushed up position, so even if the lever is released, it is held
at the RAISE position.
10-179
(9)
DUMP CONTROL LEVER
5. Dump control lever RAISE canceled

When lever (1) is returned from the RAISE position, 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 .........................................................................................................
Standard value table for chassis ........................................................................................................
Standard value table for electrical parts ............................................................................................
TESTING AND ADJUSTING ...................................................................................................................
TROUBLESHOOTING ............................................................................................................................
20- 2
20- 3
20- 7
20-101
20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
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 machine 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 results 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)
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine model
HM300-1
Engine
SAA6D125E-3
Standard value for
new machine
Service limit
value
Power mode
2,200 50
2,200 50
Economy mode
2,000 50
2,000 50
945 25
945 25
700 25
700 25
Power mode
2,000
2,000
Economy mode
1,600
1,600
kPa
{mmHg}
Min. 106.7
{Min. 800}
79.8
{600}
Bosch
index
Max. 4.5
6.5
Max. 1.0
Exhaust temperature
Whole speed range
(Turbocharger inlet
(Ambient temperature 20C)
temperature)
Max. 650
700
Intake valve
Valve clearance
(normal temperature) Exhaust valve
mm
0.33
0.71
MPa
{kg/cm2}
Min. 2.9
{Min. 30}
(rpm)
(150 200)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
392 588
{4.0 6.0}
206
{2.1}
343 539
{3.5 5.5}
176
{1.8}
At low idle (SAE30)
Min. 147
{Min. 1.5}
69
{0.7}
At low idle (SAE10W)
Min. 98
{Min. 1.0}
69
{0.7}
90 120
Min. 120
10
10
10
Item
Measurement conditions
High idle
Engine speed
Power mode
Low idle
Economy mode
Rated speed
Air supply
(boost pressure)
Exhaust gas color
Compression
pressure
(SAE oil)
Blow-by pressure
(SAE oil)
At rated output
At sudden acceleration
At high idle
Oil temperature: 40 60C

(Engine speed)
(Coolant temperature: Operating range)
At rated output
Unit
rpm
(Coolant temperature: Operating range)

At high idle (SAE30)
Oil pressure
At high idle (SAE10W)
Oil temperature
Whole speed range (Inside oil pan)
Belt tension
Deflection when
pressed with a
finger force of
approx. 58.8N
{approx. 6kg}.
20-2
c 1
1c
(9)
kPa
{kg/cm2}
Alternator crankshaft pulley

mm
Air conditioner compressor
fan belt
HM300-1
STANDARD VALUE TABLE FOR CHASSIS

Machine model
Category
Accelerator pedal
Item
Engine speed
Standard value for

new machine
Service limit
value
17.7 4.9
{1.8 0.5}
17.7 4.9
{1.8 0.5}
42.2 + 2.0
4.9
42.2 + 2.0
4.9
{4.3 + 0.2
0.5 }
{4.3 + 0.2
0.5 }
45 5
45 5
1,400 50
1,400 50
950 50
950 50
850 50
850 50
Power
mode
1,910 100
1,910 100
Economy
mode
1,730 100
1,730 100
2,150 50
2,150 50
1,250 50
1,250 50
2,200 50
2,200 50
1,550 50
1,550 50
1,550 50
1,550 50
2,600 50
2,600 50
2,350 50
2,350 50
N
{kg}
21.6 3.9
{2.2 0.45}
Max. 19.6
{Max. 2.0}
mm
24.5 1
24.5 2
2.55 0.2
{26 2.0}
2.55 0.2
{26 2.0}
2.55 0.2
{26 2.0}
2.55 0.2
{26 2.0}
0.91 0.10
{9.3 1.0}
0.91 0.10
{9.3 1.0}
0.59 0.10
{6.0 1.0}
0.59 0.10
{6.0 1.0}
1.81 0.15
{18.5 1.0}
1.81 0.15
{18.5 1.0}
Point 150mm from ped- Starting to
al fulcrum
depress
Operating effort
Travel
Fully
depressed
Point 150mm from pedal fulcrum
Torque converter lock- Engine coolant

up actuation speed
temperature:
Within operating range
Torque converter oil
Torque converter locktemperature:
up cancel speed
Hydraulic oil
temperature:
Torque converter stall
45 55C
speed
Engine
HM300-1
Transmission
shift-up speed
Transmission
shift-down speed
Transmission
shift-up speed
Transmission
shift-down speed
Transmission downshift inhibit speed
Engine coolant
temperature:
temperature:
Hydraulic oil
temperature:
45 55C
Brake mode:
Accelerator OFF or
brake ON
Brake
OFF
Brake
mode
Gearshift
lever
Power train
Oil pressure
Torque converter
outlet port pressure
Torque converter lockup clutch pressure
HM300-1
rpm
rpm
rpm
Center of lever grip

Between each position
Travel
Torque converter
inlet port pressure
mm
Normal
mode
Overrun prevention
cancel speed
Power train main relief

pressure
N
{kg}
Brake
ON
Overrun prevention
actuation speed
Operating effort
Unit

Low idle
temperature:
High idle
Gearshift lever: N
Torque converter oil temperature:
Engine speed: High idle
MPa
{kg/cm2}
MPa
{kg/cm2}
20-3
1c
1
(9)
Machine model
Category
Standard value for

new machine
Service limit
value
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
Transmission 1st
clutch pressure
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
Transmission 2nd
clutch pressure
2.35 0.15
{24.0 1.5}
2.35 0.15
{24.0 1.5}
Transmission 3rd
clutch pressure
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
2.45 0.15
{25.0 1.5}
Inter-axle differential
lock clutch pressure
2.35 0.15
{24.0 1.5}
2.35 0.15
{24.0 1.5}
Transmission
lubricating pressure
(reference)
0.147 0.029
{1.5 0.3}
0.147 0.029
{1.5 0.3}
6.2 5%
6.2 5%
9.8 5%
9.8 5%
15.2 5%
15.2 5%
23.9 5%
23.9 5%
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%
0.343
{3.50}
0.343
{3.50}
0.402
{4.1}
0.402
{4.1}
N
{kg}
Max. 299
{Max. 30.5}
Max. 299
{Max. 30.5}
mm
66 5
66 5
N
{kg}
5.9 9.8
{0.6 1.0}
3.0 14.7
{0.3 1.5}
(degree)
78 02
78 40
Item
Transmission Lo
clutch pressure
Oil pressure
Transmission Hi
clutch pressure

Power train
F2
Travel speed
F3
F4
km/h
Front
Standard tire: 23.5 R25

Dump body: Unloaded
Brake
pedal
Center,
rear
Operating effort
Retarder
lever(q1)
Tire inflation
pressure
Brakes
MPa
{kg/cm2}
Flat ground
Engine coolant temperature:
Dump body: Unloaded
Travel resistance: 3.3%
F1
Operating effort
Tip of pedal
Travel
Travel
q1. Not installed in E-SPEC
20-4
Unit
MPa
{kg/cm2}
Transmission R
clutch pressure
c (4
1c
9)
HM300-1
Point 10mm from tip of lever
MPa
{kg/cm2}
HM300-1
Machine model
Item
Charge
pressure
Accumulator
Category
For front service brake
Oil pressure
Charge valve cut-out

pressure
Wheel brake
actuation pressure
Drop in wheel brake
actuation pressure
Wheel brake
Exhaust brake
actuation pressure
Parking
brake
Brakes
Parking brake
actuation pressure
Foot brake
braking performance
Retarder brake
braking performance
Foot brake braking
distance
Braking slope angle
Steering wheel
Operating effort
Steering
Service limit
value
4.4 0.15
{45 1.5}
4.4 0.15
{45 1.5}
4.4 0.15
{45 1.5}
4.4 0.15
{45 1.5}
11.77 + 0.29
0
11.77 + 0.29
0
{120 + 3.0
0 }
{120 + 3.0
0 }
20.59 + 0.98
0.5
20.59 + 0.98
0.5
{210 + 10
5 }
{210 + 10
5 }
4.9 0.49
{50 5}
4.9 0.49
{50 5}
Max. 0.49
{Max. 5}
Max. 0.49
{Max. 5}
3.92 0.4
{40 4.0}
3.92 0.4
{40 4.0}
2.60 0.4
{26.5 4.0}
2.60 0.4
{26.5 4.0}
1,440
1,440
1,440
1,440
Max. 22.3
Max. 22.3
rpm
1,490
1,490
When load is 27.3t

Slope angle (sin )
Min. 25
Min. 25
9 1% downhill slope
When load is 27.3t
Travel speed: 50 3km/h
Max. 102
Max. 102
N
{kg}
Max. 29.4
{Max. 3.0}
Max. 35.3
{Max. 3.6}
mm
Max. 150
Max. 150
Turns
4.3 0.4
4.3 0.6
Sec.
Max. 6
Min. 6
MPa
{kg/cm2}
20.59 + 0.98
0
20.59 + 0.98
0
{210 + 10
0 }
{210 + 10
0 }
Gas temperature
(atmosphere temperature):
20 5 C
Play
No. of turns
Turning time
Steering relief pressure
Unit
MPa
{kg/cm2}
Wheel brake actuation pressure:

Actuation pressure when brake is
operated for first time after engine is stopped
Drop in wheel brake actuation
pressure:
Drop in pressure 5 minutes after
MPa
specified oil pressure (4.9MPa
2
}
{kg/cm
2
{50kg/cm }) is applied
Parking, exhaust brake actuation
pressure:
Engine at high idle
Parking brake switch: ON
Exhaust brake switch: ON
Gearshift lever: D
Torque converter stall speed
Flat, dry road surface
When load is 27.3t
Travel speed: 32km/h
Engine at high idle

Braking performance Gearshift lever: D
Engine stall speed
Emergency brake braking

distance
HM300-1
Standard value for

new machine
For rear service brake

Charge valve cut-in
pressure
HM300-1
Engine speed: Low idle

Gearshift lever: N (stopped)
Measure at circumference of steering wheel
Operating effort:
When turning at 10rpm
Play:
Until point where tires start to move
No. of turns: Lock - lock
Turning time: Lock - lock
Hydraulic oil temperature:
45 55 C
rpm
20-5
1
(10)
Machine model
Front
Item
Rear
Suspension cylinder
Category
Installed length (a)

Pressure
HM300-1
Horizontal
road surface
Dump body:
Unloaded
Installed length (a)

Pressure
Engine stopped
Center of grip
Unit
Standard value for

new machine
Service limit
value
mm
163 10
163 10
MPa
{kg/cm2}
5.88 0.49
{60 5.0}
5.88 0.49
{60 5.0}
mm
106 5
106 5
MPa
{kg/cm2}
0.98 0.15
{10 1.5}
0.98 0.15
{10 1.5}
Max. 29.4
{Max. 3.0}
Max. 35.3
{Max. 3.6}
HOLD
RAISE
RAISE
HOLD
Dump lever operating effort
HOLD
FLOAT
FLOAT
HOLD
Must return smoothly when engine is

at high idle
N
{kg}
FLOAT
LOWER
LOWER
FLOAT
Dump body
Dump
Lifting time
Lowering time
Hydraulic drift
Dump main relief pressure
Dump pilot relief pressure
Sec.

70 90 C
Hold at point where No. 2 cylinder
is extended 100mm
Engine stopped
Downward movement at tip of
dump body over 5 minutes
mm

45 55 C
20-6
41
(10)

45 55 C
Engine speed: Low idle
(Reference value)
Max. 35.3
{Max. 3.6}
Max. 29.4
{Max. 3.0}
Max. 35.3
{Max. 3.6}
Max. 29.4
{Max. 3.0}
Max. 35.3
{Max. 3.6}
Must return smoothly when engine is

at 2,000rpm

70 90 C
Lowering time when operating
FLOAT

45 55 C
Max. 29.4
{Max. 3.0}
MPa
{kg/cm2}
12 1.5
12 1.5
Max. 12.5
Max. 12.5
Max. 85
170
20.59 + 0.98
0
20.59 + 0.98
0
{210 + 10
0 }
{210 + 10
0 }
3.4 0.49
{35 5}
3.4 0.49
{35 5}
2.6 0.49
{27 5}
2.6 0.49
{27 5}
HM300-1
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

System Name of component
Connector Inspection
No.
method
Measurement
conditions
Judgement table
If the condition is as shown in the table below, it is 1)Insert T-adapter to

normal
AS1.
Potentiometer
Between (3) and (1)
Between (2) and (3)
Acceleration pedal
(throttle sensor)
AS1
Measure Switch
voltage
Pin
Between (5)
and (4)
Between (6)
and (4)
Engine Ne rotation
sensor
NE
(male)
Measure
resistance
Engine G rotation
sensor
G
(male)
Measure
resistance
Potentiometer
voltage
Max. 0.446V
Min. 0.446V
Max. 0.446V
Min. 0.446V
4.6 5.4V
0.3 4.5V
2)Turn starting
switch ON.
Voltage
Max. 1V
15 30V
20 30V
Max. 1V
If the condition is as shown in the table below, it is 1)Turn starting

normal
switch OFF.
Between (1) and (2)
Between (1) (2) and ground
85 210
Min. 1M
2)Disconnect NE.

normal
switch OFF.
Between (1) and (2)
1.4k 3.5k
Min. 1M
2)Disconnect G.
Engine controller system

normal
switch OFF.
Engine oil
low-pressure switch
PSL
Measure
(terminal) resistance
Position
Engine
Between
switch terminal
and ground
Engine
stopped
At 600rpm
and above
Resistance
value
2)Disconnect PSL.
Max. 1
Min. 1M

normal
switch OFF.
Engine oil
high-pressure switch
PSH
Measure
Engine coolant
low-temperature
sensor
TWL
(male)
Measure
resistance
Engine coolant
high-temperature
sensor
TWH
(male)
Measure
resistance
Fuel temperature
sensor
THL
(male)
Measure
resistance
Position
Engine
Between
switch terminal
and ground
Engine
stopped
At 1,300rpm
and above
Resistance
value
2)Disconnect PSH.
Max. 1
Min. 1M

normal
switch OFF.
Between (1) and (2)
9k 0.3k
Min. 1M
2)Disconnect TWL.

normal
switch OFF.
Between (1) and (2)
90k 3.5k
Min. 1M
2)Disconnect TWH.

normal
switch OFF.
Between (1) and (2)
9k 0.3k
Min. 1M
2)Disconnect THL.

normal
switch OFF.
Engine oil filter

clogging switch
HM300-1
OF
Measure
Resistance
value
Position
Oil filter
Between
switch terminal
and ground
When normal
Max. 1
When clogged
Min. 1M
2)Disconnect OF.
20-7
1c
1
(9)
No.
method
Measurement
conditions
Judgement table

normal
switch OFF.
Engine oil level switch
20-8
c 11 c
OL
(male)
Measure
resistance
Boost pressure sensor
PIM
(male)
Measure
voltage
Common rail fuel

pressure sensor
PFUEL
(male)
Measure
voltage
Fuel supply pump

PCV1
PCV1
(male)
Measure
resistance
Fuel supply pump

PCV2
PCV2
(male)
Measure
resistance
No. 1 injector solenoid
CN1
(male)
Measure
resistance
CN2
(male)
Measure
resistance
CN3
(male)
Measure
resistance
CN4
(male)
Measure
resistance
CN5
(male)
Measure
resistance
CN6
(male)
Measure
resistance
Pin
Oil level
Between (1)
and ground
When normal
When low
Resistance
value
Max. 1
Min. 1M
2)Disconnect OL.

normal
PIM.
Between (1) and (3)
Between (2) and (3)
4.6 5.4V
0.3 4.7V
2)Turn starting
switch ON.

normal
PFUEL.
Between (1) and (3)
Between (2) and (3)
4.6 5.4V
0.3 4.7V
2)Turn starting
switch ON.

normal
switch OFF.
Between (1) and (2)
2.3 5.3
Min. 1M
2)Disconnect PCV1.

normal
switch OFF.
Between (1) and (2)
2.3 5.3
Min. 1M
2)Disconnect PCV2.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN1.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN2.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN3.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN4.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN5.

normal
switch OFF.
Between (1) and (2)
0.4 1.1
Min. 1M
2)Disconnect CN6.
HM300-1
No.
method
Measurement
conditions
Judgement table

normal
SF1.
Pin
Transmission controller system
Gearshift lever
Acceleration pedal
(throttle sensor)
Engine speed sensor
SF1
Measure
voltage
AS2
Measure
voltage
EREV
(male)
Measure
resistance
Gearshift lever position

and voltage
2)Turn starting
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
Between (6)
Other than D:
D: 20 30V
and (2)
Max. 1V
Between (7)
Other than 5:
5: 20 30V
and (2)
Max. 1V
Between (8)
Other than 4:
4: 20 30V
and (2)
Max. 1V
Between (9)
Other than 3:
3: 20 30V
and (2)
Max. 1V
Between (10)
Other than 2:
2: 20 30V
and (2)
Max. 1V
Between (11)
Other than 1:
1: 20 30V
and (2)
Max. 1V
Between (12)
Canceled:
HOLD: 20 30V
and (2)
Max. 1V
normal
AS2.
Between (1) and (3)
Between (2) and (3)
4.6 5.4V
1.0 4.0V
2)Turn starting
switch ON.

normal
switch OFF.
Between (1) and (2)
500 1,000
Min. 1M
2)Disconnect EREV.

normal
switch OFF.
Air cleaner clogging

sensor
T11
(male)
Measure
resistance
Pin
Air cleaner
Between (1)
and (2)
When normal
When clogged
Resistance
value
Max. 1
Min. 1M
2)Disconnect T11.

normal
switch OFF.
Radiator coolant level

switch
T01
(male)
Measure
resistance
Pin
Between (1)
and (2)
Radiator
coolant level
When normal
When low
Resistance
value
Max. 1
Min. 1M
2)Disconnect T01.
If the condition is as shown in the table below, it is 1)Disconnect terminormal

nal R.
Alternator
R, E
terminal
Measure
voltage
Position
Between R
and E
Engine
Mid-range
speed or above
Voltage
2)Start engine.
27.6 29.5V
If the battery is old, or after starting in cold areas,

the voltage may not rise for some time.
normal
switch OFF.
Fuel level sensor
HM300-1
T08
(male)
Measure
resistance
Pin
Fuel level
Between (1)
and (2)
Full
Empty
Resistance
value
Max. 12
74 100
2)Disconnect T08.
20-9
1c
1
(9)
No.
method
Transmission input
shaft speed sensor
N1
(male)
Measure
resistance
Transmission
intermediate shaft
speed sensor
N2
(male)
Measure
resistance
Transmission output
shaft R speed sensor
N3
(male)
Measure
resistance
Measurement
conditions
Judgement table

normal
switch OFF.
Between (1) and (2)
Between (2) and (3)
500 1,000
Min. 1M
2)Disconnect N1.

normal
switch OFF.
Between (1) and (2)
500 1,000
Min. 1M
2)Disconnect N2.

normal
switch OFF.
Between (1) and (2)
500 1,000
Min. 1M
2)Disconnect N3.

normal
switch OFF.
Lock-up clutch
ECMV fill switch
L/U-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect
L/U-SW.

normal
switch OFF.
R clutch
ECMV fill switch
R-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect R-SW.

normal
switch OFF.
Hi clutch
ECMV fill switch
H-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect H-SW.

normal
switch OFF.
Lo clutch
ECMV fill switch
L-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect L-SW.

normal
switch OFF.
1st clutch
ECMV fill switch
1-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect 1-SW.

normal
switch OFF.
2nd clutch
ECMV fill switch
2-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect 2-SW.

normal
switch OFF.
3rd clutch
ECMV fill switch
20-10
c
1c
3-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect 3-SW.
HM300-1
No.
method
Measurement
conditions
Judgement table

normal
switch OFF.
Differential lock clutch

ECMV fill switch
D/L-SW
(male)
Measure
resistance
Pin
Clutch
Between (1)
and ground
When disengaged
When engaged
Resistance
value
Min. 1M
Max. 1
2)Disconnect
D/L-SW.

normal
switch OFF.

temperature sensor
TC-SE
(male)
Measure
resistance
Pin
Between (1)
and (2)

pressure sensor
TC-INT
(male)
Measure
voltage
Torque converter
Resistance
oil temperature
value
25C
37k 50k
100C
3.5k 4.0k
2)Disconnect
TC-SE.

normal
TC-INT.
Between (2) and (1)
Between (3) and (1)
20 30V
0.8 2.0V
2)Turn starting
switch ON.

normal
switch OFF.
Transmission oil filter

clogging switch
T03
(male)
Measure
resistance
Pin
Between (1)
and (2)
Transmission
oil filter
When normal
When clogged
Resistance
value
Max. 1
Min. 1M
2)Disconnect T03.

normal
switch OFF.
Transmission valve oil

temperature sensor
LUB-T
(male)
Measure
resistance
Pin
Between (1)
and (2)
Transmission
oil temperature
25C
100C
Resistance
value
37k 50k
3.5k 4.0k
2)Disconnect LUB-T.

normal
switch OFF.
Hydraulic tank oil

level switch
T06
(male)
Measure
resistance
Pin
Between (1)
and (2)
Hydraulic
oil level
When normal
When low
Resistance
value
Max. 1
Min. 1M
2)Disconnect T06.

normal
switch OFF.
Hydraulic oil filter

clogging switch
T05
(male)
Measure
resistance
Pin
Between (1)
and (2)
Hydraulic
oil filter
When normal
When clogged
Resistance
value
Max. 1
Min. 1M
2)Disconnect T05.

normal
switch OFF.
Steering oil
temperature switch
T04
(male)
Measure
resistance
Pin
Between (1)
and ground
Steering oil
temperature
25C
123C
Resistance
value
Max. 1
Min. 1M
2)Disconnect T04.

normal
switch OFF.
Front brake oil

temperature sensor
T15
(male)
Measure
resistance
Pin
Between (1)
and (2)
HM300-1
Brake oil
temperature
25C
100C
Resistance
value
37k 50k
3.5k 4.0k
2)Disconnect T15.
20-11
1!
No.
method
Measurement
conditions
Judgement table

normal
switch OFF.
Center brake oil

temperature sensor
T14
(male)
Measure
resistance
Pin
Between (1)
and (2)
Brake oil
temperature
25C
100C
Resistance
value
37k 50k
3.5k 4.0k
2)Disconnect T14.

normal
T10.
Inclination sensor
T10
(male)
Measure
voltage
Between (1) and (3)
Between (2) and (3)
20-12
!
1!
Lock-up clutch
ECMV solenoid
L/U-PS
(male)
Measure
resistance
R clutch
ECMV solenoid
R-PS
(male)
Measure
resistance
Hi clutch
ECMV solenoid
H-PS
(male)
Measure
resistance
Lo clutch
ECMV solenoid
L-PS
(male)
Measure
resistance
1st clutch
ECMV solenoid
1-PS
(male)
Measure
resistance
2nd clutch
ECMV solenoid
2-PS
(male)
Measure
resistance
3rd clutch
ECMV solenoid
3-PS
(male)
Measure
resistance
Differential lock clutch

ECMV solenoid
D/L-PS
(male)
Measure
resistance
11 13V
1.4 4.6V
(when horizontal:
2.9 3.1V)
2)Turn starting
switch ON.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect
L/U-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect R-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect H-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect L-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect 1-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect 2-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect 3-PS.

normal
switch OFF.
Between (1) and (2)
5 15
Min. 1M
2)Disconnect
D/L-PS.
HM300-1
No.
method
Transmission output
shaft F speed sensor
FE1
(male)
Measure
resistance
Front accumulator oil

pressure sensor
B25
(male)
Measure
voltage
Rear accumulator oil

pressure sensor
B24
(male)
Measure
voltage
Measurement
conditions
Judgement table

normal
switch OFF.
Between (1) and (2)
500 1,000
Min. 1M
2)Disconnect FE1.

normal
B25.
Between (2) and (1)
Between (3) and (1)
20 30V
1.8 3.5V
2)Turn starting
switch ON.

normal
B24.
Between (1) and (2)
Between (1) and (3)
20 30V
1.8 3.5V
2)Turn starting
switch ON.
If the condition is as shown in the table below, it is Measuring voltage

normal
1)Insert T-adapter to
Potentiometer
Retarder controller(q1) system
Between (1) and (3)

Between (2) and (3)
Retarder lever
RTL
Measure
voltage,
measure
resistance
4.1 4.8V
0.3 4.7V
Switch
Pin (male)
Between (4)
and (6)
Between (5)
and (6)
Lever position
Released
position
Applied
position
Released
position
Applied
position
Resistance
value
RTL.
2)Turn starting
switch ON.
Measuring resistance
1)Turn starting
switch OFF.
2)Disconnect RTL.
Max. 1
Min. 1M
Min. 1M
Max. 1

normal
switch OFF.
Brake cooling filter

clogging sensor
B03
(male)
Measure
resistance
Pin
Retarder filter
Between (1)
and (2)
When normal
When clogged
Resistance
value
Max. 1
Min. 1M
2)Disconnect B03.
If the condition is as shown in the table below, it is 1)Disconnect B15.

normal
2)Start engine.
Foot brake oil

pressure switch
B15
(male)
Measure
resistance
Pin
Between (1)
and (2)
Brake oil
pressure
Max. 0.39MPa
{Max. 4kg/cm2}
Min. 0.59MPa
{Min. 6kg/cm2}
Resistance
value
Min. 1M
Max. 1

normal
2)Start engine.
Retarder oil
pressure switch
B16
(male)
Measure
resistance
Pin
Between (1)
and (2)
q1. Used as the brake controller in E-SPEC.
HM300-1
Brake oil
pressure
Max. 0.39MPa
{Max. 4kg/cm2}
Min. 0.59MPa
{Min. 6kg/cm2}
Resistance
value
Min. 1M
Max. 1
20-13
4c
1
No.
method
Measurement
conditions
Judgement table

normal
2)Start engine.
Parking brake oil

pressure switch
B17
(male)
Measure
resistance
Pin
Parking brake
Between (1)
and (2)
When released
When applied
Resistance
value
Min. 1M
Max. 1

normal
2)Start engine.
Exhaust brake oil

pressure switch
B30
(male)
Measure
resistance
Pin
Exhaust brake
Between (1)
and (2)
When released
When applied
Resistance
value
Min. 1M
Max. 1

normal
switch OFF.
Front brake (L.H.)

wear switch
B01
(male)
Measure
resistance
Pin
Brake
Between (1)
and (2)
When normal
When worn
Resistance
value
Max. 1
Min. 1M
2)Disconnect B01.

normal
switch OFF.
Front brake (R.H.)

wear switch
B28
(male)
Measure
resistance
20-14
Brake
Between (1)
and (2)
When normal
When worn
Resistance
value
Max. 1
Min. 1M
2)Disconnect B28.

normal
switch OFF.
Center brake (L.H.)

wear switch
B02
(male)
Measure
resistance
Pin
Brake
Between (1)
and (2)
When normal
When worn
Resistance
value
Max. 1
Min. 1M
2)Disconnect B02.

normal
switch OFF.
Center brake (R.H.)

wear switch
B26
(male)
Measure
resistance
Dump lever
(potentiometer)
HSL
Measure
voltage
Body positioner
sensor
B34
(male)
Measure
voltage
Front brake pressure

reducing valve
B19
(male)
Measure
resistance
Rear brake pressure

reducing valve
B18
(male)
Measure
resistance
c 4
1c
Pin
Pin
Brake
Between (1)
and (2)
When normal
When worn
Resistance
value
Max. 1
Min. 1M
2)Disconnect B26.

normal
HSL.
Between (4) and (1)
Between (3) and (1)
Between (2) and (1)
4.6 5.4V
0.3 4.7V
0.3 4.7V
2)Turn starting
switch ON.

normal
B34.
Between (3) and (1)
Between (2) and (1)
4.6 5.4V
0.3 4.7V
2)Turn starting
switch ON.

normal
switch OFF.
Between (1) and (2)
10 30
Min. 1M
2)Disconnect B19.

normal
switch OFF.
Between (1) and (2)
10 30
Min. 1M
2)Disconnect B18.
HM300-1
No.
method
Exhaust brake
solenoid
B29
(male)
Measure
resistance
Dump lever
(kick-out solenoid)
LKO
(male)
Measure
resistance
Dump pilot valve

(selector solenoid)
B31
(male)
Measure
resistance
Dump pilot valve

(EPC solenoid)
B32
(male)
Measure
resistance
Measurement
conditions
Judgement table

normal
switch OFF.
Between (1) and (2)
20 60
Min. 1M
2)Disconnect B29.

normal
switch OFF.
Between (1) and (2)
39 5%
Min. 1M
2)Disconnect LKO.

normal
switch OFF.
Between (1) and (2)
15 35
Min. 1M
2)Disconnect B31.

normal
switch OFF.
Between (1) and (2)
15 20
Min. 1M
2)Disconnect B32.

normal
switch OFF.
Machine monitor
check switch
CK1
(male)
Measure
resistance
Pin
Switch
Between (3)
and (6)
Released
Pressed
Resistance
value
Max. 1
Min. 1M
2)Disconnect CK1.

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

normal
switch OFF.
Machine mode
selector switch 2
CH2
(male)
Measure
resistance
Pin
Between (2)
and (3)
Between (1)
and (3)
Switch
[ >] Pressed
Neutral
Neutral
[ < ] Pressed
Resistance
value
Max. 1
Min. 1M
Min. 1M
Max. 1
2)Disconnect CH2.

normal
switch OFF.
Power mode
selector switch
PWM
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect PWM.

normal
switch OFF.
AISS LOW switch
AISS
(male)
Measure
resistance
HM300-1
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect AISS.
20-15
4c
1
No.
method
Measurement
conditions
Judgement table

normal
switch OFF.
Inter-axle differential
lock switch
DEF
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect DEF.

normal
switch OFF.
Exhaust brake switch
EXH
(male)
Measure
resistance
Pin
Switch
Between (1)
and (2)
Up
Neutral
Neutral
Down
Between (1)
and (3)
Resistance
value
Max. 1
Min. 1M
Min. 1M
Max. 1
2)Disconnect EXH.

normal
switch OFF.
Seat belt switch
SBS
(male)
Measure
resistance
Pin
Belt
Between (1)
and (2)
Removed
Fitted
Resistance
value
Min. 1M
Max. 1
2)Disconnect SBS.

normal
switch OFF.
Working lamp (front)

switch
WRF
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect WRF.

normal
switch OFF.
Others (other than controllers)
Working lamp (rear)

switch
WRR
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect WRR.

normal
switch OFF.
Hazard lamp switch
Night lighting dimmer

switch
HAZ
(male)
LS
Measure
resistance
Measure
voltage
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect HAZ.

normal
LS.
Between (1) and (3)
Between (2) and (3)
20 30V
6 27V
2)Turn starting
switch ON.

normal
switch OFF.
Fog lamp switch
FOG
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect FOG.

normal
switch OFF.
Yellow rotating lamp

switch
20-16
c
1c
BLS
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect BLS.
HM300-1
No.
method
Measurement
conditions
Judgement table

normal
switch OFF.
Side lamp switch
SDE
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect SDE.

normal
switch OFF.
Emergency steering
switch
ST
Measure
Position
Switch
Between ST1
and ST2
OFF
ON
Resistance
value
Min. 1M
Max. 1
2)Disconnect ST1
and ST2.

normal
switch OFF.
Parking brake switch
R33
(male)
Measure
resistance
Pin
Switch
Between (1)
and (3)
Up
Down
Resistance
value
Min. 1M
Max. 1
2)Disconnect R33.

normal
switch OFF.
Front accumulator oil

pressure switch
B21
(male)
Measure
resistance
Pin
Between (1)
and (2)
Differential lock
oil pressure
Max. 4.9MPa
{Max. 50kg/cm2}
Min. 5.9MPa
{Min. 60kg/cm2}
Resistance
value
2)Disconnect B21.
Min. 1M
Max. 1

normal
switch OFF.
Rear accumulator oil

pressure switch
B20
(male)
Measure
resistance
Pin
Between (1)
and (2)
Parking brake
solenoid
Relay (5-pin type)
Relay (6-pin type)
HM300-1
B14
(male)
(male)
(male)
Measure
resistance
Measure
resistance
Measure
resistance
Differential lock
oil pressure
Max. 4.9MPa
{Max. 50kg/cm2}
Min. 5.9MPa
{Min. 60kg/cm2}
Resistance
value
2)Disconnect B20.
Min. 1M
Max. 1

normal
switch OFF.
Between (1) and (2)
30 50
Min. 1M
2)Disconnect B14.

normal
switch OFF.
Between (1) and (2)
Between (3) and (5)
Between (3) and (6)
100 500
Min. 1M
Max. 1
2)Disconnect relay
connector.

normal
switch OFF.
Between (5) and (6)
Between (1) and (2)
Between (3) and (4)
100 500
Min. 1M
Max. 1
2)Disconnect relay
connector.
20-17
1!
No.
method
Measurement
conditions
Judgement table
Combination switch

normal
switch OFF.
Lamp switch
CM
(male)
Measure
resistance
Dimmer switch
CM
(male)
Measure
resistance
2)Disconnect CM.
Between
connected pins:
!
!
Small
Max. 1
Head
!
!
!
Between
other pins:
If the condition is as shown in the table below, it is
Min. 1M
normal
Switch
Switch
Turn signal switch
CM
(male)
Measure
resistance
Switch
(6)
L (left)
R (right)
(4)
(5)
(7)
(8)
!

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

normal
WPS
(male)
Measure
resistance
Switch
(7)
WASH
(8)
(9)
!
(10)
!
OFF
WASH
1!
(3)

normal
ON
20-18
(2)
OFF
PASS
Rear wiper switch
(1)
OFF
HM300-1
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
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Measurement Item
Symbol
Part Number
Part Name
Air supply pressure
799-201-2202 Boost gauge kit
101 199.9kPa
{760 1,500mmHg}
Exhaust, coolant, and

oil temperatures
799-101-1502 Digital temperature gauge
99.9 1,299C
Exhaust color
799-201-9001 Handy smoke checker
Commercially
available
Smoke meter
Feeler gauge
Bosch index : 0 9
Valve clearance
Commercially
available
Blow-by pressure
799-201-1504 Blow-by checker
0 4.9MPa {0 500mmH2O}
799-101-5002 Hydraulic tester
2.5, 5.9, 39.2, 58.8MPa

{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
07002-11023 O-ring
799-101-5260 Nipple
799-101-5270 Seal washer
799-101-5230 Nipple
07002-11423 Seal washer
Brake oil pressure
Accumulator
Suspension cylinder
20-102
Remarks
(10)
1
793-520-1805 Brake test kit
P1
762-610-1700 Gas charge tool
M10 P1.25
M12 P1.5
M14 P1.5
792-610-1310 Nipple (For Russia)
GOST
792-610-1320 Nipple (For USA)
CGA No. 351
792-610-1330 Nipple (For USA)
ASA B-571-1965
792-610-1350 Nipple (For Germany)
DIN 477-1963
NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK)
BS 341 Part1-1962
792-610-1000 Suspension tool
792-610-1130 Pump
H2 H6: Pump assembly

Kit Part No.: 792-610-1100
792-610-1110 Hose
792-610-1120 Joint
07020-21732 Fitting
792-610-1140 Joint
792-610-1250 Valve
792-610-1260 Nipple
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}
P2
Intake: 0.35mm; exhaust: 0.57mm
H7 H13: Charging tool assembly

Kit Part No.: 792-610-1200
HM300-1
Measurement Item
Symbol
Part Number
Part Name
79A-264-0021 Push-pull scale
0 294N {0 30kg}
79A-264-0091 Push-pull scale
0 490N {0 50kg}
792-454-1100 Pump assembly
For tilt cylinder
Operating effort
Method of tilting cab up
Stroke, hydraulic drift
Commercially
available
Scale
Work equipment speed
Commercially
available
Stop watch
Voltage, resistance
79A-264-0211 Tester
Compression pressure
Remarks
795-502-1590 Compression garge
795-471-1410 Adapter
Kit Part No.: 795-502-1205

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
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 55C
60 80C
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 MACHINE MONITOR in the TROUBLESHOOTING 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
c
1 c
(9)
HM300-1
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE
(BOOST PRESSURE)
Be careful not to touch any hot parts when removing or installing the measuring tools.
1. Open the engine hood.
2. Remove air supply pressure measurement plug
(1).
5. Turn the parking brake switch ON, depress the

brake pedal, then set the gearshift lever to the D
position.
If the gearshift lever is operated to any position other than the D position, the machine
may move off even if the brake is being depressed, so always measure at the D position.
6. Depress the accelerator pedal gradually, run the
engine at high idle and stall the torque converter,
then measure the air supply pressure.
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 condition.
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 pressure 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 coupling (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)
MEASURING EXHAUST
TEMPERATURE
Wait for the temperature of the exhaust pipe to
go down before removing or installing the measuring equipment.
1. Open the engine hood and remove the adiabatic
cover of the turbocharger.
2. Remove exhaust temperature measurement
plug (1).
3. Install sensor, then connect to digital temperature gauge B.

Clamp the wiring harness of the temperature
gauge at a suitable place to prevent it from
touching any hot part.
MEASURING EXHAUST TEMPERATURE
1) Start the engine and raise the temperature of

the coolant to the operating range.
2) Turn the parking brake switch ON, depress
the brake pedal, then set the gearshift lever
to the D position.
If the gearshift lever is operated to any
position other than the D position, the
machine may move off even if the brake
is being depressed, so always measure
at the D position.
3) Depress the accelerator pedal gradually, run
the engine at high idle and stall the torque
converter. At the same time, operate the
dump lever to the LOWER position and relieve the oil pressure (full stall).
Continue until the exhaust temperature
reaches the standard value of 650C.
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.
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
down from the full stall condition, so
measure the temperature when it stabilizes.
If the exhaust temperature does not go
down but rises, make the set temperature at full stall higher.
After completing the measurement, lower the engine speed to low idle, then return 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 overheating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the exhaust temperature, then stall only the torque
converter and measure the temperature.
20-106
c
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(9)
HM300-1
MEASURING EXHAUST TEMPERATURE
5. When measuring the maximum value for the exhaust 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 automatically recorded.
HM300-1
20-107
1 c
MEASURING EXHAUST COLOR
MEASURING EXHAUST
COLOR
Be careful not to touch any hot parts when removing 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
1) Install filter paper to Handy Smoke Checker
C1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
4) Accelerate the engine suddenly, and operate
the handle of Handy Smoke Checker C1
while running at high idle to collect the exhaust gas on the filter paper.
2) Connect the air hose and the socket of the

probe hose and accelerator switch to Smoke
Meter C2.
Keep the pressure of the air supply below 1.5MPa {15kg/cm2}.
3) Connect the power cord to the AC100V
socket.
Before connecting the cord, check that
the power switch of the Smoke Meter is
OFF.
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.
20-108
c
1 c
(9)

7) Accelerate the engine suddenly, and depress 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 exhaust 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 original condition.
HM300-1
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be
careful not to touch the exhaust manifold or muffler and burn yourself, or to get caught in any rotating parts.
MEASURING COMPRESSION PRESSURE
5. Fit adapter N2 and connect to compression

gauge N1.
Coat the connection of the adapter and
gauge with a small amount of engine oil to
make leakage more difficult.
Secure the adapter with the injector holder.
3 Mounting bolt:
58.8 73.5Nm {6.0 7.5kgm}
Measure the compression pressure with the engine warmed up (engine oil temperature: 40
60C).
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 without fail.
Cover the connector at the controller end
with vinyl to prevent short circuits and leakages 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 indicator remains steady.
measuring equipment and return to the original
condition.
For details of the assembly of the fuel injector and fuel high-pressure tub, see DISASSEMBLY AND ASSEMBLY.
HM300-1
20-109
1 !
ADJUSTING VALVE
CLEARANCE
1. Open left and right engine side covers.
ADJUSTING VALVE CLEARANCE
5. To adjust the valve clearance, insert feeler gauge

F into clearance b between rocker arm (4) and
cross head (5), and adjust the valve clearance
with adjustment screw (6).
Insert the feeler gauge and turn the adjustment 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).
3 Head cover mounting bolt:

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 clearance 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 compression top dead center, so rotate it one more
turn.
7. Rotate the crankshaft 120 each time in the normal 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 highpressure tube, see DISASSEMBLY AND ASSEMBLY.
20-110
!
1 !
HM300-1
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.

3. Start the engine and raise the temperature of the

coolant to the operating range.
parking brake pedal, then set the gearshift lever
to the D position.
engine at high idle and stall the torque converter,
and measure the blow-by pressure.
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)
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
2. Remove oil pressure measurement plug (1).

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

gauge F.
Use a 0.98MPa {10kg/cm2} oil pressure gauge.

coolant to the operating range.
5. Measure the oil pressure with the engine at both
low idle and high idle.
20-112
c
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(9)
HM300-1
HANDLING EQUIPMENT IN FUEL CIRCUIT

RELEASING REMAINING
HANDLING EQUIPMENT
PRESSURE IN FUEL SYSTEM
CIRCUIT
HANDLING EQUIPMENT IN
FUEL CIRCUIT
RELEASING REMAINING
PRESSURE IN FUEL SYSTEM
Precautions when carrying out inspection and

maintenance of fuel system
With the common rail type fuel injection system,
more precise equipment is used than on the conventional fuel injection pump and nozzle, so
problems may occur if dirt or dust get in.
When carrying out inspection or maintenance of
the fuel line, pay more attention than usual to
prevent dirt or dust from getting in. If there is any
dirt stuck to any part, use clean fuel to wash it off
completely.
Precautions when replacing fuel filter cartridge
Always use a genuine Komatsu part for the fuel
filter cartridge.
With the common rail type fuel injection system,
more precise equipment is used than on the conventional fuel injection pump and nozzle. To prevent dirt or dust from getting in, so a special filter
with highly efficient filtering performance is used.
For this reason, do not use imitation filters. If
they are used, there is danger of problems occurring in the fuel line.
When the engine is running, pressure is generated in both the low-pressure circuit and highpressure circuit of the fuel line.
Low-pressure circuit:
Feed pump fuel filter fuel supply pump
High-pressure circuit:
Fuel supply pump common rail fuel injector
For both the low-pressure circuit and high-pressure circuit, the pressure automatically goes
down to a safe level 30 seconds after the engine
is stopped.
The remaining pressure in the fuel circuit must
be completely released before carrying out inspection of the fuel system or removal or installation of the equipment. Always obey the
following precautions when carrying out the operation.
When inspecting the fuel line or removing or installing equipment, wait for at least 30 seconds
after the engine is stopped to release the remaining pressure in the fuel system before starting the operation. (There is still pressure
remaining in the circuit, so do not start operations immediately after the engine is stopped).
HM300-1
20-113
1 c
MEASURING FUEL PRESSURE
MEASURING FUEL
PRESSURE
Measure the fuel pressure only for the low-pressure circuit between the feed pump fuel filter
fuel supply pump.
The high-pressure circuit between the fuel supply pump common rail fuel injector is under
extremely high pressure, so it cannot be measured.
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
c
(9)
1 c
HM300-1
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 places) 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
2. Remove air bleed plug (2) of the fuel filter and

operate priming pump (4).
Continue operating the priming pump until
flow out from the plug hole. When fuel comes
out, install the plug.
3 Air bleed plug:
7.8 9.8Nm {0.8 1.0kgm}

3. There are the following two cases that the engine does not start up easily after bleeding air
from CRI, (Common Rail Injection System), i.e.
even after carrying out the Items 1 and 2 above.
If air has not been removed completely, leaving some in the system, cranking up the engine with the engine starting motor cannot
get rid of the remaining air in a short span of
time. Thus the engine start-up becomes difficult.
1) In the cases that the fuel has run out, that the
fuel filter has been replaced or that some fuel
device has been removed and installed.
Most of the fuel is left in the fuel circuit,
so the engine may be started after bleeding air with the air bleeding methods introduced in the Items 1 and 2 above.
2) In the case that a number of fuel devices
have been removed and installed in course
of engine overhauling.
Little fuel is left in the fuel circuit, so air
cannot be got rid of completely with the
air bleeding methods introduced in the
Items 1 and 2 above (i.e. ordinary method). In that case, bleed air in the following manner.
20-116
c
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(9)
Air bleeding steps

i) Remove air bleeding plug (2) of fuel filter
(1) and operate priming pump (4).
Continue to operate the priming
pump until fuel is confirmed to flow
out of the air bleeding plug hole and
then tighten it.
3 Air bleeding plug:
7.8 9.8Nm {0.8 1.0kgm}

ii) Remove fuel pressure measuring plug
(3) for the fuel filter and operate priming
pump (4).
out of the air bleeding plug hole and
then tighten it.
3 Fuel pressure measuring plug:
3.9 6.9Nm {0.4 0.7kgm}

iii) Loosen air bleeder (5) of the fuel supply
pump (only after loosening the lock nut)
and operate priming pump (4) 90 to 100
times.
out of air bleeder (5) and then tighten
it.
3 Air bleeder:
4.9 6.9Nm {0.5 0.7kgm}
Still continue to operate the priming

pump until it becomes harder to operate and a relief sound of overflow
valve (6) in the fuel supply pump is
heard. (A high pitch sound) It requires 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 motor running idly for more than 20 seconds. 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 seconds 4 times, insufficient air bleeding
is suspected of. In that case, start the
air bleeding steps once again from
the beginning.
HM300-1
REDUCED CYLINDER MODE OPERATION FOR ENGINE
4. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (4) 90 to 100 times.
Continue operating the priming pump until
fuel flows out from the bleeder.
When fuel comes out, tighten the bleeder,
then operate several times until the priming
pump becomes stiff.
3 Air bleeder:
4.9 6.9Nm {0.5 0.7kgm}

5. Crank the engine with the starting motor and
start the engine.
When the engine is cranked, the air in the
high-pressure circuit is automatically bled.
If the engine does not start, the air has probably been not properly bled from the lowpressure circuit, so repeat the procedure
from Step 2.
HM300-1
REDUCED CYLINDER MODE

OPERATION FOR ENGINE
Reduced cylinder mode operation for the engine
means setting the fuel injectors of a single cylinder or multiple cylinders electronically to the NO
injection condition to run the engine on a reduced number of cylinders. The reduced cylinder mode operation is used when it is thought
that one of the engine cylinders is not giving normal output (combustion). It is a method to determine which cylinder is not operating normally.
The reduced cylinder mode operation is carried
out by using the reduced cylinder mode operation setting function on the monitor panel.
For details of the method of operation, see the
SPECIAL FUNCTIONS OF MACHINE MONITOR.
20-117
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(9)
CHECKING FOR LEAKAGE IN

FUEL CIRCUIT
With the fuel system, the high-pressure circuit is
under extremely high pressure, so if fuel leaks
when the engine is running, there is danger of
fire.
Check for fuel leakage as follows when checking
the fuel circuit or when equipment has been removed and installed.
To make it easier to check for fuel leakage, wipe
the engine itself and the surrounding area clean
and remove all oil and grease before starting the
inspection.
1. Spray the fuel supply pump, common rail, fuel injector, and high-pressure piping connections
with a color checker (developing solution).
CHECKING FOR LEAKAGE IN FUEL CIRCUIT
7. Check the fuel piping and equipment for fuel

leakage.
Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with
color checker.
If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.
8. Start the engine, run it at high idle, then apply
load to the engine.
Carry out dump relief.
leakage.
color checker.
If no fuel leakage is found, the check is complete.
2. Start the engine, run it at under 1000rpm, and

when the speed stabilizes, stop the engine.
leakage.
color checker.
4. Start the engine and run it at low idle.
leakage.
color checker.
6. Start the engine and run it at high idle.
20-118
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HM300-1
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 !

ALTERNATOR BELT
TENSION
TESTING AND ADJUSTING AIR

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

TESTING AND
ADJUSTING
AIR CONDITIONER
COMPRESSOR
BELTTENSION
TENSION
TESTING
AND ADJUSTING
ALTERNATOR
BELT
1 !
HM300-1
ADJUSTING THE BODY MOUNT
ADJUSTING THE BODY

MOUNT
(If clearance is found by clearance check)
a Perform shim adjustment of dump body mount
according to the following procedure if there is
clearance between dump body bottom mount
and the frame top.
1. Measure the maximum clearance of (a) between
dump body mount (1) and top of frame (2) by using steel tape measure [1] and steal scale [2].
Measure 4 places in total of (A), (B) on right and
left sides.
3. Insert shims to each part of bottom mount.

a Use mounting bolt (3) of appropriate length
according to the thickness of the shims.
3 Mounting bolt:
235 285 Nm {23.5 29.5 kgm}
4. Raise the dump body and check that all of the 4
places of bottom mount are in contact with the
top of frame (2) evenly.
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 integral 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)
TESTING TORQUE
CONVERTER STALL SPEED
Stop the machine on flat ground, turn the parking
brake switch ON, and block the tires.
1. Switch the machine monitor display to the monitoring function of service mode 1 and display the
following 2 items at the same time with the monitoring function.
Monitoring items
(1) Code No. 01001:
Engine speed
(2) Code No. 30100:
MONITOR.
TESTING TORQUE CONVERTER STALL SPEED

engine at high idle and stall the torque converter
to raise the torque converter oil temperature.
5. When the torque converter oil temperature goes
above 90C, run the engine immediately at low
idle and return the gearshift lever to the N position.
Never operate the gearshift lever with the accelerator pedal depressed. It will cause a big
shock and will also lead to a reduction in the
service life of the machine.
6. Run the engine at a mid-range speed, and when
the torque converter oil temperature goes down
to approx. 80C, run at low idle.
Keep the gearshift lever at the N position.
7. Repeat Steps 3 6 and equalize the oil temperature in the torque converter and transmission.
8. At the same time as repeating Steps 3 and 4,
measure the stall speed when the torque converter oil temperature is 80C.
Measure the stall speed 2 or 3 times.

hydraulic oil and torque converter oil.
Torque converter oil temperature: 60 80C
Hydraulic oil oil temperature: 45 55C
brake pedal, then set the gearshift lever to the D
position.
HM300-1
The stall speed may vary according to the following conditions, so always measure the stall
speed at the time of delivery.
1) Variations according to the engine serial
number
2) Variations in engine output due to atmospheric pressure and temperature
3) Variations due to consumption torque of accessories
4) Variations due to features of the torque converter
5) Variations according to the method of measuring the stall
20-121
1 c
(9)
MEASURING POWER TRAIN OIL PRESSURE
Table of oil pressure measurement port positions and gauges to use

No.
Measurement location
Gauge
(MPa {kg/cm2})
Power train main relief pressure
5.9 {60}
Torque converter inlet port pressure
5.9 {60}
Torque converter outlet port pressure
0.98 {10}
Torque converter lock-up clutch pressure
5.9 {60}
Transmission Lo clutch pressure
5.9 {60}
Transmission Hi clutch pressure
5.9 {60}
Transmission 1st clutch pressure
5.9 {60}
Transmission 2nd clutch pressure
5.9 {60}
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 represented by the torque converter outlet port
pressure, so there is no need to measure it.
20-122
c
1 c
(9)
HM300-1

Wait for the oil temperature to go down fully before removing or installing the measuring tools.
When measuring the oil pressure when traveling, make sure that there is a wide travel area
and check the safety in the surrounding area.
When tilting the cab up or down, see METHOD
OF TILTING CAB UP for details.
When taking measurement of ECMV-related hydraulic oil pressure, remove and install the nipple, hoses and gauge for the measurement from
the rear underside of the cab.
Power train overall

1. Measuring power train main relief pressure
1) Tilt the cab up.
2) Remove oil pressure measurement plug (1),
then install nipple and hose [1].
Pull the hose out to the rear of the transmission.
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.

HM300-1
20-123
1 c
(9)
Torque converter related

2. Measuring torque converter inlet oil pressure
1) Fit hose [1] to hydraulic oil pressure measuring coupler (2).

range.
measure the oil pressure at high idle.
3. Measuring torque converter outlet oil pressure

1) Tilt the cab up.
2) Remove oil pressure measurement plug (3),
then install nipple and hose [1].
Pull the hose out to the rear of the transmission.
3) Tilt the cab down and return it to its original

position.
range.
measure the oil pressure at high idle.

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

pressure
1) Remove hydraulic oil pressure measuring
plug (4) and install the nipple and hoses for
measurement.
Transmission related
Table of gearshift lever positions, speed
ranges, and clutches actuated
Gearshift lever
R3 R2 R1 N D 5
!
! !
! !
! !
! !
!
!
!
!
!

range.
4) Turn the parking brake switch OFF, depress
to position 1.
5) Release the brake, travel at high idle, and
measure the oil pressure when the lock-up
pilot lamp lights up.
In F1, a maximum travel speed of approx. 6.2km/h is reached, so check carefully that the surrounding area is safe.

HM300-1
4
!
!
!
!
Speed range
Clutches
3 2 1
Lo Hi 1st 2nd 3rd R
! ! ! F1 "
"
! !
"
F2
"
F3
!
F4
"
F5
F6
N
"
R1
R2
R3
The ! mark indicates the speed ranges that are

actuated for each position of the gearshift lever.
The mark and " mark indicate the clutches
that are actuated for each travel speed.
The " mark indicates the speed range when
measuring the oil pressure for each clutch.
5. Measuring transmission Lo clutch pressure
the measurement.

range.
to position 1.
5) Release the brake and measure the oil pressure when traveling at high idle.
20-125
1 !
(9)
6. Measuring transmission Hi clutch pressure

the measurement.
7. Measuring transmission 1st clutch pressure

the measurement.

range.
to position 2.
measure the oil pressure when the shift indicator shows 2.

range.
to position 1.

20-126
c
1 c
(9)
HM300-1
8. Measuring transmission 2nd clutch pressure

the measurement.
9. Measuring transmission 3rd clutch pressure

the measurement.

range.
to position 3.
In F3, a maximum travel speed of approx. 15.2km/h is reached, so check
carefully that the surrounding area is
safe.

range.
to position 5.
In F5, a maximum travel speed of approx. 37.5km/h is reached, so check
carefully that the surrounding area is
safe.

HM300-1
20-127
1 c
(9)
10. Measuring transmission R clutch pressure

the measurement.

range.
to position R1.
In R1, a maximum travel speed of approx. 6.2km/h is reached, so check carefully that the surrounding area is safe.
11. Measuring inter-axle differential lock clutch

pressure
the measurement.

range.
move the inter-axle differential lock switch to
the MANUAL position.
5) Measure the oil pressure when the engine is
at high idle.

20-128
c
1 c
(9)
HM300-1
ADJUSTING TRANSMISSION SPEED SENSOR
There are 4 speed sensors installed to the transmission. Adjust each sensor as follows.
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 output F shaft speed sensor, remove the transmission and front differential assembly before
carrying out adjustment.
4) Fixing sensor (1), tighten nut (3).
3 Nut: 49.0 68.6Nm {5 7kgm}
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 !
2. Adjusting intermediate shaft speed sensor

(N2)
1) Remove intermediate shaft speed sensor (4)
and check that its tip is free from steel chips
and flaws, and then reinstall it temporarily.

tooth tip of intermediate shaft gear (5).
At this time, clearance (b) between the
mm.
3 Nut: 49.0 68.6Nm {5 7kgm}
3. Adjusting output shaft R speed sensor (N3)

1) Remove output shaft R speed sensor (7) and
check that its tip is free from steel chips and
flaws, and then reinstall it temporarily.
tooth tip of rear output shaft gear (8).
At this time, clearance (c) between the
mm.
4. Adjusting output shaft F speed sensor (B09)

1) Remove output shaft F speed sensor (10)
and check that its tip is free from steel chips
and flaws, and then reinstall it temporarily.

tooth tip of front output shaft gear (11).
At this time, clearance (d) between the
mm.
3 Nut: 49.0 68.6Nm {5 7kgm}
5. Checking sensor input signal

After finishing the adjustment, check that the
monitoring function of the machine monitor indicates each transmission shaft speed normally.
For details of the monitoring function, see
Special function of machine monitor.
3 Nut: 49.0 68.6Nm {5 7kgm}
20-129-1
!
(7) !
HM300-1

BRAKE OIL PRESSURE
TESTING
1. Measuring charge valve cut-in pressure and
cut-out pressure
Measure the charge valve oil pressure at remote pressure detection port (1).
1) Install hose [1] and connect oil pressure

gauge F.
Use a 39.2MPa {400kg/cm2} oil pressure
gauge.
20-130
c
1 c
(9)
TESTING AND ADJUSTING BRAKE OIL PRESSURE
2) Start the engine.

3) Measure the cut-in pressure at high idle.
i) Repeatedly depress and release the
brake pedal to gradually lower the pressure inside the accumulator.
ii) Measure the pressure at the point where
the indicator of oil pressure gauge F
stops going down and starts to go up
again.
4) Measure the cut-out pressure at high idle.
Measure the oil pressure when the pressure
goes up after the cut in and the indicator of
pressure gauge F stops.

HM300-1
2. Measuring wheel brake actuation pressure

and drop in pressure
Use the same procedure to measure the
front brake circuit, center brake circuit.
1) Remove air bleeder (2) of the slack adjuster.
2) Install brake test kit G and bleed the air from

the brake circuit.
For details, see BLEEDING AIR FROM
BRAKE CIRCUIT.
4) Measure the actuation pressure of the retarder brake under the following conditions.
i) Run the engine for several minutes at
low idle to charge the accumulator, then
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 pressure and the retarder actuation pressure
are correct before starting.
stop the engine.
ii) Depress the brake pedal fully and measure the oil pressure.
Keep the brake pedal depressed.
iii) Measure the oil pressure after 5 minutes
and calculate the drop in pressure.
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.
stop the engine.
ii) Depress the brake pedal fully and measure the oil pressure.
HM300-1
20-131
1 c
(9)
3. Measuring actuation pressure of parking

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

2) Install adapter [1] and nipple and hose [2],
and connect oil pressure gauge F.
gauge.
3) Start the engine and operate the parking

brake switch several times at high idle to
bleed the air from the circuit.
4) Stop the engine and turn the starting switch
ON.
5) Measure oil pressure when parking brake
switch is turned OFF.
20-132
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(9)
4. Measuring actuation pressure of exhaust

brake solenoid (machine equipped with exhaust brake)
1) Open the engine hood.
2) Disconnect hose (4) of the exhaust brake
cylinder.
3) Install adapter [1] and nipple and hose [2],

and connect oil pressure gauge F.
gauge.
HM300-1
4) Start the engine and turn the exhaust brake

switch ON. (In the condition shown in Fig. 1
(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.
1. Remove mudguard sheet inside left front tire

housing.
2. Loosen locknut (6).
Fig. 1
During the measuring operation, check
that the surrounding area is safe and
drive carefully.
If the accelerator pedal is released while
the machine is traveling with exhaust
brake switch at position (a) and the
torque converter in the lock-up condition,
the exhaust brake is actuated.
3. Turn adjustment screw (7) and adjust oil pressure.

Adjust with the adjustment screw as follows.
To INCREASE pressure, turn clockwise
To DECREASE pressure, turn counterclockwise
4. Hold adjustment screw (7) in position and tighten
locknut (8).
Locknut: 10.2Nm {1kgm}
After completing the adjustment, repeat the procedure for measurement to check the oil pressure again.
ADJUSTING
Adjusting charge valve cut-in pressure and cutout 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 pressure and cut-up pressure will both change.
HM300-1
20-133
1 c
4
TESTING OF ACCUMULATOR NITROGEN GAS

PRESSURE AND PROCEDURE FOR CHARGING
ACCUMULATOR WITH NITROGEN GAS
TESTING OF ACCUMULATOR
NITROGEN GAS PRESSURE
AND PROCEDURE FOR
CHARGING ACCUMULATOR
WITH NITROGEN GAS
a
Testing instrument
Symbol
P1
Part No.
792-610-1310
P2
Part name
Remarks
792-610-1700 Gas charge tool

Nipple
(For Russia)
GOST
Nipple
792-610-1320 (For USA)
CGA No. 351
792-610-1330 Nipple
(For USA)
ASA B-571-1965
792-610-1350
Nipple
(For Germany)
DIN 477-1963
NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS 341 Part 1-1962

k
Put on proper protection gear (goggles,

leather gloves and protective clothes) so
that the leaking nitrogen gas will not touch
your skin or clothes and work on the windward side as long as possible.
When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate the work place forcibly and observe
the Oxygen Deficiency Prevention Rules of
the Labor Safety and Sanitation Law.
Since the accumulator is charged with highpressure 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.
3.
Connect gas charge tool P1 to valve (4) of

accumulator (1) according to the following procedure.
1) Turn handle (a) of gas charge tool P1 to
the left until it stops.
q
Nitrogen gas cylinder (c) must be connected even when you measure only
the gas pressure.
q
Close the valve of nitrogen gas cylinder (c) and handle (b).
q
For connection of nitrogen gas cylinder (c) and gas charge tool P1, see
"Procedure for charging accumulator
with nitrogen gas".
2) Connect gas charge tool P1 to valve (4) of
accumulator (1).
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be measured 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 accumulator (1).
20-133-1
(10)
HM300-1
4.
Turn handle (a) of gas charge tool P1 to the left

and read the gauge.
a Since the indicated value varies with the
ambient temperature, correct it by the following formula. (The unit of each value in
the formula is C.)
Indicated gas pressure =
Standard gas pressure x ((273 + t)/
(273 + 20))
Standard gas pressure =
Indicated gas pressure/((273 + t)/
(273 + 20))
t = Gas temperature at time of charge (C)
Reference: t may be assumed to be ambient temperature.
5.
If the gas pressure is too high or too low, adjust

it referring to "Procedure for charging accumulator with nitrogen gas".
a Each time the pressure is measured, some
nitrogen gas is discharged and the pressure lowers. Add nitrogen gas by the loss.
6.
Remove gas charge tool P1 from accumulator

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

3.
Connect gas charge tool P1 and nitrogen gas

cylinder (c) to valve (4) of accumulator (1)
according to the following procedure.
1) Turn handle (a) of gas charge tool P1 to
the left until it stops.
2) Turn handle (b) to the left to open.
3) Connect gas charge tool P1 to valve (4) of
accumulator (1).
4) Connect gas charge tool P1 and nitrogen
gas cylinder (c).
q
There are 2 types of threads of nitrogen gas cylinders, W22-14 thread
(mail screw, type A) and W23-14
thread (female screw, type B). When
using a gas cylinder of W23-14 thread
(female screw, type B), connect the
hose by using the adapter. (The
adapter is attached to gas charge tool
P1.) [For Japan]
q
Use nipple P2 to connect the hose,
depending on the specification of the
nitrogen gas cylinder. [For overseas]
4.
Open nitrogen gas cylinder (c) slightly to discharge nitrogen gas at pressure of 0.19 0.29
MPa {2 3 kg/cm}.
5.
After nitrogen gas starts flowing out of handle

(b), close handle (b).
Procedure for charging accumulator with nitrogen gas

a The disconnected from the machine can be
charged with nitrogen gas 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 accumulator (1).
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) further to charge the accumulator with nitrogen
gas.
8.
During the work, close the valve of nitrogen gas

cylinder (c) and check the nitrogen gas pressure in the accumulator.
a Since the indicated value varies with the
ambient temperature, correct it by the following formula. (The unit of each value in
the formula is C.)
Indicated gas pressure =
Standard gas pressure x ((273 + t)/
(273 + 20))
Standard gas pressure =
Indicated gas pressure/((273 + t)/
(273 + 20))
t = Gas temperature at time of charge (C)
Reference: t may be assumed to be ambient temperature.
9.
After the accumulator is charged to the standard pressure, close the valve of nitrogen gas
cylinder (c).
q
If the accumulator is charged too much,
turn handle (b) to the left slowly with the
valve of nitrogen gas cylinder (c) closed to
release the nitrogen gas gradually to
adjust.

13. In a week after charging the accumulator with

nitrogen gas, check that the nitrogen gas pressure has not lowered.
a Check the functions in 5 minutes after
stopping the engine. (If the engine is
stopped for more than 5 minutes, the
brake circuit pressure lowers and the functions cannot be checked accurately.)
1) Stop the machine on a level place and set
the parking brake switch in the "PARK"
position.
2) Start the engine and run it at medium
speed for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly.
Count the number of presses until the
brake oil pressure caution lamp lights up.
q
If number of presses is less than 5:
Accumulator gas pressure may have
lowered.
q
If number of presses is 5 or more:
Accumulator gas pressure is normal.
10. Remove gas charge tool P1 from valve (4) of

accumulator (1) according to the following procedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and discharge 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 accumulator to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumulator (1).
3 Cap: 9.8 12.7 Nm {1.0 1.3 kgm}
20-133-3
(10)
HM300-1
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
brake must be carried out with the gearshift lever at the D position. Do not place
the gearshift lever at any other position.
3) Depress the accelerator pedal gradually and
check that the machine does not move when
the torque converter is stalled at the specified speed.
4) After completing the inspection, run the engine at low idle and set the gearshift lever to
the N position.
2. Testing braking performance of retarder
brake (which is not used in E-SPEC)
switch OFF.
2) Pull the retarder lever fully, then set the gearshift lever to the D position.
Testing of the performance of the retarder brake must be carried out with the
gearshift lever at the D position. Do not
place the gearshift lever at any other position.
the N position.
3. Testing braking performance of parking brake
If the machine starts to move, it can cause a
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 gearshift lever at the D position. Do not place
the gearshift lever at any other position.
4) If the machine moves at a revolution lower
than specified, adjust clearance of the brake
pad, referring to 2. Adjusting Clearance in
Brake Pad in INSPECTING PARKING
BRAKE WEAR AMOUNT.
the N position.
20-134
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1
(9)
4 c
HM300-1
4. Testing braking performance of overrun protection brake (E-SPEC)

switch OFF.
2) Insert a screwdriver in hole (a) on the side of
the combination switch box and move it to
the lower end and place the gearshift lever at
the D position.
Testing of the performance of the overrun 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 potentiometer in the switch box is rotated
and the overrun protection brake pilot
lamp lights up.
HM300-1
TESTING BRAKE PERFORMANCE

After completing the inspection, move
the screwdriver inserted in hole (a) to the
upper end and remove it.
20-134-1
4 c
BLEEDING AIR FROM BRAKE

CIRCUIT
If the equipment in the brake circuit has been removed and installed again, bleed the air from the
brake circuit as follows.
When bleeding the air from the wheel brake circuit, always bleed the air from the slack adjuster
first, then bleed the air from the wheel brake.
1. Bleeding air from slack adjuster portion of
wheel brake circuit
front brake circuit, and center brake circuit.
In case of bleeding air from the front brake
circuit, however, the brake oil pressure caution lamp may light up while bleeding air. If
that happens, tighten the air bleeder, accumulate hydraulic oil pressure in the accumulator by stepping on the service brake 8 to 10
times, and then bleed air. Oil pressure accumulating signals are received from the rear
(center) brake circuit. Hence the circuit is so
designed that oil pressure is not accumulated in the front brake (low pressure), even if
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).
Air bleeder:
10 20Nm {1 2kgm}
HM300-1
BLEEDING AIR FROM BRAKE CIRCUIT
4) Bleed air from retarder brake circuit in the

following procedure.
i) Pull the retarder lever fully and hold it in
position.
then drain oil mixed with oil.
Air bleeder:
10 20Nm {1 2kgm}
5) Bleed air from the overrun protection brake
circuit in the following procedure (E-SPEC).
i) Insert a screwdriver in hole (a) on the
side of the combination switch box and
move it to the lower end and keep it in
that position.
ii) Loosen air bleeder approx. 1/2 turn, then
drain the air mixed with the oil.
Air bleeder :
10 - 20 Nm {1 - 2 kgm}
After bleeding air, be sure to move the
screwdriver inserted in hole (a) to the upper end and remove it.
6) After completing the adjustment, set to the

original condition.
20-135
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(9)
4
BLEEDING AIR FROM BRAKE CIRCUIT
2. Bleeding air from wheel brake portion of foot

brake circuit
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.
then drain the air mixed with the oil.
4) When no more air comes out with the oil,
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
c
4 c
(9)
HM300-1
TESTING WEAR OF WHEEL

BRAKE DISC
Carry out the inspection when the brake oil temperature is less than 60C.
When the disc comes close to the wear limit, carry out the inspection more frequently. Be sure to
carry out inspection of the retarder braking performance at the same time.
1. Check that the brakes other than parking brake
are not being actuated.
TESTING WEAR OF WHEEL BRAKE DISC
5. Push in the rod (2) of the gauge until it contacts

the piston and judge the amount of wear.
There are three lines (A, B, C) on the rod.
For HM300-1 model, the front brake is expressed with A mark and the center brake
with B mark.
With a new machine, adjust so that initial
mark a on the rod (2) is aligned with the end
face of guide (3).
The adjustment position will move out of
alignment, so do not loosen the locknut of
guide (3) except when replacing the disc.
Limit mark b indicates the wear limit for the
disc. If limit mark b reaches the end face of
guide (3), the disc has reached the wear limit.
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 position.

When the engine is started, the brake cooling oil is actuated and the inspection cannot
be carried out accurately, so always stop the
engine before carrying out inspection.
20-136
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HM300-1
TESTING WEAR OF PARKING

BRAKE PAD
Before carrying out the inspection, start the engine and raise the dump body fully. Then insert
the lock pin and stop the engine.
1. Testing wear of pad
1) Remove top cover of parking brake.
2) Measure thickness a of pad (1).
Thickness limit of pad: 1.5mm
If either the front or rear pad has reached
the thickness limit, replace both pads at
the same time.
HM300-1
TESTING WEAR OF PARKING BRAKE PAD
2. Adjusting pad clearance

When the parking brake does not work properly, or when the brake pads were replaced
with new ones, adjust clearance in the brake
pad in the following manner.
Keep hydraulic oil pressure at a high level
while in adjustment so that the parking brake
may not be automatically applied and also
hang a warning tag on the parking brake
switch so that nobody may operate the machine by mistake.
Do not smear the surfaces of brake pads or
brake discs with oil or grease.
1) Install 2 pads (5).
2) Install 2 each of springs (3) and (4) to left and
right brackets (2), then install left and right
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 temporarily 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
20-137
1 c
(9)
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE
METHOD FOR EMERGENCY

RELEASE OF PARKING
BRAKE

6) Release the parking brake and check the
clearance of the pad again.
Clearance (total of b and c):
1.88 0.08mm
If the clearance is not correct, carry out
the adjustment again from Step 3).
7) Tighten the mounting bolts of left and right
brackets (2).
Be careful not to let the mounting position move out of alignment.
8) Check the clearance between pad (5) and
disc (6) again.
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.
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 release 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 parking brake, always tow the machine at low speed
to a safe place.
When carrying out the operation to release the
parking brake, stop the machine on flat ground
and check that the surrounding area is safe before starting the operation. If the parking brake
must be released on a slope in an emergency or
other unavoidable situation, put blocks securely
under the tires.
1. Turn adjustment screw (1) of the parking brake
clockwise to create a gap between the pad and
disc.
2. Tow the machine and move it to a safe place.

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

STEERING CIRCUIT
PRESSURE
1. Measuring steering relief oil pressure
Measure the steering relief pressure at remote pressure detection port (1).
2. Adjusting steering relief oil pressure
If the steering relief oil pressure is not correct, adjust relief valve (2) of the flow amp
valve as follows.

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)
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 follows.
To INCREASE pressure, turn clockwise
To DECREASE pressure, turn counterclockwise
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
c
1 c
4
HM300-1

SUSPENSION CYLINDER
1. Testing cylinder length
Test the installed length of the suspension cylinder under the following conditions.
Machine standing on horizontal road surface
Engine stopped
Dump body unloaded
Installed length a of front cylinder:
163 10mm
Installed length b of rear cylinder:
101 5mm
If the length of the cylinder is not correct, use
the procedure in Steps 2 to 5 to adjust.
TESTING AND ADJUSTING SUSPENSION CYLINDER
2. Releasing nitrogen gas

1) Set a hydraulic jack under the frame of the
machine and raise the tires slightly from the
ground.
Use a 50ton {490,000N} jack.
Set the jack securely under the frame.
When carrying out work at the front, jack
up the front frame until the front tires
come slightly off the ground.
When carrying out work at the rear, jack
up the frame until either the center or
rear tires come slightly off the ground.
2) Remove cover (1).
3) Loosen oil level valve (2) slowly, and when
the nitrogen gas starts to come out, hold the
valve in that position.
If oil spurts out from the valve together
with the nitrogen gas, tighten the valve
slightly until no more oil comes out and
take time to release the nitrogen gas
slowly.
4) Operate the hydraulic jack to lower the frame

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

Adjust the oil level after completing the release 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 remove air supply valve (3).
3 Air supply valve:
39.2 49.0Nm {4 5kgm}
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!
1 !
HM300-1
4. Charging with nitrogen gas

Charge with nitrogen gas after completing
the adjustment of the oil level.
1) Remove the cap at the top of air supply valve
(3).
2) Connect suspension tools H7 H12 as shown
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 higher than the internal pressure of the cylinder (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 cylinders reaches the specified installation
length, turn the handle of regulator H11 to
the left to stop charging with nitrogen gas.
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
8) Remove suspension tools H7 H12.

Be careful not to lose the O-ring of the air
supply valve.
9) Install the cap at the top of air supply valve
(3).
10) Install the cover of the suspension cylinder.
20-143
1 c
(9)
5. Adjusting cylinder length

Adjust the cylinder length after completion of
charging with nitrogen gas.
When adjusting the cylinder length, stop the
machine on a horizontal surface with the
dump body unloaded.
1) Drive the machine approx. 15m forward,
then stop suddenly. Next, drive in reverse
and stop the machine suddenly at the original point. Repeat this procedure 3 or 4 times.
Finally, apply the retarder brake a little at a
time and stop slowly.
When using the retarder brake, stop as
slowly as possible to remove any sliding
resistance in the cylinder (packing,
catching of the bushing).
2) Measure the installed length of the cylinder.
163 10mm
Installed length b of front cylinder:
106 5mm
3) If the installed length is too long, adjust by
discharging nitrogen gas from oil level valve
(2).
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 installed 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 cylinder gland.
Use soapy water to check for leakage of
gas.
20-144
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1 c
Note 1: Checking after changing oil or gas

If the machine is operated after changing the
oil and gas, the gas will dissolve in the oil and
saturate the oil inside the cylinder. If this happens, the volume of the gas will decrease
and the length of the cylinder will go below
the permissible value.
For this reason, check the installed length of
the cylinder again 48 hours after changing
the oil and the gas, and adjust the gas if it is
below the specified dimension.
Note 2: Checking cylinder length according to change
in ambient temperature
The gas in the suspension will expand or
contract according to the change in the ambient temperature when the machine is
working, so the length of the cylinder will
change.
For this reason, in areas where there is a big
difference in temperature during the year,
carry out daily inspection and adjust so that
the installed length of the cylinder is within
the specified range.
HM300-1
METHOD OF TILTING CAB UP

a Equipment for tilt cylinder
(Uselessness for external crane)
Symbol
Part number
792-454-1100
k
k
k
k
k
k
k
k
k
Part name
Pump assembly
When tilting the cab, observe the following precautions to prevent a serious injury or fatal accident caused by fall of the cab.
To prevent interference between the cab and
the dump body, set the steering in a straight
ahead position and stop the machine on the
level ground.
Lock the dump lever with the dump lever lock
knob.
Turn the parking brake switch ON and chock the
wheels.
Set the lock bar to the frame and lock front and
rear frame.
2. Tilting cab up
Method using tilt cylinder
a External hydraulic pump assembly R is necessary.
1) Disconnect cylinder hose (1) at quick coupler
(Q)
.
Precautions in tilting cab

When tilting the cab, check that the lock lever is
fixed securely.
Do not start the engine while the cab is tilted.
When it is obliged to start the engine for testing
etc., check that there is nobody under the cab.
Do not operate the gear shift lever or dump
lever.
Do not give a large shock to the machine.
Do not tilt the cab while it is loaded.
a When carrying out inspection and maintenance

work around the hydraulic pump or at the top of
the torque converter or transmission, tilt the cab
up to the rear of the machine as follows.
a There are the following two methods of tilting the
cab up, so select the method to match the operating conditions.
Method using tilt cylinder
a The external hydraulic pump assembly
R is necessary.
Method using external crane
2) Exchange female quick coupler (F) to male

quick coupler (M) of external hydraulic pump
assembly.
a It is possible to get male quick coupler
(M) by removing it from (Q) on the
machine.
a Connecting adapter (Unit of male and
female quick coupler (Q). Both machine
side and tool side are same.): 56B-5416391 (Size of hose connection end: RC
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
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/cm}
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 position.
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 cylinder, release the hydraulic pressure
gradually, and lower the cab slowly.
3) Remove the external pump or external
crane.
k Check that the cab is held securely in position by the lock bar.
20-145-1
4
(10)
4. Tilting cab down

a Tilt the cab down in the reverse order from
tilting the cab up.
a After tilting the cab down, tighten the mounting bolts and return the lock bar to the storage place.
HM300-1
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 abnormal, adjust it with relief valve (1) of the hoist
valve according to the following procedure.

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
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4 c
HM300-1
2) Support adjustment screw (3) with a screwdriver and tighten locknut (2).
4) Run the engine at high idle and measure the

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)
4. Adjusting dump pilot relief oil pressure

If the dump pilot relief oil pressure is abnormal, 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 locknut (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
c
4 c
HM300-1
ADJUSTING BODY
POSITIONER SENSOR
a If the body positioner rod has been disconnected
and connected again or the body positioner sensor has been removed and installed again, inspect and adjust the body positioner sensor as
follows.
1. Checking sensor output/input voltage
1) Switch the machine monitor display to the
monitoring function of service mode 1 and
display the body positioner sensor input voltage.
a Monitoring item
Code No. 34400: BODY POSITION
a For details of the method of operation,
see SPECIAL FUNCTIONS OF MACHINE MONITOR.

3) Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position and RAISE
position.
a When operated fully to LOWER:
0.38 0.44V
a When operated fully to RAISE:
4.00 4.70V
2. Adjusting link length
a If the monitoring voltage is not within the normal range, adjust the length of the link as follows.
1) Loosen locknut (1).
2) Remove mounting bolt (2).
3) Turn rod end (3) to adjust the length of the
link (4).
a Standard installed length (a) of link: 210
mm
a Installed length (a) must be longer than
208 mm
HM300-1
ADJUSTING BODY POSITIONER SENSOR
a Input voltage:
Becomes lower when the link becomes
longer.
Becomes higher when the link becomes shorter.
a Change in voltage per 1 turn of rod end:
Approx. 0.04V
4) Install mounting bolt (2).

5) Tighten locknut (1).
6) Repeat the checking procedure above to
check that the input voltage is within the normal range.
3. System calibrating operation

1) Start the engine and raise the hydraulic oil
temperature to 80 90C.
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
OFF.
3) While running the engine at low idle, raise
the dump body to the raise stroke end and
keep the dump lever in the raise position
for at least 5 seconds.
4) While running the engine at low idle, lower
the dump body to the lower stroke end.
5) While running the engine at high idle, raise
then lower the engine speed to low idle and
set the dump lever to the lower position. After the dump body starts lowering, return the
dump lever to the float position and lower
a Repeat the above operation 5 - 10 times.
6) While running the engine at high idle, raise
then keep the engine speed at high idle and
set the dump lever to the lower position. After the dump body starts lowering, return the
dump lever to the float position and lower
a Repeat the above operation 5 - 10 times.
20-147
(13)
PROCEDURE
FOR ADJUSTING
LENGTH
SPRING
IN BODY
HEATING
PROCEDURE
FOR ADJUSTING
LENGTH OF
SPRING OF
IN BODY
HEATING
SPHERICAL
JOINT
SPHERICALCIRCUIT
JOINT
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE
PROCEDURE FOR
ADJUSTING LENGTH OF
SPRING IN BODY HEATING
SPHERICAL JOINT
HANDLING ENGINE
CONTROLLER HIGH-VOLTAGE
CIRCUIT
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)
2. After finishing adjustment
1) Check that exhaust gas does not leak.
2) Check that the spherical joint is free from
sticking and scuffing and it rotates smoothly.
The engine controller uses a high-voltage circuit

(110 130V) for the fuel injector drive.
For this reason, the high-voltage circuit is connected to the wiring harness and connectors
from the engine controller to the fuel injector.
Normally, high voltage is output from the engine
controller to the fuel injector only when the engine is running. When the engine stops, the output also stops.
If you touch the high-voltage circuit directly, there
is danger of electrocution, so when carrying out
inspection, always obey the following precautions.
1. The connectors included in the high-voltage circuit 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 disconnecting or connecting the connectors.
3. Never start the engine if a T-adapter has been inserted or connected to the connector.
Operate the starting switch only to the OFF
or ON positions. Never turn it to the START
position.
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1 c
HM300-1
ADJUSTING TRANSMISSION CONTROLLER
ADJUSTING TRANSMISSION
CONTROLLER
1. Setting rotary switch
If the transmission controller has been replaced, set the rotary switches for the network data and model selection as follows.
Use a precision cross-head screwdriver and
turn the rotary switch slowly.
The mark on the rotary switch is the guideline for setting.
1) Remove 2 grommets at the top of the controller.
2) Align the SW1 rotary switch and SW2 rotary
switch with the set position.
Rotary switches and set position
Switch
HM300-1
Purpose of switch
Position
SW1
Network data
SW2
Model data
2. Adjusting transmission
After carrying out any of the following operations, adjust the transmission in order to adjust the fitting between the transmission and
When the transmission has been overhauled or replaced
When the transmission control valve has
been repaired or replaced
When the transmission controller has
been replaced
When the power train speed sensor has
been repaired or replaced
When the transmission oil temperature
sensor has been repaired or replaced
When the transmission oil filter has become clogged and has been cleaned
When adjusting the transmission, use the
service function of the machine monitor.
MONITOR.
20-149
1 !
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN

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 MONITOR.
1
Did [Engine system

caution lamp] on
machine monitor flash
when engine stopped?
YES
2
NO
NO Tow machine to safe
Is there fuel in fuel tank?
YES
place (see note)
Does engine start when

following fuse is replaced?
YES
Fuse unit (30A)
BT2-No. 2 (10A)
BT4-No. 4 (10A)
Is following service code

displayed or recorded?
DB22KK (ENG)
NO
5
NO
YES
If there is no relay to
NO replace or engine does
following relay is replaced?
not start, tow machine to
R36 (engine power relay)
safe place (see note)
YES
Start engine and move

machine (do not turn
electric power ON except
when absolutely
necessary)
6

DB20KT (ENG)
NO
YES

engine controller is
replaced?
YES

DLE3LC (ENG) (Ne speed
sensor system)
DLH1LC (ENG) (G speed
sensor system)
NO
7
NO
If there is no controller to
replace, tow machine to
safe place (see note)

If there is no speed
following speed sensor is
YES
NO sensor to replace or
replaced?
engine does not start, tow
machine to safe place
Ne speed sensor (Ne)
(see note)
G speed sensor (G)
YES
10
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
Tow machine to safe

place (see note)
20-150
!
1 !
Note:
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 EMERGENCY RELEASE OF PARKING BRAKE.
HM300-1

ELECTRICAL SYSTEM
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 MONITOR.
Service
code
1380MW
1500LO
15GOMW
15HOMW
15JOMW
15KOMW
15LOMW
15MOMW
15SBL1
15SBMA
15SCL1
15SCMA
15SDL1
15SDMA
15SEL1
15SEMA
15SFL1
15SFMA
15SGL1
15SGMA
15SJL1
15SJMA
Condition when
failure occurred
Occurrence condition 1
Escape method
Escape procedure 1
Escape procedure 2
Escape procedure 3
Escape procedure 1
Escape procedure 1
Escape procedure 3
Escape procedure 3
Escape procedure 3
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
D1B0KZ Occurrence condition 2 Escape procedure 4

DAQ0KK Occurrence condition 2 Escape procedure 5
DAQ9KM Occurrence condition 4 Escape procedure 7
DAQ9KQ Occurrence condition 4 Escape procedure 7
DAQAKQ Occurrence condition 4 Escape procedure 7
DDTGKA
DDTHKA
DDTJKA
DDTKKA
DDTLKA
DDTMKA
DDTNKA
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
DF10KA Occurrence condition 5 Escape procedure 8

DF10KB Occurrence condition 2 Escape procedure 8
DLE2KA
DLE2LC
DLF1KA
DLF1LC
HM300-1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Lever position for speed range to

move off after escape operation
D 1: F2, R1 R2: R1
D 1: F2
D 1: F1, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F3, R1 R2: R2
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
R1 R2: R1
D 1: F2
D 1: F2
D 1: F1, R1 R2: R1
D 1: F1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F3, R1 R2: R2
D 1: F3, R1 R2: R2
D 1: F2, R1 R2: R1
D 1: F5, R1 R2: R3 or equivalent
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
Normal travel possible if display returns to normal (Note 1)
D 1: F2, R1 R2: R1
D 1: F2
D 1: F1
D 1: F2, R1 R2: R1
D 1: F3, R1 R2: R2
D 1: F5, R1 R2: R3 or equivalent
R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
Remarks
Occurrence condition 1:
Speed range remains fixed;
when the machine is moved off
again, speed range does not shift
When lever is returned to N,
transmission shifts to neutral
Transmission suddenly shifts to
neutral when the machine is traveling; after machine is stopped,
transmission stays in neutral
even when lever is operated, and
machine does not move off
Transmission suddenly shifts to
neutral
After engine is started, transmission stays in neutral even when
lever is operated, and machine
does not move off
Response of lever becomes abnormal; lever does not work as
operated
When lever is operated, transmission shifts to neutral
Speed range remains fixed;
when the machine is moved off
again, speed range does not shift
When lever is returned to N,
transmission shifts to neutral, but after that, transmission does not shift to any
speed range
Note 1:
Even when the machine condition is restored after a failure, the
neutral condition is maintained
until the lever is returned to the N
position.
Note 2:
This phenomenon applies when
there is no display on the machine monitor and there is also
no display in the display window
of the transmission controller.
20-151
1 c
(9)
Service
code
DLF2KA
DLF2LC
DLT3KA
DLT3LC
DXH1KB
DXH2KA
DXH2KB
DXH3KA
DXH3KB
DXH4KA
DXH4KB
DXH5KA
DXH5KB
DXH6KA
DXH6KB
DXH7KA
DXH7KB
Condition when
failure occurred

ELECTRICAL SYSTEM
Escape method
Escape procedure 1
Escape procedure 1
Escape procedure 3
Escape procedure 3
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
Escape procedure 1
(Note 2) Occurrence condition 2 Escape procedure 5
Lever position for speed range to

move off after escape operation
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F1, R1 R2: R1
D 1: F1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F3, R1 R2: R2
D 1: F3, R1 R2: R2
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F2, R1 R2: R1
D 1: F3, R1 R2: R2
D 1: F2
D 1: F1
Remarks
Note 1:
Even when the machine condition is restored after a failure, the
neutral condition is maintained
until the lever is returned to the N
position.
Note 2:
This phenomenon applies when
there is no display on the machine monitor and there is also
no display in the display window
of the transmission controller.
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 EMERGENCY 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 emergency 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
c
1 c
HM300-1

ELECTRICAL SYSTEM
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)
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.
HM300-1
20-153
1 !

Machine monitor rotary switches (SW1, SW2, SW3), dipswitches (SW5, SW6), and option setting connectors (OP1 OP7)
20-154
!
1 !
HM300-1
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 setting)
When parts have been replaced with new parts (service meter, odometer, reverse travel odometer setting)
When carrying out of these settings, it is necessary to use the special operation of the character display 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 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE) for details.
Condition of switch setting functions and option setting connectors

Switch
Position
Purpose of switch
SW1
0F
Travel speed compensation
Not needed
SW2
0F
Not used (always set to 0)
OP3 always released
SW3
0F
Not needed
OFF
Odometer display unit: km
ON
Odometer display unit: Mile
OFF
Exhaust brake: Not installed
Connector
Not needed
Remarks
For standard tires, set to position 7
Set to ON only in areas where mile

display is used
Released
OP1
ON
Exhaust brake: Installed
Connected
SW5
OFF
3
OP2 always released
ON
OFF
Left and right differential lock: Not installed
Released
OP4
4
ON
Left and right differential lock: Installed
Connected
OFF
1
OP5 always released
OP6 always released
Not needed
Not needed
ON
OFF
2
ON
SW6
OFF
3
ON
OFF
4
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)
All setting operations are carried out with the

starting switch OFF and the monitor panel removed.
Always set each switch and connector as instructed.
Be careful not to touch anything inside the grommet except for the switch.
When turning the rotary switch, use a precision
cross-head screwdriver and turn slowly.
The protruding triangular part of the rotary switch
is the setting arrow.
When changing the dipswitch, use a precision
flat-headed screwdriver and turn slowly.
When setting, always avoid foreign matters or
dust.
After setting, be sure to install grommet.
1. Setting rotary switch SW1

Rotary switch SW1 is used to set the travel
speed compensation. The machine monitor
uses the size of the standard tire to calculate the
travel speed.
If the tire size is changed, adjust the position of
the switch to compensate for the speed display.
Tire size and setting position
Tire size
SW1 Connector
23.5 R25
Remarks
Not needed HM300-1 standard tire
The connector in the table indicates the

number of the connector to be connected or
released when changing the setting. (In the
case of SW1, there is no need to connect or
release the connector.)
Travel speed compensation using SW1
Position
0
Speed
compensation
+ 7%
Position
Speed
compensation
0%
+ 6%
1%
+ 5%
2%
+ 4%
3%
+ 3%
4%
+ 2%
5%
+ 1%
6%
0%
7%

Rotary switch SW2 is set as follows. The setting
must not be changed.
Set position of SW2: 0
Connector OP3: Released
Rotary switch SW3 is set as follows. The setting
Set position of SW3: 0
Connector setting: Not needed
20-156
c
1 c
HM300-1
4. Setting dipswitch SW5-1

Dipswitch SW5-1 is set as follows. The setting
Monitor
Part No.
SW5-1 Connector
7831-46-100*
OFF
7861-46-200*
ON
Remarks
Distance:
Displayed in km
Not
Needed Distance:
Displayed in Miles
The connector in the table indicates the number of the connector to be connected or released when changing the setting. (In the
case of SW5-1, there is no need to connector or release the connector.)
Use dipswitch SW5-2 to set the exhaust brake.
When the exhaust brake has been installed or
removed, set as follows.
Exhaust brake SW5-2
Connector
OP1
Not installed
OFF
Released
Installed
ON
Connected
Remarks

Set position of dipswitch SW6-1: OFF
Connector operation: Not needed
Connector operation: Not needed

Use dipswitch SW5-4 to set the left and right differential lock.
When the left and right differential lock has been
installed or removed, set as follows.
Left and right
Connector
SW5-4
differential lock
OP4
Not installed
OFF
Released
Installed
ON
Connected
HM300-1
Remarks
20-157
1 !
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 displayed on the character display in the middle of the machine monitor. The display items are divided by the internal 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 operator 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 meter, odometer display

1
function (default)
Distance traveled in reverse dis2
play function
3
Filter, oil replacement interval

display function
4
5
6
7
Telephone number input function

Language selection function
Action code display function
Failure code display function
20-158
!
(7)
1 !
8
9
10
11
12
Service mode
Electrical system trouble data
display function
Mechanical system trouble data
display function
Machine data monitoring function
Reduced cylinder mode
Adjustment function
13
Filter, oil replacement time setting function
14
Initialize function (exclusive function for factory)
HM300-1
Flow of modes and functions

Operator mode
2
Distance traveled in reverse display function
[>]
1
Service meter, odometer

display function (default)
[<]
Filter, oil replacement interval

3
display function
["]
[>]
[<]
[#] 4
Telephone number input function

[>]
[<]
Language selection function
Distance traveled in reverse display function
[>]
(Automatic)
[<]
1
Meter display function
Failure code display function
[>]
6
Action code display function
[>]
[#] & [ < ] + (ID input: 6491)
[<]
[#]
Service mode
8
Electrical system trouble data display function
[>]
9
[<]
Mechanical system trouble data display function
[>]
[<]
10 Machine data monitoring function

[>]
11

[>]
12
Sub menu: 2 types
[<]
Filter, oil replacement time

setting function
[>]
14
[<]
Initialize function
[>]
[<]
Adjustment function
[>]
13
Sub menu: 5 types
[<]
(Exclusive function for factory)
[<]
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 automatically 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 bottom 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
!
(7)
1 !
HM300-1
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 FUNCTION, Machine monitor system.
2. Distance traveled in reverse display function

Use the switch to display the total distance traveled in reverse of the machine monitor (Fig. 2)
3. Filter, oil replacement interval display function

1) Filter, oil replacement time display (automatic display)
When the replacement interval for the filters
or oil approaches, this information is automatically 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 filters and oil replacement has been completed, the switches on the machine monitor can
be used to reset the interval (Fig. 4)
The replacement time can be set using Service 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 display can be selected by operating the switches
(Fig. 6)
The functions of Service mode are not included 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 displayed 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 displayed, [CALL+ Telephone number] is not
displayed.
Correspondence between user code and recommendation to operator

Action code
CALL+ Telephone number
Action recommended to operator
E01
Not displayed
Carry out inspection and maintenance after completion of operations or when changing shifts between operators
E02
Not displayed
When overrun related display is shown:

Reduce engine speed and machine speed while continuing operations.
When overheat related display is shown:
Stop machine and keep engine running at mid-range speed under
no load.
E03
Displayed
20-162
!
(7)
1 !
Stop engine and machine immediately and contact serviceman.
HM300-1
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 divided into failures of the electrical system
and the mechanical system and are recorded 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 different.
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
code
Location of failure
(location, component with failure)
Controller
Action
code
q See separate table (L0)
TM
E03
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)
E03
1380MW Lock-up clutch

1500LO
Transmission clutch
Slipping (MW)
ECMV for R clutch
TM
TM
E03
15SBMA ECMV for R clutch
Function impossible (MA)
E03
15SBL1
ECMV for Hi clutch
TM
TM
E03
15SCMA ECMV for Hi clutch
E03
15SCL1
ECMV for Lo clutch
TM
TM
E03
15SDMA ECMV for Lo clutch
E03
15SDL1
ECMV for 1st clutch
TM
TM
E03
15SEMA ECMV for 1st clutch
E03
15SEL1
ECMV for 2nd clutch
TM
TM
E03
15SFMA ECMV for 2nd clutch
E03
15SFL1
ECMV for 3rd clutch
TM
TM
E03
15SGMA ECMV for 3rd clutch
E03
15SGL1
15SJL1
ECMV for lock-up clutch
TM
TM
E03
15SJMA
ECMV for lock-up clutch
E03
15SKL1
ECMV for inter-axle differential lock clutch
TM
TM
E03
15SKMA ECMV for inter-axle differential lock clutch
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)
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
c
Nature of failure
(problem, nature of failure)
1 c
4
HM300-1
Failure
code
Location of failure
Nature of failure
Controller
Action
code
A570NX
Engine oil filter
Clogged (NX)
ENG
E01
AA10NX
Air cleaner element
Clogged (NX)
TM
E01
TM
E03
AB00MA Alternator
Common rail
ENG
E03
AD00MA Common rail
AD00L2
ENG
E03
Fuel supply pump
ENG
E03
AD10MA Fuel supply pump
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
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
AD10L3
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
ENG
E03
D182KZ
Preheating relay coil
ENG
E03
D1B0KZ
Transmission cut relay
TM
E03
D1C0KZ
Brake cut relay
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
TM
E01
D5ZCKZ Exhaust brake command signal
E01
D5ZDL4
Forced neutral demand signal
TM
TM
E01
D5ZEKX
Engine load signal
TM
E01
HM300-1
20-165
1 c
(9)
Failure
code
D5ZFKZ
Location of failure
Nature of failure
Controller
Action
code
Neutral signal 1
BK
E01
D5ZGKZ Neutral signal 2
BK
E01
(DAF0KM) Monitor panel
MON
E03
(DAF9KM) Monitor panel
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
TM
E03
DAQ2KK Transmission controller load power supply line
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
TM
E03
(DAQ9KQ) Transmission controller wiring harness
TM
E03
(DAQAKQ) Transmission controller rotary switch
TM
E03
DAQSKR Transmission controller S-NET
Defective transmission, abnormality in applicable component system (KR)
MON
E03
DAQSMA Transmission controller
TM
E03
DB10KK Retarder controller(q1)
BK
E03
DB11KK Retarder controller(q1) main power supply line
BK
E03
DB12KK Retarder controller(q1) load power supply line
BK
E03
DB13KK Retarder controller(q1) battery direct power supply line Drop in power source voltage, input (KK)
BK
E03
BK
E03
DB1SKQ Retarder controller(q1) S-NET line
BK
E03
DB1SKR Retarder controller(q1) S-NET
MON
E03
Abnormality inside controller (KT)
ENG
E03
DB22KK Engine controller load power supply line
ENG
E03
DB29KQ Engine controller connecting wiring harness
ENG
E03
DB2AMA Engine controller fuel injection quantity control switch
ENG
E01
DB2SKR Engine controller S-NET
MON
E03
DD11KB Starting switch
Short circuit (KB)
ENG
E03
ENG
E01
ENG
E01
(DB19KM) Retarder controller(q1) wiring harness
DB20KT
Engine controller
DDA1L5
Accelerator switch
DDE2L6
Engine oil pressure switch
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
Disconnection (KA)
TM
E03
Gearshift lever
20-166
c
1 c
4
HM300-1
Failure
code
Location of failure
Nature of failure
DF10KB
Gearshift lever
Short circuit (KB)
DGE2KX
Engine coolant temperature sensor

(for high temperature)
DGE3L6
Engine coolant temperature sensor (for low temperature) q See separate table (L6)
Controller
Action
code
TM
E03
ENG
E01
ENG
E01
DGE4KX Fuel temperature sensor
ENG
E01
DGF1KX Transmission valve oil temperature sensor
TM
E03
TM
E01
TM
E01
DGR3L8 Brake oil temperature sensor (center)
DGR4L8 Brake oil temperature sensor (front)
DGT1KX Torque converter oil temperature sensor
TM
E01
DH30KX Boost pressure sensor
ENG
E01
DH40KX Common rail pressure sensor
ENG
E03
DHT5KX Torque converter oil pressure sensor
TM
E01
TM
E01
DHT5L6
Torque converter oil pressure sensor
DHU2KX Accumulator oil pressure sensor (front)
BK
E01
DHU3KX Accumulator oil pressure sensor (rear)
BK
E01
DJF1KA
Disconnection (KA)
TM
E01
Fuel level sensor
DK10KX Throttle angle sensor
ENG
E03
DK11KX
Throttle angle sensor
TM
E03
DK51L5
Retarder lever potentiometer
BK
E03
BK
E03
BK
E03
DK52KX Dump lever potentiometer 1

DK53L8
Dump lever potentiometer 2

DK54KX Body position sensor
BK
E03
DLE2KA Engine speed sensor
Disconnection (KA)
TM
E03
TM
E03
ENG
E03
TM
E03
TM
E03
TM
E03
TM
E03
BK
E01
ENG
E03
DLE2LC
Engine speed sensor
DLE3LC
Engine Ne speed sensor
DLF1KA Transmission input shaft speed sensor

DLF1LC
Transmission input shaft speed sensor
DLF2KA Transmission intermediate shaft speed sensor

DLF2LC
Transmission intermediate shaft speed sensor
DLF4KA Transmission output shaft F speed sensor

DLH1LC Engine G speed sensor
q See separate table (LC)

Disconnection (KA)
Disconnection (KA)
Disconnection (KA)
DLT3KA
Transmission output shaft R speed sensor
Disconnection (KA)
TM
E03
DLT3KA
Disconnection (KA)
BK
E01
DLT3LC
Separate table (LC)
TM
E03
DV00KB
Alarm buzzer
Short circuit (KB)
MON
E01
DW71KZ Exhaust brake solenoid
BK
E01
DW72KZ Dump lever kick-out solenoid
BK
E01
DW73KZ Dump selector valve solenoid
BK
E03
DX11KA
Rear brake reducing pressure valve solenoid
Disconnection (KA)
BK
E03
DX11KB
Short circuit (KB)
BK
E03
HM300-1
20-167
1 !
(9)
Failure
code
Nature of failure
Controller
Action
code
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
BK
E03
DX13KA Dump EPC valve solenoid
Disconnection (KA)
BK
E03
DX13KB Dump EPC valve solenoid
Short circuit (KB)
BK
E03
DX13KY
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
DX11KY
20-168
c
Location of failure
1 c
Front brake reducing pressure valve solenoid
Dump EPC valve solenoid
HM300-1
q Separate table: Detailed phenomena of L Series problem codes (L)

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
L6
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch,
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 system.
Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting 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
(9)
4
Procedure for switching to Service mode and

screen display
When using Service mode, carry out the following special operation to switch the screen display.
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 buttons.
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 (operator mode).
If the cursor is not at the left side, the cursor returns to the left side.
If the switch on the ID input screen is not operated 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
c
(7)
1 c
(9)
HM300-1
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 [].
[ > ] button: Goes on to next menu
[ < ] button: Goes back to previous menu
(1) ELECTRIC FAULT:
Trouble data display function for electrical system
(2) MACHINE FAULT:
Trouble data display function for mechanical system
(3) REAL-TIME MONITOR:
Machine data monitoring function
(4) CYLINDER CUT-OUT:
(5) TUNING:
Adjustment function
(6) MAINTENANCE MONITOR:
Filter, oil replacement time setting function
(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 (operator mode) by mistake, repeat the procedure 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
(9)
1 c
8. Electrical system trouble data display function (ELECTRIC FAULT)

The machine monitor retains the data for problems 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 [] button 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 maximum of 20 items)
A: Failure code (4-digit location code + 2digit problem code)
2: Number of occurrences (number of occurrences 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 explanation 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 displayed on the display portion for 1, and
[] is displayed on the display portion for
A, 2, 3, and 4.
20-172
c
(7)
1 c
HM300-1
4) Switching trouble data display

If the [ > ] button or [ < ] button is pressed during the display of trouble data, the display
switches to the other recorded trouble data.
[ > ] button:
Goes on to data for next record number
[ < ] 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 explanation on the screen (Fig. 4).
[ < ] button: Select YES
[ > ] button: Select NO
[] button: Run
The data for an existing problem (flashing 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 explanation on the screen (Fig. 6).
[] button: Run
The data for an existing problem (flashing display) cannot be deleted.
HM300-1
20-173
1 c
9. Mechanical system trouble data display function (MACHINE FAULT)

The machine monitor retains the data for problems 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 [] button 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 + 2digit problem code)
2: Number of occurrences (number of occurrences 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 explanation 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 displayed on the display portion for 1, and
[] is displayed on the display portion for
A, 2, 3, and 4.
20-174
c
(7)
1 c
(9)
HM300-1
4) Switching trouble data display

If the [ > ] button or [ < ] button is pressed during the display of trouble data, the display
switches to the other recorded trouble data.
[ > ] button:
Goes on to data for next record number
[ < ] button:
Goes back to data for last record
number
5) Deleting trouble data (not permitted)
The trouble data for the mechanical system 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 following 2 types of display can be shown.
1st item independent display (for each controller)
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 [$] button and display the initial screen of the sub
menu (Fig. 2).
[$] 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 ["] portion.
[ > ] 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
!
(7)
1 !
HM300-1
4) Setting 1st item individual monitoring

i) Select the controller system for monitoring on the sub menu screen (Fig. 4: example).
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 select the item for monitoring (Fig. 5: example).
[ > ] 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 monitoring, 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 monitoring

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
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 monitoring code for the 2 monitoring items directly.
[ > ] 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: example).
To hold or cancel monitoring data:
If the [] button is pressed during monitoring, 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 monitoring

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
c
1 c
(9)
HM300-1
Monitoring Code Table

MONITOR PANEL [Machine monitor system]
No.
Monitoring item
Item display
Monitoring
Display range
code
Unit
1 Engine speed
ENG SPEED
01001
0 65535
rpm
2 Engine coolant temperature (for high temperature)
COOLANT TEMP H
04102
0 160
3 Torque converter oil temperature
T/C OIL TEMP
30100
0 160
4 Brake oil temperature
BRAKE OIL TEMP
30200
0 160
5 Fuel level sensor input resistance value
FUEL SENSOR
04201
0 150
6 Rheostat input voltage
RHEOSTAT
30300
0.0 51.0
7 Operation status of AISS switch
AISS SW
30400
ON / OFF
Status display
UPPER / NEUStatus display

TRAL / LOWER
8 Operation status of exhaust brake switch
EXH BRAKE SW
30500
9 Operation status of inter-axle differential lock switch
INTER AXLE SW
30600
10 Operation status of left and right differential lock switch
L-R DIFF SW
30610
11 Operation status of left and right differential lock pedal
FOOT DIFF SW
30620
ON / OFF
Status display
12 Input status of connector check (1 & 2)
CONN CHK 1, 2
30700
ON / OFF,
ON / OFF
Status display
13 Setting status of rotary switch (SW1 & SW2 & SW3)
SW1, SW2, SW3
30800
0 F, 0 F,
0F
Status display
14 Setting status of dip switch (SW5-1 & SW5-2)
SW5-1, SW5-2
30900
ON / OFF,
ON / OFF
Status display
SW5-3, SW5-4
30901
ON / OFF,
ON / OFF
Status display
SW6-1, SW6-2
30902
ON / OFF,
ON / OFF
Status display
SW6-3, SW6-4
30903
ON / OFF,
ON / OFF
Status display
18 Setting status of option selection connector (OP1 & OP2)
OPTION 1, 2
31000
ON / OFF,
ON / OFF
Status display
OPTION 3, 4
31001
ON / OFF,
ON / OFF
Status display
OPTION 5, 6
31002
ON / OFF,
ON / OFF
Status display
UPPER /
LOWER
Status display
UPPER / NEUStatus display

TRAL / LOWER
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)
TRANSMISSION [Transmission controller system]

No.
Monitoring item
Monitoring
Display range
code
Unit
1 Transmission service meter
SERVICE METER
31100
0 65535
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
27
Output current command value for transmission differential lock

clutch solenoid
ECMV D DIR
31607
0 1020
mA
28
Output current detection value for transmission differential lock

clutch solenoid
ECMV D
31617
0 1020
mA
FILL TIME H
41801
0 2550
ms
29 Hi clutch fill time

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
02
Status display
36 Lo clutch fill status
FILL L
31500
02
Status display
37 R clutch fill status
FILL R
31506
02
Status display
38 1st clutch fill status
FILL 1
31502
02
Status display
39 2nd clutch fill status
FILL 2
31503
02
Status display
20-180
c
Item display
1 c
(9)
HM300-1
No.
Monitoring item
Item display
Monitoring
Display range
code
Unit
40 3rd clutch fill status
FILL 3
31504
02
Status display
41 Axle sensor input voltage
THROTTLE POS
31700
0.00 5.10
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
45 Operation status of shift hold switch
SHIFT HOLD SW
32000
ON / OFF
Status display
46 Actuation status of emergency steering (1 & 2)
EMERG STRG 1, 2
32100
ON / OFF,
ON / OFF
Status display
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
51 Torque converter oil pressure
T/C OIL PRESS
32600
0.00 5.02
MPa
52 Steering oil temperature
STRG OIL TEMP
32700
OVERHEAT /
Status display
NORMAL
53 Tilt angle
ANGLE SENSOR
32900
0.52
0.00 0.37
rad
CONN CHK 1, 2
30701
ON / OFF,
ON / OFF
Status display
55 Transmission oil level
OIL LEVEL
33000
LOW /
NORMAL
Status display
56 Radiator coolant level
COOLANT LEVEL
33100
LOW /
NORMAL
Status display
57 Clogging status of air cleaner
AIR CLEANER
33200
CLOGGED /
NORMAL
Status display
58 Clogging status of transmission filter
T/M FILTER
33300
CLOGGED /
NORMAL
Status display
59 Clogging status of hydraulic oil filter
HYD OIL FILTER
33400
CLOGGED /
NORMAL
Status display
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
MACHINE SEL2
02702
GND / OPEN
Status display
MACHINE SEL3
02703
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)
ENGINE [Engine controller system]

No.
Monitoring item
Item display
Monitoring
Display range
code
Unit
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
4 Transmission throttle correction value
MODIFY SIGNAL
36000
100 100
5 Axle sensor input voltage
THROTTLE POS
31702
0.00 5.00
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
13 Coolant temperature for engine low temperature
COOLANT TEMP L
04101
30 100
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
MACHINE SEL2
02705
GND / OPEN
Status display
MACHINE SEL3
02706
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
c
1 c
(9)
HM300-1
BRAKE [Retarder controller(q

q1) system]
No.
Monitoring item
Item display
Monitoring
Display range
code
Unit
1 Brake service meter
SERVICE METER
31101
0 65535
2 Output current command value for front brake EPC solenoid

3 Output current detection value for front brake EPC solenoid
F BK OUTP DIR
F BRAKE OUTPUT
33700
33701
0 1020
0 1020
mA
mA
4 Output current command value for rear brake EPC solenoid

5 Output current detection value for rear brake EPC solenoid
R BK OUTP DIR
R BRAKE OUTPUT
33800
33801
0 1020
0 1020
mA
mA
6 Retarder lever(q2) input (voltage & conversion amount)
RETARD LEVER
33900
7 Input status of retarder lever(q2) validation switch (1 & 2)
RLV SW 1, 2
34000
8 Operation status of retarder lever(q2) switch
RETARDER
34100
9 Dump lever potentiometer 1 input voltage
DUMP LEVER 1
34300
0.00 5.10
0 100
ON / OFF,
ON / OFF
WORKING /
RELEASE
0.00 5.10
10 Dump lever potentiometer 2 input voltage
DUMP LEVER 2
34301
0.00 5.10
11 Body position sensor input voltage

12 Input status of body seat switch
BODY POSITION
BODY SEATING
34400
34600
0.00 5.10
ON / OFF
V
Status display
13 Output status of dump lever solenoid

14 Output status of dump selector solenoid
KICKOUT SOL
SWV FOR HOIST
34700
34800
ON / OFF
ON / OFF
Status display
Status display
15 Output current command value for dump EPC solenoid

16 Output current detection value for dump EPC solenoid
EPC HOIST DIR

EPC HOIST
34900
34901
0 1020
0 1020
mA
mA
17 Input status of overrun command

18 Input status of service brake oil pressure switch
OVERRUN SIG
SERVICE BRAKE
35000
35100
ON / OFF
ON / OFF
Status display
Status display
19 Input status of starting switch terminal C
KEY SW C
32300
Status display
CONN CHK 1, 2
30702
21 Front & rear differential slipping condition
INT DIFF SLIDE
35200
ON / OFF
ON / OFF,
ON / OFF
SLIDE / NO
Status display
22 Input status manual differential lock command

23 Transmission output shaft F speed
INT M DIFF SIG

T/M SPEED : OUT
35300
31401
ON / OFF
0 65535
Status display
rpm
24 Transmission output shaft R speed

25 Front accumulator oil pressure
T/M DIFF OUT

ACC OIL PRE F
31402
35500
0 65535
0.00 50.26
rpm
MPa
26 Rear accumulator oil pressure
ACC OIL PRE R
35501
MPa
27 Clogging status of brake filter
BK OIL FILTER
35600
28 Clogging status of brake cooling filter
RETARD FILTER
35700
0.00 50.26
CLOGGED /
NORMAL
CLOGGED /
NORMAL
29 Wear status of R.H. front brake
DISK WEAR FR
35800
CLOGGED /
NORMAL
Status display
30 Wear status of L.H. front brake
DISK WEAR FL
35801
CLOGGED /
NORMAL
Status display
31 Wear status of R.H. center brake
DISK WEAR RFR
35802
32 Wear status of L.H. center brake
DISK WEAR RFL
35803
EXH BRAKE
35900
33
Exhaust brake solenoid output (detection status & command status)

q2. The lever is not installed in E-SPEC.
CLOGGED /
NORMAL
CLOGGED /
NORMAL
ON / OFF,
(ON / OFF)
V (%)
Status display
Status display
V
Status display
Status display
Status display
Status display
Status display
Status display
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
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 completion 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
!
(7)
1 !
HM300-1
12. Adjustment function (TUNING)

Through the transmission controller, the machine monitor can carry out the the adjustment
function to correct the difference in operating
feeling to a constant level caused by the the individual differences in the ECMV. It can also carry 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
When the transmission valve has been replaced
When the transmission controller has been
replaced
When an abnormality has occurred in the
power train speed sensor and it has been repaired (for details, see the failure code in the
chart on the right)
When an abnormality has occurred in the
transmission oil temperature sensor and it
has been repaired (for details, see the failure
code in the chart on the right)
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)
Failure code
Component name
DLF1KA
Transmission input shaft speed

sensor
DLF1LC
DLF2KA
DLF2LC
DLT3KA
DLT3LC
Transmission intermediate
shaft speed sensor
Transmission output shaft R
speed sensor
DGF1KX
Transmission valve oil temperature sensor
15BONX
For the adjustment operation, operate the machine monitor and machine itself, and carry out
the following items in order (Fig. 2).
( ) indicates the menu to use for the adjustment 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
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 machine and adjust the ECMV oil temperature
as follows.
2) Display [ECMV oil temperature] with the machine data monitoring function. (Fig. 1).
TRANSMISSION No. 50
3) Raise ECMV oil temperature to 60 70C 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 70C.
20-186
c
1 c
(9)
HM300-1
Adjustment operation (1): Adjusting individual difference of valve

See Preparatory work and check that the
ECMV oil temperature is at the specified
temperature.
The adjustment operation is carried out automatically 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 adjustment 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
right.
For each adjustment operation, the result is
displayed as normal or abnormal, so take action according to the display (Fig. 6).
If [3-3 OK] is displayed:
The adjustment operation has been completed correctly.
(When the starting switch is turned OFF, the
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 displayed:
Carry out troubleshooting for failure code
[15S[]L1], and if it is found to be normal,
repeat from Step 1).
HM300-1
No.
Valve
1st time
2nd time
3rd time
Lo
IP L-1
IP L-2
IP L-3
Hi
IP H-1
IP H-2
IP H-3
IP R-1
IP R-2
IP R-3
1st
IP 1-1
IP 1-2
IP 1-3
2nd
IP 2-1
IP 2-2
IP 2-3
3rd
IP 3-1
IP 3-2
IP 3-3
20-187
1 c
(9)
Adjustment operation (2): Resetting gearshifting 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 following operation, regardless of the
present initial status.
2) With the menu selected, press the [] button 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 bottom line of the screen.
Initializing completed: INITIAL STATUS
20-188
c
1 c
(9)
HM300-1
Adjustment operation (3): Initial learning of

gearshifting feeling stabilization
Check that the ECMV oil temperature is the
specified temperature. For details, see Preparatory 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 display.
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 complete.
If the display is [1], repeat Steps 4) and
5) until it becomes [0].
HM300-1
20-189
1 c
(9)
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 endlessly in the internal set order (for details,
see Table of filter and oil replacement 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 displayed (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 displayed on the screen.
20-190
c
(7)
1 c
HM300-1
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 confirmed, the change confirmation screen
is displayed, so operate the buttons according to the screen display (Fig. 5).
[] button: Run
Table of filter and oil replacement time set items
No.
Item
Code
Display
Replacement time
Fuel filter
03
FUEL FILT
0500
Engine oil filter
02
ENG FILT
0500
Engine oil
01
ENG OIL
0500
Corrosion resistor
06
CORR RES
1000
Transmission oil
12
TM OIL
1000
13
TM FILT
1000
Brake oil
17
BK OIL
1000
Brake oil filter
14
BK OIL FIL
1000
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)
PM-CLINIC INSPECTION SHEET
Pm-CLINIC INSPECTION SHEET

Model: HM300-1 #1001
#
Serial #
Eng. Serial #
Hour inspection
Service meter
Date
Work No.
SAA6D125E-3 #
(YYYY/MM/DD)
Name of inspector
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
Coolant temperature maximum level?
T/C oil temperature maximum level?
During operation
During operation
1234567
1234567
Failure code
Code / Content
Retarder oil temperature max. level?

During operation
1234567
Location of failure
Result of inspection
Sat
Us
Sat
Us
After starting engine!

Item
Engine speed
Engine
Blow-by press.
Condition
Low idle
High idle
Economy mode Torque converter
stall
Low idle
High idle
Power mode
Torque converter
stall
1,630 1,830
1,630 1,830
1,810 2,010
1,810 2,010
Max. 0.98
{Max. 100}
Max. 1.96
{Max. 200}
392 588
{3.5 5.0}
Min.206
{Min. 2.1}
Min 147
{Min. 1.2}
Min. 69
{Min. 0.7}
High idle
343 539
{3.0 5.0}
Min. 176
{Min. 1.8}
Low idle
Min. 98
{Min. 1.0}
Min 69
{Min. 0.7}
Min. 106.7
{Min.800}
79.8
{600}
kPa
{mmAq}
High idle
kPa
{kg/cm2}
kPa
{mmHg}
Exhaust temperature
Ambient temperature
1
(10)
675 725
1,950 2,050
920 970
Boost pressure
20-192
675 725
1,950 2,050
2,150 2,250
SAE10W
Permissible
value
2,150 2,250
Low idle
Engine lub.
oil pressure
rpm
Standard
value
920 970

SAE 30 or
15W-40
Unit
Max. 650
700
Result
HM300-1
Item
Condition
Unit
Standard
value
Permissible
value
Result
Sat
Us
Sat
Us
T/C, T/M
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}
2.35 2.75
2.35 2.75
Engine high idle, T/M in N
{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}
MPa
Engine high idle, T/M in N
{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
shows "1"
Shift-indicator
shows "1"
* T/C Lock-up
* T/M Lo clutch
Shift-indicator
shows "2"
Shift-indicator
* T/M 1st clutch
shows "1"
Shift-indicator
* T/M 2nd clutch
shows "3"
Shift-indicator
* T/M 3rd clutch
shows "5"
Gearshift lever
* T/M R clutch
to "R1"
Inter-axle differential Gearshift lever
lock clutch
to "N"
* T/M Hi clutch
Engine full
(Machine travel)
MPa
{kg/cm2}
Engine full
1.66 -- 1.96
{17.5 -- 19.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.30 -- 2.60
{23.5 -- 26.5}
1.66 -- 1.96
{17.5 -- 19.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.20 -- 2.50
{22.5 -- 25.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.20 -- 2.50
{22.5 -- 25.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.20 -- 2.50
{22.5 -- 25.5}
2.30 -- 2.60
{23.5 -- 26.5}
2.20 -- 2.50
{22.5 -- 25.5}
Change oil, clean inside of transmission case and strainer at every 1000 hours service!
Brake performance
Steering
T/M
Item
Condition
Unit
Visual check of transmission strainer
Steering time lock

to lock
Steering relief
pressure
Through the whole

area of engine
Parking brake
Cut-in
pressure
Cut-out
pressure
Hydraulic temperature
Hydraulic system
Max. 6.0
Min. 6.0
Max. 6.0
Min. 6.0
MPa
{kg/cm2}
20.59 -- 21.57
{210 -- 220}
20.59 -- 21.57
{210 -- 220}
MPa
{kg/cm2}
11.77 -- 12.06
{120 -- 123}
20.54 -- 21.57
{205 -- 220}
11.77 -- 12.06
{120 -- 123}
20.54 -- 21.57
{205 -- 220}
1,440
1,440
1,440
1,440
1,490
1,490
Left to right
Apply brake, set gearshift lever

to D, gradually raise engine
speed, and check that the
machine does not move at
specified speed (See right).
Retarder brake
Result
sec
Engine full
Foot brake
Permissible
value
Must be no excessive metallic

particles or rayflex (Black powder)
Right to left
Engine high idle
Charge valve
Standard
value
rpm
Hoist relief pressure
Engine full
MPa
{kg/cm2}
20.59 -- 21.57
{210 -- 220}
20.59 -- 21.57
{210 -- 220}
Dump body raise

speed
Engine full
sec.
10.5 -- 13.5
10.5 -- 13.5
mm /
5 min
Max. 85
170
Set dump body and stop engine!

Hydraulic drift of
hoist cylinder
HM300-1
Set dump body with No.2 cylinder

extended 100 mm
20-193
1
(10)
Every 1000 hrs service!

Item
Condition
Brake
Front
Wheel brake
Center
Rear
Parking brake
Suspension
Front left
Front right
Rear left
Rear right
Unit
L.H.
R.H.
L.H.
R.H.
L.H.
R.H.
mm
Pad thickness
Standard
value
mm
Oil gas leaking

Suspension cylinder length
Oil gas leaking
mm

Oil gas leaking
Oil gas leaking
mm
mm
Result
Sat
Us
Within limit mark on wear gauge
Min. 1.5
Permissible
value
Min. 1.5
158 -- 178
153 -- 173
There must be no leakage
158 -- 178
153 -- 173
106 -- 116
101 -- 111
106 -- 116
101 -- 111
MEMO: Write any data or phenomena that you noticed during today's check.
20-194
1
(10)
HM300-1
TROUBLESHOOTING
20 Troubleshooting
TROUBLESHOOTING
Points to remember when troubleshooting ..............................................................................................
Sequence of events in troubleshooting ...................................................................................................
Points to remember when carrying out maintenance ..............................................................................
Checks before troubleshooting ................................................................................................................
Connector types and mounting locations ................................................................................................
Connection table for connector pin numbers ...........................................................................................
T-adapter table ........................................................................................................................................
Categories, procedure, and method of using troubleshooting charts ......................................................
20-202
20-203
20-204
20-212
20-213
20-228
20-250
20-253
Troubleshooting of engine controller system (ENG mode) ......................................................................

Troubleshooting of transmission controller system (TM mode) ...............................................................
Troubleshooting of retarder controller (q1) system (BK mode) ...............................................................
Troubleshooting of machine monitor system (MON mode) .....................................................................
Troubleshooting of hydraulic, mechanical system (H mode) ...................................................................
Troubleshooting of the engine body (S mode) .........................................................................................
20-301
20-401
20-601
20-701
20-801
20-901
HM300-1
20-201
1 c
(5)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
20-202
c
(9)
1 c
HM300-1
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 problem.
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
causes.
Step
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
tools.
T-adapter
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
TEW00186
1) Before starting troubleshooting, locate and

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
Step 4
Go to jobsite
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 5
Ask operator questions to
failure.
TEW00189
confirm details of
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
failure?
TEW00190
HM300-1
20-203
(9)
1 c
TROUBLESHOOTING
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 repairs 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, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted 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 frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful 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 connectors

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 plating at the joint will peel and cause improper
connection or breakage.
20-204
c
(9)
1 c
HM300-1
TROUBLESHOOTING
HM300-1
20-205
(9)
1 c
TROUBLESHOOTING
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 connectors 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 connectors 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 improper contact to occur, so always cover
the connector.
TEW00198
20-206
c
(9)
1 c
HM300-1
TROUBLESHOOTING
Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation, defective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or breakage 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 connector, 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, replace 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.
(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 position.
If the connector cannot be corrected easily, remove the clamp and adjust the
position.
TEW00200
(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
(9)
1 c
TROUBLESHOOTING
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 water 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 follows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with compressed air, there is the risk that oil in the
air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer 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 related parts too hot, as this will cause deformation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected 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 reassemble.
20-208
c
(9)
1 c
HM300-1
TROUBLESHOOTING
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 unless 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 control 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 welding 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
TROUBLESHOOTING
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure 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 repairing the machine in rain or high winds, or places 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. Disassembly 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 entering. 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, collect 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 refilling operations.

Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler 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
c
(9)
1 c
HM300-1
TROUBLESHOOTING
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 possible 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 contaminants 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 equipment, or changing the oil, use flushing oil to remove 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 secondary 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 3) 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
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Lubricating oil, coolant

Hydraulic,
Electrical
mechanical equipment
equipment
20-212
(9)
1 c
Action
Check fuel level
Add fuel
2.
Check for impurities in fuel
Clean, drain
3.
Check hydraulic oil level
Add oil
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
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
13. Check for abnormal noise, smell
Repair
14. Check for oil leakage
Repair
15. Carry out air bleeding
Bleed air
20 - 30 V
Replace
17. Check battery electrolyte level
Add or replace
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
to water leaking on connectors or terminals)
Disconnect connector
21. Check for water on wiring

22. Check alternator voltage (engine running at 1/2 throttle or above)
23. Check operating sound of battery relay (starting switch ON, OFF)
Judgement
Value
1.
16. Check battery voltage (engine stopped)

Electrical equipment
Other check items
Checks before starting
Item
and dry
Replace
After running for

several minutes:
27.5 - 29.5 V
Replace
Replace
HM300-1
TROUBLESHOOTING
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
1.PS
DT
Transmission 1st clutch solenoid
AJ-7
1.SW
DT
Transmission 1st clutch fill switch
AJ-7
2.PS
DT
Transmission 2nd clutch solenoid
AH-8
2.SW
DT
Transmission 2nd clutch fill switch
AH-8
3.PS
DT
Transmission 3rd clutch solenoid
AH-8
3.SW
DT
Transmission 3rd clutch fill switch
AI-8
A1
Emergency escape switch
W-4
A2
Emergency escape switch
W-5
AC1
1-pin connector
Air conditioner
M-3
ACBM
YAZAKI
Air conditioner blower motor
T-2
ACC
Terminal
Staring switch
ACM1
AMP
Air conditioner temperature adjustment servo motor
V-3
ACM2
AMP
Air conditioner vent mode selector servo motor
M-5
ACM3
AMP
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
Air conditioner pressure switch
U-3
ACR1
AMP
Air conditioner blower main relay
V-4
ACR2
AMP
Air conditioner blower Hi relay
W-4
ACR3
AMP
Air conditioner blower M2 relay
W-4
ACR4
AMP
Air conditioner blower M1 relay
W-4
ACR5
AMP
Air conditioner compressor clutch relay
W-4
ACRE
AMP
Air conditioner blower resistor
U-2
ACTH
YAZAKI
Air conditioner thermistor
U-3
AISS
AISS switch
M-3
AS1
SWP
Accelerator pedal sensor
N-2
AS2
Accelerator pedal sensor
O-2
ASS
DT-T
Air suspension seat
T-2
ATC1
MIC
17
Transmission controller
W-7
ATC2
MIC
21
W-6
ATC3A
AMP040
20
W-7
ATC3B
AMP040
16
W-7
ATC4
AMP040
12
W-7
ATC5A
AMP040
20
W-6
ATC5B
AMP040
16
W-6
ATC6
W-6
Terminal
Staring switch
HM300-1
Name of component
Address
20-213
1 c
(9)
TROUBLESHOOTING
Connector No.
Type
No. of pins
B01
DT
Brake wear switch (FL) (if equipped)
F-1
B1
Clearing memory
W-5
B02
DT
Brake wear switch (ML) (if equipped)
J-9
B2
Clearing memory
W-4
B03
DT
Brake cooling filter clogging switch (if equipped)
D-1
B09
DT
Transmission output shaft sensor (front)
B14
DT
Parking brake solenoid valve
E-8
B15
DT
Service brake switch
F-9
B16
DT
Retarder switch
G-9
B17
DT
Parking brake actuation switch
D-8
B18
DT
Rear brake EPC valve
F-9
B20
DT
Rear accumulator oil pressure switch
C-7
B21
DT
Front accumulator oil pressure switch
C-7
B24
DT
Rear accumulator oil pressure sensor
D-7
B25
DT
Front accumulator oil pressure sensor
B-7
B26
DT
Center brake wear switch (MR) (if equipped)
L-5
B27
DT
Steering angle sensor (if equipped)
H-2
B28
DT
Brake wear switch (FR)
A-4
B29
DT
Exhaust brake solenoid valve (if equipped)
A-4
B30
DT
Exhaust brake actuation switch (if equipped)
A-2
B31
DT
Dump selector solenoid
I-9
B32
DT
Dump EPC solenoid
I-2
B34
DT
Body positioner sensor
K-9
BL47
DT
Back-up lamp
L-8
BLS
Rotating lamp
O-2
BR
Terminal
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
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
Buzzer
R-1
Terminal
Starting switch
CAB1
DT
8 (Gr)
20-214
c
1
(9)
4 c
Name of component
Cab wiring harness
Address
F-1, AJ-4
R-9
HM300-1
TROUBLESHOOTING
Connector No.
Type
No. of pins
CAB2
DT
8 (B)
CAN1
DT-T
CAN2
Name of component
Address
Cab wiring harness
Q-8
Resistor
Q-9
DT-T
Resistor
Q-1
CG1
1-pin connector
Cigarette lighter
M-4
CG2
Terminal
Cigarette lighter
M-5
CH1
Machine monitor mode selector switch 1
M-1
CH2
Machine monitor mode selector switch 2
M-1
CJA
DT
8 (B)
Joint connector
A-6
CJAB
DT-T
Joint connector
G-1
CJAC
DT-T
Joint connector
F-9
CJB
DT
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
Joint connector
B-6
CJK
DT
8 (B)
Joint connector
L-7
CJL
DT
8 (B)
Joint connector
E-1
CJM
DT
Joint connector
A-5
CJP
DT
Joint connector
B-2
CJR
DT
8 (B)
Joint connector
B-6, L-7
CJS
DT
8 (B)
Joint connector
F-1
CJT
DT
Joint connector
F-1
CJU
DT
Joint connector
B-6
CJX
DT
Joint connector
B-2
CJY
DT
8 (B)
Joint connector
B-1
CK1
YAZAKI
Blown bulb checking switch
M-2
CM
Oil pressure switch
D-1
CM
DT-T
8 (G)
Lighting switch
P-8
CN1
DT
Injector A
Z-6
CN1
AMP070
12
Engine controller
S-9
CN2
DT
Injector E
Z-7
CN2
AMP070
18
Engine controller
S-9
CN3
DT
Injector C
AA-7
CN4
DT
Injector F
AA-7
CN4
AMP070
20
Engine controller
CN5
DT
Injector B
CN-5
Brake controller (Selecting model)
CN-13
Brake controller (Selecting model)
CN-41
Terminal
Backing-up alarm buzzer
L-8
CN-49
Terminal
Backing-up alarm buzzer
L-8
CN-86
DT
Side lamp, left
I-3
HM300-1
S-9
AB-7
20-215
1 c
(9)
TROUBLESHOOTING
Connector No.
Type
No. of pins
CN6
DT
Injector D
CN6
AMP070
10
Engine controller
S-9
CN7
AMP070
14
Engine controller
T-9
CNS1
DT-T
12 (Br)
Console wiring harness
S-1
CNS2
DT-T
12 (G)
S-2
CNS3
DT-T
12 (B)
S-1
COM
1-pin connector
Air conditioner unit
N-3
D/L PS
DT
Inter-axle differential lock clutch solenoid
AJ-6
D/L SW
DT
Inter-axle differential lock clutch fill switch
AJ-6
D01
DT-T
Diode
U-9
D02
DT-T
Diode
U-9
D03
DT-T
Diode
U-9
D04
DT-T
Diode
M-5
D05
DT-T
Diode
U-8
D06
DT-T
Diode
U-8
D07
DT-T
Diode
P-1
D08
DT-T
Diode
P-2
D09
DT-T
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
Machine monitor
N-7
DPC7
Machine monitor
P-2
DT
DT
8 (B)
D-1
DT1
DT
A-4
DT2
DT
12 (B)
A-5
DT4
DT
G-1
DT5
DT
8 (B)
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
T-2
E02
DT
Flow switch
E-1
E-2
Terminal
E-1
EG1
DT-T
12 (Gr)
Engine wiring harness
R-9
EG2
DT-T
12 (B)
R-9
EG3
DT-T
12 (G)
R-9
EG4
HD-24
23
A-4
EG5
HD-24
31
A-4
20-216
c
1 c
Name of component
Address
AC-7
HM300-1
TROUBLESHOOTING
Connector No.
Type
No. of pins
EMR2
Fuse (30A)
E-1
ER1
Terminal
Ground
Q-1
ER2
Terminal
Ground
X-2
ER3
Terminal
Ground
O-2
EREV
DT-T
Engine speed sensor
AD-5
EXH
Exhaust brake switch
N-3
FLB
Terminal
Flasher
R-1
FLL
Terminal
Flasher
R-1
FOG
Fog lamp switch
N-1
FS2
1-pin connector
Spare power source connector
U-9
FS3
1-pin connector
T-9
FS4
1-pin connector
T-9
FS5
1-pin connector
T-9
FS6
1-pin connector
U-9
FS7
1-pin connector
U-9
FS8
1-pin connector
T-9
FU
Fuse (30A)
E-1
DENSO
G sensor
G2
Terminal
Ground
E-8
G21
Terminal
Ground
S-2
H.PS
DT
Transmission Hi clutch solenoid
AJ-7
H.SW
DT
Transmission Hi clutch fill switch
AJ-6
H1
Terminal
Horn valve
B-1
H2
Terminal
Horn valve
A-3
H10
1-pin connector
Heater unit
M-4
H20
1-pin connector
Heater unit
M-4
HAZ
Hazard switch
N-6
HN
1-pin connector
Horn switch
P-8
HSL
DT-T
Dump lever (potentiometer)
U-3
JO1
HD-24
L-2
JO2
HD-24
23
J-3
JO4
HD-24
21
K-3
JO5
HD-24
31
J-2
JO6
HD-24
31
K-3
JO7
HD-18
23
K-3
JO8
HD-18
14
J-2
JO9
HD-24
31
J-2
JO10
HD-24
23
J-1
JO11
HD-24
31
L-1
JO12
DT
8 (B)
H-1
JO13
DT
8 (B)
J-3
HM300-1
Name of component
Address
AB-2
20-217
1 c
(9)
TROUBLESHOOTING
Connector No.
Type
No. of pins
JO14
DT
8 (G)
H-9
JO15
DT
8 (G)
I-9
JO18
DT
12 (B)
D-1
J19
HD-24
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
Rotating lamp
B-8
L.PS
DT
Transmission Lo clutch solenoid
AI-8
L.SW
DT
Transmission Lo clutch fill switch
AJ-7
L/C PS
DT
Torque converter lock-up clutch solenoid
AG-8
L/C SW
DT
Torque converter lock-up clutch fill switch
AG-8
LKO
DT-T
Control lever kick-out solenoid
U-3
LS
Rheostat
M-2
LUB.T
DT
Transmission oil temperature sensor
AI-2
M-2
Terminal
E-1
MC1
Memory clear
T-9
MC2
Memory clear
T-9
MON1
1-pin connector
Rear view monitor
M-6
MON2
1-pin connector
Rear view monitor
M-6
MON3
1-pin connector
Rear view monitor
M-6
MS
Model selection connector
U-9
MS11
Model selection connector
W-5
N1
DT
Transmission input shaft speed sensor
AF-7
N2
DT
Transmission intermediate shaft speed sensor
AJ-5
N3
DT
Transmission output shaft speed sensor
AJ-6
NE
DENSO
Engine NE speed sensor
AD-4
OF
Engine oil filter clogging switch
AC-7
OL
DT
Engine oil level sensor
AC-3
OP1
Machine monitor setting connector
M-8, N-9
OP2
M-8, N-9
OP3
M-8, O-9
OP4
M-8, O-9
OP5
N-7, O-9
OP6
N-7, O-8
OP7
N-7, O-8
OPS
DT-T
Seat heater (if equipped)
20-218
c
1 c
Name of component
Address
T-2
HM300-1
TROUBLESHOOTING
Connector No.
Type
No. of pins
P01
Left head lamp
C-1
P02
1-pin connector
Clearance lamp, left
C-1
P03
1-pin connector
Left combination ground
C-1
P04
1-pin connector
Turning signal lamp, left
C-1
P07
Left fog lamp (L.H.) (if equipped)
D-1
P13
Terminal
Horn valve
C-1
P14
Terminal
Horn valve
A-3
P20
Rear combination lamp (L.H.)
K-9
P21
Rear combination lamp (R.H.)
L-8
P22
DT
Side lamp, right (if equipped)
C-7
P06
DT
Turning signal lamp, right
P05
DT
Turning signal lamp, left
P30
1-pin connector
Right combination ground
A-3
P31
1-pin connector
Clearance lamp, right
A-3
P32
Right head lamp
A-3
P33
Right fog lamp (if equipped)
A-3
PCV1
DENSO
Fuel supply pump 1
AB-2
PCV2
DENSO
Fuel supply pump 2
AB-3
PFUEL
AMP174357-2
Engine common rail pressure sensor
AD-4
PHO
Terminal
Heater relay
PIM
DENSO
Engine boost pressure sensor
AD-6
PSH
1-pin connector
Engine oil high-pressure sensor
AA-2
PSL
1-pin connector
Engine oil low-pressure sensor
Z-2
PWM
Power mode switch
M-4
R.PS
DT
Transmission R clutch solenoid
AI-8
R.SW
DT
Transmission R clutch fill switch
AI-8
R01
KES0
Engine drive relay
V-3
R02
KES0
Transmission neutral relay
V-3
R03
KES0
Parking brake relay
V-2
R04
KES0
Rear brake relay
V-2
R05
KES0
Back-up buzzer relay
W-3
R06
KES0
Fog lamp relay (if equipped)
V-2
R07
KES0
Front working lamp relay
V-1
R08
KES0
Rear working lamp relay (if equipped)
W-3
R11
KES0
Horn relay
W-3
R14
KES0
Brake cut relay
W-1
R15
KES0
Transmission cut relay
W-3
R16
KES0
Hazard relay 1
W-1
R17
KES0
Hazard relay 2
W-1
R19
KES0
Parking brake safety relay
X-3
R21
KES0
Side lamp relay (if equipped)
W-1
HM300-1
Name of component
Address
20-219
1 c
(9)
TROUBLESHOOTING
Connector No.
Type
No. of pins
R22
KES0
Rotating lamp relay (if equipped)
X-2
R25
KES0
Right power window down relay
X-1
R26
KES0
Right power window up relay
W-1
R27
KES0
Left power window down relay
X-2
R28
KES0
Left power window up relay
X-1
R29
KES0
Head lamp Hi relay
X-1
R30
KES0
Head lamp Lo relay
X-2
R31
10
Passing relay
Q-1
R32
KES0
Dust indicator relay
X-1
R33
Parking brake manual switch
Q-8
R34
YAZAKI (FA)
Left power window switch
S-9
R35
YAZAKI (FA)
Right power window switch
S-9
R36
KES0
Engine power relay
V-2
R37
KES0
Auto preheat relay
V-2
RAD
PA
Cassette stereo
P-2
RDC
PA
Radio
P-1
RE1
KES1
Resistor
W-6
R-L2
1-pin connector
Room lamp 2
E-8
RT2
Terminal
Emergency steering timer
RT6
Terminal
RT7
Terminal
RT8
Terminal
RTL
DT-T
Retarder lever potentiometer
P-8
RWL
1-pin connector
Left rear working lamp
A-8, G-9
RWR
1-pin connector
Right rear working lamp
B-8, E-9
SBS
DT-T
Seat belt switch
U-3
SDE
Side lamp switch
N-2
SF1
DT-T
12 (G)
Gearshift lever
Q-8
SF2
DT-T
Gearshift lever
P-8
S-NET
MIC
S-NET monitoring connector
V-8
ST1
Terminal
ST2
Terminal
ST3
Terminal
ST4
Terminal
T01
DT
Radiator coolant level switch
B-2
T03
DT
Transmission oil filter switch
E-8
T04
DT
Steering oil temperature switch
H-9
T05
DT
Hydraulic oil filter switch
H-2
T06
DT
Hydraulic oil level switch
H-9
T08
DT
Fuel level sensor
A-2
T10
DT
Inclination sensor
K-9
20-220
c
1 c
(9)
Name of component
Address
HM300-1
TROUBLESHOOTING
Connector No.
Type
No. of pins
T11
DT
Air cleaner clogging sensor
A-4
T14
DT
Retarder oil temperature sensor (M)
L-4
T15
DT
Front brake oil temperature sensor
A-2
TC.INT
DT
Torque converter oil pressure sensor
AF-6
TC.SE
DT
Torque converter oil temperature sensor
AF-7
TEL
DT-T
12 (B)
Tele-management
Q-8
TG
1-pin connector
Tachograph
C-9
TG2
1-pin connector
Tachograph
C-9
TM1
HD-18
14
AF-8
TM2
HD-24
31
AF-8
TMF
V-3
TMO
W-7
TWH
DT
Engine coolant high-temperature sensor
Y-6
TWL
DT
Engine coolant low-temperature sensor
AB-8
WFM
Front wiper motor
Q-1
WFR
KES0
Intermittent windshield wiper relay
R-1
WM
Washer motor
A-4
WPS
DT-T
12 (B)
Wiper switch
P-7
WRF
Front working lamp switch
N-2
WRR
Rear working lamp switch
N-2
HM300-1
Name of component
Address
20-221
1 c
(9)
TROUBLESHOOTING
20-222
c
1 c
HM300-1
TROUBLESHOOTING
HM300-1
20-223
1 !
TROUBLESHOOTING
20-224
!
1 !
HM300-1
TROUBLESHOOTING
HM300-1
20-225
1 !
TROUBLESHOOTING
20-226
!
1 !
HM300-1
TROUBLESHOOTING
HM300-1
20-227
1 !
TROUBLESHOOTING
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
1
Male (female housing)
Female (male housing)
T-adapter
Part No.
Part number: 08055-00181
799-601-7010
799-601-7020
799-601-7030
799-601-7040
Terminal part number: 79A-222-3370
Electric wire size: 0.85

Grommet: Black
Qty: 20

Grommet: Black
Qty: 20

Grommet: Red
Qty: 20

Grommet: Red
Qty: 20
20-228
!
1 !
HM300-1
TROUBLESHOOTING
No. of
pins
SWP type connector

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

Grommet: Black
Qty: 20

Grommet: Black
Qty: 20

Grommet: Red
Qty: 20

Grommet: Red
Qty: 20
20-230
!
T-adapter
Part No.
1 !
HM300-1
TROUBLESHOOTING
No. of
pins
1
M type connector
T-adapter
Part No.
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
HM300-1
20-231
(5)
1 !
TROUBLESHOOTING
No. of
pins
S type connector
799-601-7140
10
(White)
799-601-7150
12
(White)
799-601-7350
16
(White)
799-601-7330
20-232
!
1 !
T-adapter
Part No.
HM300-1
TROUBLESHOOTING
No. of
pins
S type connector
10
(Blue)
12
(Blue)
799-601-7160
16
(Blue)
799-601-7170
HM300-1
T-adapter
Part No.
20-233
1 !
TROUBLESHOOTING
No. of
pins
MIC type connector

T-adapter
Part No.
Body part number: 79A-222-2640

(Qty: 5)

(Qty: 5)
11

(Qty: 5)

(Qty: 5)
799-601-2710

(Qty: 5)

(Qty: 5)
799-601-2950

(Qty: 5)

(Qty: 5)
13
799-601-2720

(Qty: 2)
20-234
!
1 !

(Qty: 2)
HM300-1
TROUBLESHOOTING
No. of
pins
MIC type connector

17
799-601-2730

(Qty: 2)

(Qty: 2)
21
HM300-1
T-adapter
Part No.
799-601-2740

(Qty: 2)

(Qty: 2)

(Qty: 50)

(Qty: 50)
20-235
1 !
TROUBLESHOOTING
No. of
pins
MIC type connector

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

(Qty: 5)
12
799-601-7190

(Qty: 5)
16
799-601-7210

(Qty: 5)
20
799-601-7220

(Qty: 5)
Terminal part number: 79A-222-3470 (No relation with number of pins)
20-236
!
1 !
HM300-1
TROUBLESHOOTING
No. of
pins
AMP070 type connector

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

Part number: 08027-10210 (Natural color)

08027-10220 (Black)

08027-10270 (Black)

08027-10420 (Black)

08027-10470 (Black)

08027-10620 (Black)
HM300-1
T-adapter
Part No.

08027-10670 (Black)
20-239
1 !
TROUBLESHOOTING
No. of
pins
KES 1 (Automobile) connector


08027-10820 (Black)
20-240
!
1 !
T-adapter
Part No.

08027-10870 (Black)
HM300-1
TROUBLESHOOTING
No. of
pins
Connector for relay (Socket type)

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

Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter
Part No.
799-601-9210
18-8
(1)
Part number: 08191-11201, 08191-11202,

08191-11205, 08191-11206
Part number: 08191-14101, 08191-14102,

08191-14105, 08191-14106
Pin (male terminal)
799-601-9210
Part number: 08191-11201, 08191-12202,

08191-11205, 08191-12206
Part number: 08191-13101, 08191-13102,

08191-13105, 08191-13106
Pin (male terminal)
799-601-9220
18-14
(2)
Part number: 08191-21201, 08191-12202,

08191-21205, 08191-12206
Part number: 08191-24101, 08191-24102,

08191-24105, 08191-24106
Pin (male terminal)
799-601-9220
Part number: 08191-22201, 08191-22202,

08191-22205, 08191-22206
20-242
!
1 !
Part number: 08191-23101, 08191-23102,

08191-23105, 08191-23106
HM300-1
TROUBLESHOOTING
Type
(shell size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part No.
799-601-9230
18-20
(3)
Part number: 08191-31201, 08191-31202
Part number: 08191-34101, 08191-34102
Pin (male terminal)
799-601-9230
Part number: 08191-32201, 08191-32202
Part number: 08191-33101, 08191-33102
Pin (male terminal)
799-601-9240
18-21
(4)
Part number: 08191-41201, 08191-42202
Part number: 08191-44101, 08191-44102
Pin (male terminal)
799-601-9240
Part number: 08191-42201, 08191-42202
HM300-1
Part number: 08191-43101, 08191-43102
20-243
1 !
TROUBLESHOOTING
Type
(shell size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part No.
799-601-9250
24-9
(5)
Part number: 08191-51201, 08191-51202
Part number: 08191-54101, 08191-54102
Pin (male terminal)
799-601-9250
Part number: 08191-52201, 08191-52202
Part number: 08191-53101, 08191-53102
Pin (male terminal)
799-601-9260
24-16
(6)
Part number: 08191-61201, 08191-62202,

08191-61205, 08191-62206
Part number: 08191-64101, 08191-64102,

08191-64105, 08191-64106
Pin (male terminal)
799-601-9260
Part number: 08191-62201, 08191-62202,

08191-62205, 08191-62206
20-244
!
1 !
Part number: 08191-63101, 08191-63102,

08191-63105, 08191-63106
HM300-1
TROUBLESHOOTING
Type
(shell size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part No.
799-601-9270
24-21
(7)
Part number: 08191-71201, 08191-71202,

08191-71205, 08191-71206
Part number: 08191-74101, 08191-74102,

08191-74105, 08191-74106
Pin (male terminal)
799-601-9270
Part number: 08191-72201, 08191-72202,

08191-72205, 08191-72206
Part number: 08191-73102, 08191-73102,

08191-73105, 08191-73106
Pin (male terminal)
799-601-9280
24-23
(8)
Part number: 08191-81201, 08191-81202,

08191-81203, 08191-81204,
08191-81205, 08191-80206
Part number: 08191-84101, 08191-84102,

08191-84103, 08191-84104,
08191-84105, 08191-84106
Pin (male terminal)
799-601-9280
Part number: 08191-82201, 08191-82202,

08191-82203, 08191-82204,
08191-82205, 08191-82206
HM300-1
Part number: 08191-83101, 08191-83102,

08191-83103, 08191-83104,
08191-83105, 08191-83106
20-245
1 !
(6)
TROUBLESHOOTING
Type
(shell size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part No.
799-601-9290
24-31
(9)
Part number: 08191-91203, 08191-91204,

08191-91205, 08191-91206
Part number: 08191-94103, 08191-94104,

08191-94105, 08191-94106
Pin (male terminal)
799-601-9290
Part number: 08191-92203, 08191-92204,

08191-92205, 08191-92206
20-246
!
1 !
Part number: 08191-93103, 08191-93104,

08191-93105, 08191-93106
HM300-1
TROUBLESHOOTING
No. of
pins
DT Series connector
Body (plug)
Body (receptacle)
799-601-9020
Part number: 08192-12200 (normal type)

08192-22200 (fine wire type)

799-601-9030


799-601-9040


799-601-9050

HM300-1
T-adapter
Part No.

20-247
1 !
TROUBLESHOOTING
No. of
pins
DT Series connector
Body (plug)
T-adapter
Part No.
Body (receptacle)
8GR :
8B :
8G :
8BR :
799-601-9060
799-601-9070
799-601-9080
799-601-9080
Part number: 08192-1820 " (normal type) Part number: 08192-1810 " (normal type)
08192-2820 " (fine wire type)
12GR :
12B :
12G :
12BR :
12
799-601-9110
799-601-9120
799-601-9130
799-601-9140
Part number: 08192-1920 " (normal type) Part number: 08192-1910 " (normal type)
20-248
!
(5)
1 !
HM300-1
TROUBLESHOOTING
No. of
pins
DTM Series connector

Body (plug)
Body (receptacle)
T-adapter
Part No.
799-601-9010
No. of
pins
DTHD Series connector

Body (plug)
Body (receptacle)
T-adapter
Part No.
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
1 !
(6)
20 Troubleshooting
TROUBLESHOOTING

No. of
pins
DRC26 Series connector

Body (plug)
Body (receptacle)
24
799-601-9360
Part No.: 7821-93-3110
40
(A)
799-601-9350
Part No.: 7821-93-3120
40
(B)
799-601-9350
20-249-1
!
(7) !
T-adapter
Part No.
Part No.: 7821-93-3130
HM300-1
TROUBLESHOOTING
T-ADAPTER TABLE
T-ADAPTER TABLE
! !
799-601-3300 For measuring box
Econo-24P
799-601-3360 Plate
For MS box
799-601-3370 Plate
For MS box
799-601-3380 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
799-601-9300
799-601-9200
! !
! !
! !
! !
! !
!
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
1 !
(5)
799-601-9100
799-601-2710 MIC
20-250
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
! !
799-601-7000
MS-37P
799-601-6500
799-601-6000
799-601-5500
MS-37P
799-601-3470 CASE
799-601-3000
799-601-2900
Econo-21P
Connector type
799-601-2800
Port No.
799-601-2700
Pin No.
799-601-2500
KIT No.
!
!
!
!
HM300-1
TROUBLESHOOTING
T-ADAPTER TABLE
KIT No.
Port No.
Connector type
Pin 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
(5)
1 !
TROUBLESHOOTING
T-ADAPTER TABLE
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
! !
For DT, HD
! !
799-601-9340 Case
799-601-9350 DRC26
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-9230 HD30
799-601-9330 Case
!
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
20-252
!
799-601-2900
Pin No.
799-601-2800
Connector type
799-601-2700
Port No.
799-601-2500
KIT No.
1 !
(7)
2P
HM300-1
CATEGORIES, PROCEDURE, AND METHOD OF USING

TROUBLESHOOTING CHARTS
TROUBLESHOOTING

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
ENG
Troubleshooting system
Troubleshooting of engine controller system
TM
Troubleshooting of transmission controller system
BK
Troubleshooting of retarder controller(q1) system
MON
Troubleshooting of machine monitor system
Troubleshooting of hydraulic, mechanical system
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 trouble 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 troubleshooting 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)
TROUBLESHOOTING

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 inserted.
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, component, or problem. In such cases, the failure mode is further divided into sections marked with small letters (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
, and according to the answer follow either the YES line
YES
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 judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, 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
c
1 c
(9)
HM300-1
TROUBLESHOOTING

4. Method of using YES-NO type troubleshooting (H mode)

Step 1. Questioning the operator
The questions to ask the operator are given below the failure symptom. If the answers to the
questions match the information given, follow
the arrow to reach the probable cause of the failure.
Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3
to grasp the true cause.
1. Steering does not work
Symptom [Example]
Ask the operator about the following points.

Did the steering suddenly stop working?
Breakage in steering equipment
Had the steering gradually been becoming heavy?
Internal wear of steering equipment,
defective seal
Checks before staring [Example]

Step 2. Checks before troubleshooting
Before starting the main troubleshooting and
measuring the hydraulic pressure, first check the
Checks before Starting items, and check for oil
leakage and loose bolts. These checks may
avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting
are items which must be considered particularly
for that symptom before starting troubleshooting.
Is the oil level in the hydraulic tank correct?

Is the type of oil correct?
Is there any leakage of oil from the steering valve or Orbit-roll?
Has the safety bar been removed from the
frame?
[Example 1]
Step 3. Using cross-reference table
1) Operate the machine to carry out the checks
in the troubleshooting item column.
Mark the items where the results match the
symptom.
It is not necessary to follow the troubleshooting checks in order; follow an order
which is easiest to carry out troubleshooting.
No. Problems
Remedy
Steering does not work to the left or right.
Same as Item 1, but abnormality in actuation of

work equipment.
Steering can only be operated to one side.
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 causes. (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)
TROUBLESHOOTING

3) Operate the machine and check the troubleshooting 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) remains.
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 indicate the following:
: Replace, : Repair, A: Adjust, C: Clean
20-256
c
1 c
(5)
HM300-1
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(ENG MODE)
ENG mode related electrical circuit diagram ...........................................................................................

Content of display and problem that appears on machine for each failure code......................................
ENG-1 Failure code [A000N1] (Engine: Overrun N1)) .......................................................................
ENG-2 Failure code [A570NX] (Engine oil filter: Clogged (NX)) ........................................................
ENG-3 Failure code [AD00L2] (Common rail: * See Contents (L2)) ..................................................
ENG-4 Failure code [AD00MA] (Common rail: Function impossible (MA)) ........................................
ENG-5 Failure code [AD10L3] (Fuel supply pump: * See Contents (L3)) ..........................................
ENG-6 Failure code [AD10MA] (Fuel supply pump: Function impossible (MA)) ................................
ENG-7 Failure code [AD10MB] (Fuel supply pump: Drop in function (MB)) ......................................
ENG-8 Failure code [AD11KA] (Fuel supply pump solenoid valve 1: Disconnection (KA)) ................
ENG-9 Failure code [AD11KB] (Fuel supply pump solenoid valve 1: Short circuit (KB)) ...................
ENG-10 Failure code [AD51KA] (Fuel supply pump solenoid valve 2: Disconnection (KA)) ...............
ENG-11 Failure code [AD51KB] (Fuel supply pump solenoid valve 2: Short circuit (KB)) ...................
ENG-12 Failure code [ADA1KA] (No. 1 injector solenoid valve: Disconnection (KA)) .........................
ENG-13 Failure code [ADAZKB] (No. 1, 2, 3 injector solenoid valve: Short circuit (KB)) ....................
ENG-14 Failure code [ADB1KA] (No. 2 injector solenoid valve: Disconnection (KA)) .........................
ENG-15 Failure code [ADC1KA] (No. 3 injector solenoid valve: Disconnection (KA)) .........................
ENG-16 Failure code [ADD1KA] (No. 4 injector solenoid valve: Disconnection (KA)) .........................
ENG-17 Failure code [ADDZKB] (No. 4, 5, 6 injector solenoid valve: Short circuit (KB)) ....................
ENG-18 Failure code [ADE1KA] (No. 5 injector solenoid valve: Disconnection (KA)) .........................
ENG-19 Failure code [ADF1KA] (No. 6 injector solenoid valve: Disconnection (KA)) .........................
ENG-20 Failure code [B@BAZG] (Engine oil: Drop in oil pressure (ZG)) ............................................
ENG-21 Failure code [B@BAZK] (Engine oil: Drop in level (ZK)) ........................................................
ENG-22 Failure code [B@BCNS] (Radiator coolant: Overheat (NS)) ..................................................
ENG-23 Failure code [D181KZ] (Preheating relay contact: Disconnection or short circuit (KZ)) .........
ENG-24 Failure code [D182KZ] (Preheating relay coil: Disconnection or short circuit (KZ)) ...............
ENG-25 Failure code [D1D0KB] (Engine controller load power source relay: Short circuit (KB)) ........
ENG-26 Failure code [D5ZAKX] (Engine throttle modify 1 signal: Input signal outside range (KX)) ....
ENG-27 Failure code [DB20KT] (Engine controller: Abnormality inside controller (KT)) .....................
ENG-28 Failure code [DB22KK] (Engine controller load power source relay:
Drop in power supply voltage, input (KK)) .......................................
ENG-29 Failure code [DB29KQ] (Engine controller connection wiring harness:
Model selection signal mismatch (KQ)) ...........................................
ENG-30 Failure code [DB2AMA] (Engine controller fuel injection quantity control switch:
Function impossible (MA)) ...............................................................
ENG-31 Failure code [DD11KB] (Starting switch: Short circuit (KB)) ...................................................
ENG-32 Failure code [DDA1L5] (Acceleration switch: * See Contents (L5)) .......................................
ENG-33 Failure code [DDE2L6] (Engine oil pressure switch: * See Contents (L6)) ............................
ENG-34 Failure code [DGE2KX] (Engine coolant temperature sensor (for high-temperature):
Input signal outside range (KX)) ......................................................
ENG-35 Failure code [DGE3L6] (Engine coolant temperature sensor (for low-temperature):
* See Contents (L6)) .........................................................................
ENG-36 Failure code [DH30KX] (Boost pressure sensor: Input signal outside range (KX)) ................
ENG-37 Failure code [DH40KX] (Common rail pressure sensor: Input signal outside range (KX)) .....
ENG-38 Failure code [DK10KX] (Throttle angle sensor: Input signal outside range (KX)) ..................
ENG-39 Failure code [DLE3LC] (Engine Ne speed sensor: * See Contents (LC)) ..............................
ENG-40 Failure code [DLH1LC] (Engine G speed sensor: * See Contents (LC)) ................................
ENG-41 Engine does not start (starting motor does not turn) ..............................................................
HM300-1
20-303
20-308
20-320
20-321
20-322
20-322
20-323
20-325
20-325
20-326
20-327
20-328
20-329
20-330
20-431
20-335
20-336
20-337
20-338
20-342
20-343
20-344
20-345
20-346
20-347
20-349
20-350
20-352
20-353
20-355
20-357
20-358
20-359
20-360
20-362
20-364
20-365
20-366
20-368
20-370
20-372
20-373
20-374
20-301
1 c
(9)
TROUBLESHOOTING
Appendix: Table for Failure Phenomenon Code

Failure
Phenomenon
Code
Failure
Phenomenon
Code
Summary of Failure
Disconnection
L0
An impossible combination of clutch fill signals turn ON more

than 2 channels simultaneously.
KB
Short-circuiting
L1
While the order current to ECMV is off, the fill signal is ON.
KK
Power source voltage and

input lowered
L2
The fuel pressure exceeds the specified max. value.
KQ
Model selection signal

wrong
L3
The intended unit is out of control.
KR
Communication ineffective
L4
ON and OFF signals in two systems do not concur with each

other.
KT
Controller internally abnormal
L6
Signals from engine revolution, C terminal, hydraulic pressure

switch and coolant temperature sensor do not match up with
the respective actual condition.
KX
Input signal out of range
L8
Analog signals in two systems do not concur with each other.
KZ
Disconnection or short-circuiting
LC
Signals of revolution speed in two systems do not concur with

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
KA
20-302
c
1 c
(9)
Summary of Failure
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
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
c
(9)
1 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
HM300-1
20-305
1 !
TROUBLESHOOTING
TROUBLESHOOTING
20-306
!
1 !
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE

FOR EACH FAILURE CODE
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON

MACHINE FOR EACH FAILURE CODE
Failure code
Nature of failure
Probable cause
A000N1
(ENG-1)
Engine: Overrun (N1)
A570NX
(ENG-2)
Engine oil filter: Clogged (NX) Signal circuit of engine oil filter
clogging switch became open
(shut off from GND) while engine was running
Clogged engine oil filter (when system is

working normally)
Defective engine oil filter clogging switch
Disconnection in switch signal circuit wiring harness
Defective engine controller
AD00L2
(ENG-3)
Common rail: * See Contents Common rail fuel pressure has

(L2)
risen to high pressure (level 1)
Viscosity of fuel is too high (unsuitable

fuel)
Defective overflow valve
Clogged overflow piping
Defective pressure limiter
Defective common rail fuel pressure sensor
AD00MA
(ENG-4)
Common rail: Function impossible (MA)
Common rail fuel pressure has

risen to high pressure (level 2)
Same as failure code [AD00L2]
AD10L3
(ENG-5)
Fuel supply pump: * See

Contents (L3)
Non-force feed (level 1) has oc- Defective fuel low-pressure circuit (etc.)
curred in fuel supply pump
Defective fuel supply pump PCV
Defective fuel injector
Leakage from high-pressure fuel piping
AD10MA
(ENG-6)
Fuel supply pump: Function

impossible (MA)
Abnormal pressure has oc Same as failure code [AD00L2]

curred in common rail fuel pressure
AD10MB
(ENG-7)
Fuel supply pump: Drop in

function (MB)
Non-force feed (level 2) has oc- Same as failure code [AD10L3]

curred in fuel supply pump
AD11KA
(ENG-8)
Fuel supply pump solenoid

valve 1: Disconnection (KA)
Disconnection has occurred in

Defective fuel supply pump PCV1
PCV1 circuit of fuel supply pump Disconnection in PCV1 (+) circuit wiring
harness
Disconnection or short circuit with chassis ground in PCV1 () circuit wiring harness
AD11KB
(ENG-9)

valve 1: Short circuit (KB)
Excessive current has flowed in Defective fuel supply pump PCV1

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 harness
20-308
c
Location of failure
1 c
(9)
Engine speed went above operating range
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

The code (ENG-**) given below the failure code is the troubleshooting number.
Condition when normal
Sensor resistance value

OF terminal - terminal
When normal: Max. 1
When clogged: Min. 1 M
Action by controller
Problem that appears on machine
Action code
Stops fuel injection until engine Engine speed varies abnormally

speed goes down to operating
range
E02
Carries out operation under

normal control
E01
If machine continues to be used

as it is, there is danger that dirt will
circulate inside engine
Carries out operation with lim- Engine output is reduced

ited output
E03
Carries out operation with lim- Engine output and speed are reited output and engine speed
duced
E03

ited output
E03

normal control
E03
Engine output is reduced
Carries out operation with lim- Engine output and speed are reited output and engine speed
duced
E03
Solenoid resistance value

Turns output to PCV1 OFF
PCV1 (male) (1) (2): 2.3 5.3
No great effect on machine

(however, if failure code
[AD51KA] occurs at the same
time, the engine stops)
E03

PCV1 (male) (1) (2): 2.3 5.3

[AD51KB] occurs at the same
E03
HM300-1
20-309
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
AD51KA
(ENG-10)

valve 2: Disconnection (KA)
A disconnection has occurred in Defective fuel supply pump PCV2

the PCV2 circuit of the fuel sup- Disconnection in PCV2 (+) circuit wiring
ply pump
harness
Disconnection or short circuit with chassis ground in PCV2 () circuit wiring harness
AD51KB
(ENG-11)

valve 2: Short circuit (KB)
Excessive current has flowed in Defective fuel supply pump PCV2

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 harness
ADA1KA
(ENG-12)
No. 1 injector solenoid valve: Disconnection has occurred in

Disconnection (KA)
No. 1 injector solenoid circuit
Defective No. 1 injector solenoid

Disconnection in solenoid (+) circuit wiring harness
Disconnection in solenoid () circuit wiring harness
ADAZKB
(ENG-13)
No. 1, 2, 3 injector solenoid

valve: Short circuit (KB)
ADB1KA
(ENG-14)

Disconnection (KA)

ADC1KA
(ENG-15)

Disconnection (KA)

ADD1KA
(ENG-16)

Disconnection (KA)

20-310
c

1 c
(9)
Excessive current has flowed in

No. 1 injector solenoid circuit,
No. 2 injector solenoid circuit, or

Short circuit with chassis ground or hot
short in No. 1 solenoid (+) circuit and ()
circuit wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

PCV2 (male) (1) (2): 2.3 5.3

[AD11KA] occurs at the same
E03

PCV2 (male) (1) (2): 2.3 5.3

[AD11KB] occurs at the same
E03

Turns output to No. 1 injector
CN1 (male) (1) (2): 0.4 1.1
solenoid OFF
E03

solenoid OFF
CN1 (male) (1) (2): 0.4 1.1
CN2 (male) (1) (2): 0.4 1.1 Turns output to No. 2 injector
solenoid OFF
CN3 (male) (1) (2): 0.4 1.1
solenoid OFF
Engine output is greatly reduced
E03

CN2 (male) (1) (2): 0.4 1.1
solenoid OFF
E03

CN3 (male) (1) (2): 0.4 1.1
solenoid OFF
E03

CN4 (male) (1) (2): 0.4 1.1
solenoid OFF
E03
HM300-1
20-311
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
No. 4, 5, 6 injector solenoid

valve: Short circuit (KB)
ADE1KA
(ENG-18)

Disconnection (KA)

ADF1KA
(ENG-19)

Disconnection (KA)

B@BAZG
(ENG-20)
Engine oil: Drop in oil pressure (ZG)
Drop in engine oil pressure (when system is working normally)

Defective engine oil low-pressure switch
Defective engine oil high-pressure
switch
Short circuit with chassis ground in lowpressure switch signal circuit wiring harness
Short circuit with chassis ground in highpressure switch signal circuit wiring harness
B@BAZK
(ENG-21)
Engine oil: Drop in level (ZK) Signal circuit of engine oil pressure switch became open (shut
off from GND)
Drop in engine oil level (when system is

working normally)
Defective engine oil level switch
Disconnection in switch circuit wiring
harness
B@BCNS
(ENG-22)
Radiator coolant: Overheat

(NS)
Engine coolant temperature overheats

(when system is working normally)
1 c
(9)
Excessive current has flowed in

No. 4 injector solenoid circuit,
No. 5 injector solenoid circuit, or
Probable cause
ADDZKB
(ENG-17)
20-312
c

When running at low idle, signal

circuit of engine oil pressure
low-pressure switch became
closed (connected to GND), or
when engine speed was more
than 1300 rpm, signal circuit of
oil pressure high-pressure
switch became closed (connected to GND)
Engine coolant temperature

went above operating range

short in No. 4 solenoid (+) circuit and
() circuit wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

CN4 (male) (1) (2): 0.4 1.1
CN5 (male) (1) (2): 0.4 1.1
CN6 (male) (1) (2): 0.4 1.1

solenoid OFF
solenoid OFF
solenoid OFF
Engine output is greatly reduced
E03

CN5 (male) (1) (2): 0.4 1.1
solenoid OFF
E03

CN6 (male) (1) (2): 0.4 1.1
solenoid OFF
E03
Low-pressure switch resistance Carries out operation under

value
normal control
PSL ground
When engine is stopped:
Max. 1
When engine speed is 600 rpm
or more: Min. 1 M
High-pressure switch resistance
value
PSH ground
Max. 1
When engine speed is 1300
rpm or more: Min. 1 M
If the machine continues to be

used as it is, the engine may seize
up
E03

Switch resistance value
OL (male) (1) ground
normal control
When oil level is normal:
Max. 1
When oil level is low: Min. 1 M

up
E01
Limits fuel injection until tem- Engine output is reduced

perature goes down to operating range
HM300-1
E02
20-313
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
D181KZ
(ENG-23)
Preheating relay contact: Dis- Disconnection, short circuit with Defective heater relay
ground, or hot short has occurred Defective preheater relay
connection or short circuit
in signal circuit of heater relay
Disconnection, short circuit with chassis
(KZ)
ground, or hot short in relay signal circuit
wiring harness
D182KZ
(ENG-24)
Preheating relay coil: Discon- Disconnection or short circuit

nection or short circuit (KZ) with ground has occurred in
drive circuit of preheater relay
D1D0KB
(ENG-25)
Engine controller load power Voltage was generated in power Defective engine power source relay
source relay: Short circuit
supply circuit of controller when Hot short circuit wiring harness
(KB)
starting switch was OFF
D5ZAKX
(ENG-26)
Engine throttle modify 1 signal: Input signal outside

range (KX)
DB20KT
(ENG-27)
Engine controller: Abnormali- Abnormality has occurred inside Disconnection in GND circuit wiring harty inside controller (KT)
controller
ness
DB22KK
(ENG-28)
Engine controller load power Voltage in controller power sup- Defective engine power source relay
source relay: Drop in power ply voltage circuit dropped when Disconnection or short circuit with chassis ground in relay (1) circuit wiring harsource voltage (KK)
starting switch was ON
ness
Disconnection or short circuit with chassis ground in relay (2) circuit wiring harness
DB29KQ
(ENG-29)
Engine controller connecting Model selection signal does not

wiring harness: Model selec- match setting inside controller
tion signal mismatch (KQ)
20-314
c

1 c
(9)
Voltage in throttle modify signal

circuit went outside normal
range (6 15 V)
Defective preheater relay

Disconnection or short circuit with chassis ground in relay power source circuit
wiring harness
Disconnection or short circuit with chassis ground in relay drive circuit wiring
harness
Defective transmission controller

Disconnection or short circuit with chassis ground in signal circuit wiring harness
Defective model selection connector

Disconnection in signal 1 circuit wiring
harness
harness
harness
Disconnection in GND circuit wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
Preheating input signal

voltage
normal control
CN4 (3) ground
When preheating is stopped:
Max. 1 V
When preheating is being
used: 20 30 V
It is difficult to start the engine in

low temperatures
E03
Relay resistance value

R37 (male) (1) (2):
100 500
Cannot turn preheater relay

ON

low temperatures
E03
Power source voltage

CN7 (6)(14) (5)(13)
When starting switch is OFF:
Max. 1 V
When starting switch is ON:
20 - 30 V

normal control
E01
Signal voltage
CN4 (16) ground: 6 15 V
Does not modify throttle
There is shock when shifting

transmission
E01
Unable to drive injectors prop- If the machine continues to be

erly
up
Stop driving injectors
Engine stops during operation
Engine cannot be started
Power source voltage
CN7 (6)(14) (5)(13)
When starting switch is OFF:
Max. 1 V
20 30 V
Signal voltage
CN4 (13) ground: Max. 1 V
CN4 (14) ground: 20 30 V
CN4 (15) ground: Max. 1 V
HM300-1
Uses model with default setting to carry out control
E03
Engine stops during operation

Engine cannot be started
E03
Does not give specified engine

output
E03
20-315
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DB2AMA
(ENG-30)
Engine controller fuel injection quantity control switch:

DD11KB
(ENG-31)
Starting switch: Short circuit Terminal C signal from starting Defective starting switch
(KB)
switch came ON when engine Hot short in signal circuit wiring harness
was running
DDA1L5
(ENG-32)
Acceleration switch: * See Idle validation switch of acceler- Defective accelerator pedal
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
ground, or hot short in switch signal 3
wiring harness
Disconnection in switch GND circuit wiring harness
DDE2L6
(ENG-33)
Engine oil pressure switch:

* See Contents (L6)
Engine oil pressure switch signal does not match condition of

engine
DGE2KX
(ENG-34)

sensor (for high temperature): Input signal outside
range (KX)
Signal from engine coolant high- Defective engine coolant high-temperatemperature sensor is outside
ture sensor
normal range
Disconnection or short circuit with chassis ground in sensor signal circuit wiring
harness
Disconnection in sensor GND circuit wiring harness
DGE3L6
(ENG-35)

sensor (For low-temperature): * See Contents (L6)
Signal from the engine coolant

high-temperature sensor has
not been input
20-316
!

1 !
(9)
Fuel injection quantity control

Defective setting of fuel injection quantity
set switch inside controller is not
control setting switch
set at correct position

switch
Disconnection or short circuit with chassis ground in low-pressure switch signal
Disconnection in high-pressure switch
signal circuit wiring harness
Defective engine coolant low-temperature sensor

harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

normal control
Fuel injection quantity control setting cannot be changed
E01
Signal voltage
CN4 (2) ground
Max. 1 V
When starting switch is at
START: 20 30 V

normal control
Operates normally 10 seconds after starting
E03
CN4 (11) ground (signal 2)

Throttle voltage
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

normal control
E01

up
E01
Low-pressure switch resis Carries out operation under

tance value
normal control
PSL ground
Max. 1
High-pressure switch resistance value
PSH ground
Max. 1
(coolant temperature:
10 100C)
TWH (male) (1) (2):
90 3.5 k
Coolant temperature display on

machine monitor is not correct
normal control
Fixes coolant temperature signal output to machine monitor
to 90C
E01

(coolant temperature:
10 100C)
TWL (male) (1) (2):
9 0.3 k

normal control
E01
HM300-1
Exhaust gas color in low temperatures is poor

low temperatures
20-317
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DH30KX
(ENG-36)
Boost pressure sensor: Input Signal from boost sensor is out- Defective boost pressure sensor
signal outside range (KX)
side normal range
Disconnection or short circuit with chassis ground in sensor power source circuit
wiring harness
Disconnection or short circuit with chassis ground in sensor GND circuit wiring
harness
harness
DH40KX
(ENG-37)
Common rail pressure sensor: Input signal outside

range (KX)
Signal from common rail fuel

pressure sensor is outside normal range
DK10KX
(ENG-38)
Throttle angle sensor: Input

Throttle angle signal from accel- Defective accelerator pedal

Disconnection or short circuit with chaserator pedal is outside normal
sis ground in sensor power source circuit
range
wiring harness
harness
harness
DLE3LC
(ENG-39)
Engine Ne speed sensor:

* See Contents (LC)
Signal from engine Ne speed

sensor does not match signal
from engine G speed sensor
Defective engine Ne speed sensor

harness
harness
DLH1LE
(ENG-40)
Engine G speed sensor:

* See Contents (LC)
Signal from engine G speed

sensor does not match signal
from engine Ne speed sensor
Defective engine G speed sensor

harness
harness
20-318
c

1 c
(9)

wiring harness
harness
harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
Sensor power source voltage

PIM (1) (3): 4.6 5.4 V
Sensor signal voltage
PIM (2) (3): 0.3 4.7 V
Carries out operation under nor- No great effect on machine

mal control
E03

PFUEL (1) (3): 4.6 5.4 V
PFUEL (2) (3): 0.3 4.7 V
Limits output with open control Engine output is reduced
E03

AS1 (3) (1): 4.6 5.4 V
AS1 (2) (1): 0.3 4.5 V
Controls at low idle or high idle Engine speed is fixed at low idle
or high idle, it is impossible to conaccording to signal from idle
trol acceleration at medium range
validation switch
E03

NE (male) (1) (2): 85 210 ited output
E03

G (male) (1) (2): 1.4 3.5 k ited output
E03
HM300-1
20-319
1 c
(9)
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.
Operate machine monitor.
Is another failure code also

displayed or recorded at same
time?
NO
Go to
troubleshooting
for displayed
code
YES
2
Was machine operated in way
that would cause engine to
overrun?
NO
Check cause of
failure and
repair damage
to engine
YES
Go to
troubleshooting for failure
code
[DEL3LC]
[DLH1LC]
3
Start engine.
Can engine speed be read

normally?
NO
YES
20-320
c
1 c
Replace
HM300-1
TROUBLESHOOTING
ENG-2
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
Stop engine
Is engine oil filter clogged?
NO
YES
Clogged engine oil filter
Turn starting switch
OFF.
Disconnect OF.
2
Is resistance between terminal NO
OF (switch end) and ground less
than 1?
Clean or
replace
Defective engine oil filter clogging Replace

switch
YES
OFF.
Disconnect CN6.
3
Is resistance between terminal NO
CN6 (female) (5) and ground less
than 1?
Defective contact or disconnection

in wiring harness between CN6 Repair or
replace
(female) (5) and OF
YES
Replace
ENG-2 Related electrical circuit diagram
HM300-1
20-321
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
ENG-3
ENG-3
ENG-3, ENG-4
FAILURE CODE [AD00L2] (COMMON RAIL: * SEE CONTENTS (L2))
Nature of failure:The common rail fuel pressure has risen to high pressure (level 1)
Cause
Is another failure code also NO

time?
Go to troubleshooting for
displayed
code
YES
Is suitable fuel for ambient NO

temperature being used?
Remedy
Unsuitable fuel being used
Replace
YES
Loosen joint of fuel

supply pump overflow
valve.
Does fuel leak out from joint NO

when priming pump is operated?
YES
Disassemble fuel supply

pump overflow valve.
In overflow valve, is spring NO

damaged, seat worn, or ball
stuck?
YES
Loosen joint of common

rail pressure limiter
Go to troubleshooting No.
7.
Defective overflow valve
Replace
Replace
Does fuel leak out from joint NO

when priming pump is operated?
YES
When troubleshooting is carried out NO

for failure code [DH40KX], does
problem occur in electrical system?
YES
Is overflow piping clogged?
NO
Defective electric system of

common rail fuel pressure Repair or
replace
sensor
Defective mechanical system of
common rail fuel pressure Replace
sensor
YES
Clogged overflow piping
ENG-4
Repair or
replace
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
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-5
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
1
Is another failure code also NO
time?
Remedy
displayed
code
YES
2
Is suitable fuel for ambient NO
temperature being used?
Unsuitable fuel being used
Replace
Clogged filter, strainer
Clean or
replace
YES
3
Is filter or strainer clogged?
(See Note 1)
NO
YES
Measure fuel pressure (see

TESTING AND ADJUSTING).
4
Is fuel low-pressure circuit NO
pressure 0.15 - 0.3 MPa {1.5 - 3
kg/cm2}?
YES
Defective low-pressure circuit Repair or

equipment (see Note 2)
replace
Disconnect outlet piping of

common rail pressure
limiter.
Start engine.
5
Is fuel drain amount from NO
pressure limiter less than 10
cc/min?
YES
Replace
Defective fuel injector
Replace
Defective common rail fuel

pressure sensor
Replace
Defective fuel supply pump
Replace
Disconnect PCV connector

on one side.
Start engine.
6
Does engine stop if PCV connector on NO
one side is disconnected from fuel pump
and engine is operated on one lung?
YES
Disconnect spill centralized

hose from injector.
Start engine.
7
Is spill flow from injector normal? NO
(See Note 3)
YES
8
When troubleshooting is carried out for failure NO
codes [AD11KA], [AD11KB], [AD51KA], [AD51KB],
does problem occur in electrical system?
YES
HM300-1
Defective electric system of fuel Repair or

supply pump PCV
replace
20-323
(7)
1 !
(9)
TROUBLESHOOTING
ENG-5
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
c
(7)
1 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
Note 3: Method of measuring amount of fuel spill flow

The fuel in the spill line is at high temperature (up to 90C), so be careful not to burn
yourself during the operation.
1) Disconnect the hose connected to the spill
tube return collection portion (rear of engine).
2) Connect another hose to the tip of the spill
tube and collect the spill fuel in a container.
3) Start the engine, stall the engine at each
speed, and measure the spill fuel amount for
1 minute.
ENG-6
ENG-6
ENG-5, ENG-6, ENG-7
Limits for fuel spill amount (total for 6 cylinders)

Stall speed (rpm)
Spill limit (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
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)
TROUBLESHOOTING
ENG-8
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
Turn starting switch OFF.
Disconnect PCV1.
Is resistance between PCV1

(male) (1) - (2), and between (2)
- ground as shown in Table 1?
NO

PCV1
Remedy
Replace
YES

Disconnect CN7.
NO
Is resistance between CN7
(female) (10) and (11) 2.3 - 5.3?

in wiring harness between CN7
(female) (10) - PCV1 (female) (1) Repair or
replace
or between CN7 (female) (11) PCV1 (female) (2)
YES

Disconnect CN7, PCV1.

(female) (11) and ground more
than 1 M?
NO
Short circuit with chassis ground

(female) (11) and PCV1 (female) replace
(2)
YES
Replace
Table 1
PCV1 (male)
Resistance
Between (1) and (2)
2.3 5.3
Between (2) and ground
Min. 1 M
20-326
c
1 c
HM300-1
TROUBLESHOOTING
ENG-9
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
Disconnect PCV1.
Is resistance between PCV1 NO


PCV1
Remedy
Replace
YES

Is resistance between CN7 (female) NO

(10) and ground more than 1 M
and is voltage less than 1 V?

or hot short in wiring harness
Repair or
between CN7 (female) (10) and replace
PCV1 (female) (1)
YES

Is voltage between CN7 (female) NO

(11) and ground less than 1 V?
Hot short in wiring harness

between CN7 (female) (11) and Repair or
replace
PCV1 (female) (2)
YES
Replace
Table 1
PCV1 (male)
Resistance
Between (1) and (2)
2.3 5.3
Min. 1 M
HM300-1
20-327
1 c
(9)
TROUBLESHOOTING
ENG-10
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
Disconnect PCV2.
Is resistance between PCV2

NO

PCV2
Remedy
Replace
YES

Disconnect CN7.

(4) and (12) 2.3 - 5.3?

(female) (4) - PCV2 (female) (1) or Repair or
replace
between CN7 (female) (12) PCV2 (female) (2)
YES


than 1 M?
NO

(female) (12) and PCV2 (female) replace
(2)
YES
Replace
Table 1
PCV2 (male)
Resistance
Between (1) and (2)
2.3 5.3
Min. 1 M
20-328
c
1 c
HM300-1
TROUBLESHOOTING
ENG-11
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
Disconnect PCV2.
Is resistance between PCV2 NO

Remedy

PCV2
Replace

between CN7 (female) (4) and
PCV2 (female) (1)
Repair or
replace
YES
Disconnect CN7 and PCV2.


(4) and ground more than 1 M
and is voltage less than 1 V?
YES
Disconnect CN7 and PCV2.


Hot short in wiring harness Repair or

PCV2 (female) (2)
YES
Replace
Table 1
PCV2 (male)
Resistance
Between (1) and (2)
2.3 5.3
Min. 1 M
HM300-1
20-329
1 c
(9)
TROUBLESHOOTING
ENG-12
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
Disconnect CN1 (solenoid).

(male) (1) and (2) 0.4 - 1.1?
NO
Defective No. 1 injector

solenoid
Remedy
Replace
YES

Disconnect CN6 (controller).

(female) (7) and (8) 0.4 - 1.1?
NO

(female) (7) - CN1 (female) (1) or Repair or
between CN6 (female) (8) - CN1 replace
(female) (2)
YES
Replace
20-330
c
1 c
HM300-1
TROUBLESHOOTING
ENG-13
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
Is resistance between CN6 (female)

(7) - (8), and between (7)(8) ground as shown in Table 1?
Remedy
NO
Abnormality in No. 1 injector

solenoid system

(7)(8) - ground less than 1 V?

solenoid system
Go to
troubleshooting
procedure b)
NO

solenoid system
Go to
troubleshooting
procedure c)
NO

solenoid system
Go to
troubleshooting
procedure c)

solenoid system
Go to
troubleshooting
procedure d)

solenoid system
Go to
troubleshooting
procedure d)
Replace
Go to
troubleshooting
procedure b)
YES

YES


YES

Is voltage between CN6 (female)

YES


(3) - (9), and between (3)(9) - ground
as shown in Table 1?
YES


NO
YES
Table 1
CN6 (female)
CN6 (female)
CN6 (female)
Resistance
Between (7) and (8)
Between (4) and (10)
Between (3) and (9)
0.4 1.1
Between (7)(8) and ground
Min. 1 M
HM300-1
20-331
1 c
TROUBLESHOOTING
ENG-13
b) Troubleshooting No. 1 fuel injector system
Cause
Is resistance between CN1 (male)

NO

solenoid
Remedy
Replace
YES
Disconnect CN6 and CN1.


NO
(female) (7) and ground more than
1 M and is voltage less than 1 V?

or hot short in wiring harness Repair or
CN1 (female) (1)
YES

CN1 (female) (2)
Table 2
CN1 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-13 a) b) Related electrical circuit diagram
20-332
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-13
c) Troubleshooting No. 2 fuel injector system
Cause

NO

solenoid
Remedy
Replace
YES


NO
Short circuit with chassis ground or

hot short in wiring harness Repair or
CN2 (female) (1)
YES

CN2 (female) (2)
Table 3
CN2 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-13 a) c) Related electrical circuit diagram
HM300-1
20-333
1 c
(9)
TROUBLESHOOTING
ENG-13
d) Troubleshooting No. 3 fuel injector system


Cause
NO

solenoid
Remedy
Replace
YES


NO
Short circuit with chassis ground or

hot short in wiring harness Repair or
CN3 (female) (1)
YES

CN3 (female) (2)
Table 4
CN3 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-13 a) d) Related electrical circuit diagram
20-334
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-14
ENG-14
FAILURE CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause

(1) and (2) 0.4 - 1.1?
NO

solenoid
Remedy
Replace
YES


(female) (4) and (10) 0.4 - 1.1?
YES
NO

(female) (4) - CN2 (female) (1) or replace
between CN6 (female) (10) - CN2
(female) (2)
Replace
HM300-1
20-335
1 c
(9)
TROUBLESHOOTING
ENG-15
ENG-15
FAILURE CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause

(1) and (2) 0.4 - 1.1?
NO

solenoid
Remedy
Replace
YES


(female) (3) and (9) 0.4 - 1.1?
YES
NO

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

DISCONNECTION (KA))
controller.
Cause

(1) and (2) 0.4 - 1.1?
NO

solenoid
Remedy
Replace
YES


(female) (3) and (9) 0.4 - 1.1?
YES
NO

(female) (2)
Replace
HM300-1
20-337
1 !
TROUBLESHOOTING
ENG-17
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


YES
NO

solenoid system
Go to
troubleshooting
procedure b)


NO

solenoid system
Go to
troubleshooting
procedure b)

solenoid system
Go to
troubleshooting
procedure c)
NO

solenoid system
Go to
troubleshooting
procedure c)


solenoid system
Go to
troubleshooting
procedure d)

solenoid system
Go to
troubleshooting
procedure d)
Replace
YES


YES


YES

YES


NO
YES
Table 1
CN7 (female)
CN7 (female)
CN7 (female)
Resistance
Between (3) and (9)
Between (2) and (8)
0.4 1.1
Min. 1 M
20-338
!
1 !
HM300-1
TROUBLESHOOTING
ENG-17
b) Troubleshooting No. 4 fuel injector system

Is resistance between CN4 (male) (1) NO

- (2), and between (1)(2) - ground as
shown in Table 2?
Cause
solenoid
Remedy
Replace
YES


NO
YES

CN4 (female) (1)
CN4 (female) (2)
Repair or
replace
Table 2
CN4 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-17 a) b) Related electrical circuit diagram
HM300-1
20-339
1 c
(9)
TROUBLESHOOTING
ENG-17
c) Troubleshooting No. 5 fuel injector system


shown in Table 3?
Cause
solenoid
Remedy
Replace
YES


NO
YES

CN5 (female) (1)
CN5 (female) (2)
Repair or
replace
Table 3
CN5 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-17 a) c) Related electrical circuit diagram
20-340
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-17
d) Troubleshooting No. 6 fuel injector system


shown in Table 4?
Cause
solenoid
Remedy
Replace
YES


NO
YES

CN6 (female) (1)
CN6 (female) (2)
Repair or
replace
Table 4
CN6 (male)
Resistance
Between (1) and (2)
0.4 1.1
Min. 1 M
ENG-17 a) d) Related electrical circuit diagram
HM300-1
20-341
1 c
(9)
TROUBLESHOOTING
ENG-18
ENG-18
FAILURE CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause

and (2) 0.4 - 1.1?
Remedy

solenoid
Replace

(female) (1) - CN5 (female) (1) or
(female) (2)
Repair or
replace
Replace
YES


(female) (1) and (7) 0.4 - 1.1?
NO
YES
20-342
c
1 c
HM300-1
TROUBLESHOOTING
ENG-19
ENG-19
FAILURE CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause

and (2) 0.4 - 1.1?

solenoid
Remedy
Replace
YES


(female) (2) and (8) 0.4 - 1.1?
NO

(female) (2) - CN6 (female) (1) or Repair or
between CN7 (female) (8) - CN6 replace
(female) (2)
YES
Replace
HM300-1
20-343
1 c
TROUBLESHOOTING
ENG-20
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
See TESTING AND
ADJUSTING.
Is engine oil pressure normal?
NO
Drop in engine oil pressure
YES
Insert T-adapter to CN4.
Engine at low idle
Is voltage between CN4 (5) and

ground 20 - 30 V?
Remedy
Check
cause of
failure and
repair
damage to
engine
NO
YES

Disconnect CN4 and PSL.

(5) and ground more than 1 M?
NO
YES

Engine at midrange speed
(Min. 1300 rpm)

ground 20 - 30 V?
NO
YES

Disconnect CN4, PSH.

Short circuit with chassis

ground in wiring harness beRepair or
tween CN4 (female) (5) and
replace
PSL
Defective engine oil low-pressure
Replace
switch
NO
Replace

(female) (6) and PSH
Repair or
replace
YES
Replace
switch
20-344
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-21
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
Stop engine.
NO
Is engine oil level low?

YES
Drop in engine oil level
Add
Defective engine oil level switch
Replace
2
Disconnect OL.
NO
Is resistance between OL (male)

(1) and ground less than 1?
YES
3
Disconnect CN6.


replace
(female) (1) and OL (female) (1)
YES
Replace
HM300-1
20-345
1 !
(9)
TROUBLESHOOTING
ENG-22
ENG-22
FAILURE CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))
Nature of failure:The engine coolant temperature went above the operating range
Cause
Stop engine.
Is engine overheated?
NO
Replace
Engine is overheated
Check cause
of failure and
repair damage
to engine
YES
20-346
!
1 !
(9)
Remedy
HM300-1
TROUBLESHOOTING
ENG-23
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

when preheater relay (R37) is
interchanged with other relay?
YES
Disconnect R37 and heater

relay (3).
Is voltage between R37 (female) NO

Defective preheater relay (R37)
Replace

between R37 (female) (5) and
heater relay (3)
Repair or
replace
YES

relay (3).
Is resistance between R37 NO

than 1 M?

ground in wiring harness Repair or
between R37 (female) (5) and replace
heater relay (3)
YES

relay (3).
Is resistance between R37 NO

(female) (5) and heater relay (3)
less than 1?

in wiring harness between R37
Repair or
replace

heater relay (2)
Repair or
replace
Short circuit with chassis ground in

wiring harness between CN4
Repair or
replace

Repair or
replace
Replace
Defective heater relay
Replace
YES
Disconnect CN4 and heater

relay (2).

YES

relay (2).
Is resistance between CN4 NO

than 1 M?
YES

relay (2).

less than 1?
YES

when heater relay is replaced?
YES
HM300-1
20-347
1 c
(9)
TROUBLESHOOTING
ENG-23
20-348
c
1 c
HM300-1
TROUBLESHOOTING
ENG-24
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 preheater 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

when preheater relay (R37) is
YES
Disconnect R37.
Remedy
Is voltage between R37 (female)

(1)(3) - ground 20 - 30 V?
NO
Defective preheater relay (R37)
Replace

in wiring harness between fuse
BT4-4 outlet and R37 (female)
(1)(3)
Repair or
replace
YES
Disconnect CN2.
Is voltage between CN2 (female) (5) NO

and ground 20 - 30 V?
Defective contact, disconnection, or

short circuit with chassis ground in Repair or
wiring harness between CN2 replace
(female) (5) and R37 (female) (2)
YES
Replace
HM300-1
20-349
1 c
TROUBLESHOOTING
ENG-25
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

engine power source relay (R36) is
YES
Defective engine power source Replace
relay (R36)

Is voltage between CN7 (6)(14) (5)(13) less than 8 V?
NO

between CN7 (female) (6) (14)
and R36 (female) (5)
Repair or
replace
Replace
YES
20-350
c
1 c
(9)
HM300-1
TRO UBLESHOO TING
ENG-25
HM300-1
20-351
1 !
(6)
TRO UBLESHOO TING
ENG-26
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

YES
Disconnect ATC3A.
Remedy
Is voltage between ATC3A (female) NO

Replace
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between CN4 (female)
(16) and ATC3A (female) (5)
Repair or
replace
Replace
YES
20-352
!
1 !
HM300-1
TRO UBLESHOO TING
ENG-27
ENG-27
FAILURE CODE [DB20KT] (ENGINE CONTROLLER:

ABNORMALITY INSIDE CONTROLLER (KT))
Nature of failure:An abnormality has occurred inside the controller
Cause
Disconnect CN7.

(5)(13) - ground less than 1?
Remedy
Defective contact or
disconnection in wiring harness
between CN7 (female) (5)(13) ground
Repair or
replace
Replace
YES
HM300-1
20-353
1 !
TRO UBLESHOO TING
ENG-27
20-354
!
(6)
1 !
HM300-1
TROUBLESHOOTING
ENG-28
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

engine power source relay (R36) is
YES
Disconnect R36.
Remedy
Defective engine power source

Replace
relay (R36)
Is voltage between R36 (female) (1) NO

Defective contact or disconnection in wiring harness between Repair or

R36 (female) (1) - fuse BT2-4 - replace
starting switch ACC
YES

Disconnect R36.
Is resistance between R36 (female) NO


(female) (2) and ground
Repair or
replace

(female) (3) and fuse BT4-4
Repair or
replace

(female) (6)(14) - R36 (female) (5)
Repair or
replace
Defective engine controller.
Replace
YES
Disconnect R36.

YES


(6)(14) - ground 20 - 30 V?
NO
YES
HM300-1
20-355
1 c
(9)
TROUBLESHOOTING
ENG-28
20-356
c
(6)
1 c
HM300-1
TROUBLESHOOTING
ENG-29
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
Disconnect MS.
Is resistance between MS (male)

(1)(2)(3) - (4) as shown in Table 1?
Remedy
NO
Defective model selection

connector
NO

replace
MS (female) (1) and ground
Replace
YES

Disconnect MS.
Is resistance between MS (female)

YES

Disconnect CN4.

(female) (13) and MS (female) (2)
Repair or
replace
NO

Repair or
replace


Repair or
replace
Replace

YES

Disconnect CN4.

YES

Disconnect CN4.
YES
Table 1
MS (male)
Resistance value
Between (1) and (4)
Max. 1
Between (2) and (4)
Max. 1
Between (3) and (4)
Min. 1 M
HM300-1
20-357
1 !
TROUBLESHOOTING
TROUBLESHOOTING
ENG-30
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
Are both fuel injection quantity NO
control switches 1 and 2 set to [F]?
Remedy
Replace
YES
Defective setting of fuel injection Adjust
quantity control switch
again
20-358
c
1 c
(9)
HM300-1
TROUBLESHOOTING
ENG-31
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
Connect T-adapter to CN4.

ground less than 1 V?
NO
YES
Disconnect starting switch

terminal C.
NO
Is voltage between starting switch
terminal C and ground less than 1 V?
YES
Remedy
Replace
Defective starting switch
Replace

starting switch terminal C
Repair or
replace
HM300-1
20-359
1 c
(9)
TROUBLESHOOTING
ENG-32
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
Insert T-adapter to AS1.
Does voltage (signal 2) between NO

AS1 (5) and (4) change as
shown in Fig. 1?
Remedy
Defective
(switch)
accelerator
pedal Repair or
replace
Defective
(switch)
accelerator
pedal Repair or
replace
YES


AS1 (6) and (4) change as
shown in Fig. 1?
YES

Disconnect AS1.
Is resistance between AS1 NO

(female) (4) and ground less
than 1?
YES

Disconnect CN4 and AS1.

(female) (8) and AS1 (female) (4)
less than 1?
YES


CN4 (11) and (8) change as
shown in Fig 1?

(female) (8), (19) and AS1 (female)
(4)
Repair or
replace
Replace
Defective contact, disconnection,

short circuit with chassis ground,
AS1 (female) (5)
YES


CN4 (12) and (8) change as
shown in Fig. 1?

short circuit with chassis ground, or
hot short in wiring harness between Repair or
CN4 (female) (12) and AS1 (female) replace
(6)
YES
20-360
c
1 c
(9)
Replace
HM300-1
TROUBLESHOOTING
ENG-32
Fig. 1
HM300-1
20-361
1 !
TROUBLESHOOTING
ENG-33
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
NO

ground as shown in Table 1?
Remedy
YES
Disconnect PSL.
Is resistance between PSL

(switch) and ground as shown in
Table 2?
YES
NO

NO
YES
Is resistance between PSH

(switch) and ground as shown in
Table 4?
Disconnect PSH.
NO
YES
Table 1
Replace

or short circuit with chassis ground
(female) (5) and PSL
Repair or
replace
Replace

switch
Replace

(female) (5) and PSH
Repair or
replace
Table 3
CN4
Between (5) and

ground
Engine
Voltage
When stopped
Max. 1 V
When more than

600 rpm
20 30V
Table 2
PSL (switch)
20-362
1 !
CN4
Between (6) and
ground
Engine
Voltage
When stopped
Max. 1 V
When more than

1,300 rpm
20 30V
Table 4
Engine
When stopped
Between PSL and
When more than
ground
600 rpm
Resistance value
Max. 1
Min. 1 M
PSL (switch)
Engine
When stopped
Between PSH and
When more than
ground
1,300 rpm
Resistance value
Max. 1
Min. 1 M
HM300-1
TROUBLESHOOTING
ENG-33
HM300-1
20-363
1 c
TROUBLESHOOTING
ENG-34
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
Disconnect TWH.
Coolant temperature:10 - 100C
Is resistance between TWH (male) NO

(1) and (2), and between (1) and
Defective engine coolant hightemperature sensor
Remedy
Replace
YES

Disconnect CN2.

(4) and (10) 90k - 3.5 k?

(female) (4) and TWH (female) (1) Repair or
or between CN2 (female) (10) and replace
TWH (female) (2)
YES

Disconnect CN2 and TWH.


(female) (4) and TWH (female) replace
(1)
YES
Replace
Table 1
TWH (male)
Resistance
Between (1) and (2)
90k 3.5k
Min. 1 M
20-364
!
1 !
(9)
HM300-1
TROUBLESHOOTING
ENG-35
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
Disconnect TWL.
Is resistance between TWL (male) NO

Defective engine coolant lowtemperature sensor
Remedy
Replace
YES

Disconnect CN2.

(3) and (10) 9 k - 0.3 k?

(female) (3) and TWL (female) (1) Repair or
or between CN2 (female) (10) and replace
TWL (female) (2)
YES

Disconnect CN2 and TWL.


(female) (3) and TWL (female) replace
(1)
YES
Replace
Table 1
TWL (male)
Resistance
Between (1) and (2)
9k 0.3k
Min. 1 M
HM300-1
20-365
1 !
(9)
TROUBLESHOOTING
ENG-36
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
Insert T-adapter to CN1
and CN2.
Is voltage between CN1 (3) and CN2 NO

(10) 0.3 - 4.7 V?
YES
Disconnect PIM.
Remedy
Replace

ground in wiring harness between CN2 (female) (2) and
PIM (female) (1)
Repair or
replace
Replace
Is voltage between PIM (female) (1) NO

and ground 4.6 - 5.4 V?
YES
Disconnect CN2 and PIM.


YES


ground 4.6 - 5.4 V?
NO

CN2 (female) (2) and PIM (fereplace
male) (1)
YES

Disconnect PIM.
Is resistance between PIM (female)

YES


(female) (10) and PIM (female)
(3) less than 1?
NO
YES


than 1 M?
NO

male) (3)
Replace

PIM (female) (3)
Repair or
replace
YES
Insert T-adapter to PIM.

Is voltage between PIM (2) and

ground 0.3 - 4.7 V?
NO
male) (2)
YES


than 1 M?
YES
20-366
c
1 c
NO

PIM (female) (2)
Repair or
replace
Defective boost pressure sensor
Replace
HM300-1
TROUBLESHOOTING
ENG-36
HM300-1
20-367
1 c
TROUBLESHOOTING
ENG-37
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
Insert T-adapter to CN1
and CN2.
Is voltage between CN1 (1) and CN2 NO

(10) 0.3 - 4.7 V?
YES
Disconnect PFUEL.
Remedy
Is voltage between PFUEL (female)

(1) and ground 4.6 - 5.4 V?
Replace

PFUEL (female) (1)
Repair or
replace
Replace
NO
YES
Disconnect CN2 and PFUEL.


YES


ground 4.6 - 5.4 V?
NO

CN2 (female) (2) and PFUEL
replace
(female) (1)
YES

Disconnect PFUEL.
NO
Is resistance between PFUEL
(female) (3) and ground less than 1?
YES


(female) (10) and PFUEL
(female) (3) less than 1?
NO
YES


than 1 M?

CN2 (female) (10) and PFUEL replace
(female) (3)
NO
Replace

(female) (10) and PFUEL (fereplace
male) (3)
YES
Insert T-adapter to PFUEL.

Is voltage between PFUEL (2)

NO
CN1 (female) (1) and PFUEL
replace
(female) (2)
YES


than 1 M?
YES
20-368
c
1 c
(9)
NO

PFUEL (female) (2)
Repair or
replace
Replace
HM300-1
TROUBLESHOOTING
ENG-37
HM300-1
20-369
1 c
TROUBLESHOOTING
ENG-38
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
Is voltage between CN1 (6) and (11)

0.3 - 4.7 V?
NO
YES
Disconnect AS1.
Remedy
Replace

AS1 (female) (3)
Repair or
replace
Replace
Is voltage between AS1 (female) (3) NO

YES


YES


ground 4.6 - 5.4 V?
NO

CN1 (female) (4) and AS1 (fereplace
male) (3)
YES

Disconnect AS1.
Is resistance between AS1 (female)

YES


(female) (11) and AS1 (female)
(1) less than 1?
NO
YES

. Disconnect CN1 and AS1

than 1 M?
NO

male) (1)
Replace

AS1 (female) (1)
Repair or
replace
YES

Is voltage between AS1 (2) and

ground 0.3 - 4.7 V?
NO
male) (2)
YES


than 1 M?
YES
20-370
c
1 c
(9)
NO

AS1 (female) (2)
Defective accelerator pedal (potentiometer)
Repair or
replace
Replace
HM300-1
TROUBLESHOOTING
ENG-38
HM300-1
20-371
1 !
TROUBLESHOOTING
ENG-39
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
Disconnect NE.
Is resistance between NE (male) (1) - NO

(2), and between (1)(2) - ground as
shown in Table 1?
Defective engine Ne speed

sensor
Remedy
Replace
YES

Disconnect CN1.

(5) and (12) 85 - 210 ?
NO

CN1 (female) (5) and NE (fereplace
male) (1) or between CN1 (female) (12) and NE (female) (2)
YES

Disconnect CN1 and NE.

and ground more than 1 M?

(female) (5) and NE (female) (1)
Repair or
replace

(female) (5) and NE (female) (2)
Repair or
replace
Replace
YES

Disconnect CN1 and NE.

NO
YES
Table 1
NE (male)
Resistance
Between (1) and (2)
85 210
Min. 1 M
20-372
!
1 !
HM300-1
TROUBLESHOOTING
ENG-40
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
Disconnect G.
Is resistance between G (male) (1) (2), and between (1)(2) - ground as

shown in Table 1?
NO
Defective engine G speed

sensor
Remedy
Replace
YES

Disconnect CN2.

(1) and (9) 1.4 k - 3.5 k?
NO

CN2 (female) (1) and G (fereplace
male) (1) or between CN2 (female) (9) and G (female) (2)
YES

Disconnect CN2 and G.

NO

(female) (1) and G (female) (1)
Repair or
replace
NO

(female) (12) and G (female) (2)
Repair or
replace
Replace
YES

Disconnect CN2 and G.

YES
Table 1
G (male)
Resistance
Between (1) and (2)
1.4k 3.5k
Min. 1 M
HM300-1
20-373
1 c
(9)
TROUBLESHOOTING
ENG-41
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 BT220, 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

and ground less than 1 V?
Disconnect CN78.
YES
Is voltage between CN78 (female) (2) and NO

ground less than 1 V when alternator
terminal R (CN80) is disconnected?

YES

and ground less than 1 V when diode
(D01) is disconnected?
Disconnect CN78 and D01.

Defective alternator
Replace
Hot short in wiring harness between

CN78 (female) (2) - alternator
terminal R (CN80) - D01 (female) (2)
Repair or
replace
Defective diode (D01)
Replace
YES

Disconnect CN78.
Turn starting switch to START.
YES
Turn starting switch to

START.
Does condition become normal when engine NO

starting relay (R01) or transmission neutral
relay (R02) is interchanged with other relay?
YES
Disconnect R01.
Is voltage between R01 (female) (1)

Defective engine starting relay

(R01) or defective transmission Replace
neutral relay (R02)
NO

in wiring harness between fuse Repair or
BT3-10 outlet and R01 (female) (1) replace
YES
To 12
20-374
c
1 c
(9)
To 7
HM300-1
TROUBLESHOOTING
ENG-41
From 4
Disconnect R02.
From 6

Cause
Remedy

Repair or
replace
NO

Repair or
replace
NO

(female) (1) and wiring harness
dividing point
Repair or
replace
NO

Repair or
replace
Defective starting switch or defective

contact or disconnection in wiring
harness between starting switch
terminal C and R01 (female) (3)
Repair or
replace

(female) (6) and CN78 (female) (1)
Repair or
replace

in wiring harness between battery battery relay - starting motor
terminal B
Repair or
replace
Defective starting motor
Replace
NO
YES

Disconnect R02.
Is resistance between R02 (female) (3)

and ground less than 1?
YES
Disconnect R02.

YES

Disconnect R02.
Is resistance between R02 (female)

YES
Disconnect R01.
Turn starting switch START.

NO
YES
Is voltage between starting motor

terminal B and ground 20 - 30 V?
NO
YES
HM300-1
20-375
1 !
TROUBLESHOOTING
ENG-41
20-376
!
1 !
HM300-1
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF
SYSTEM (TM MODE)
TM mode related electrical circuit diagram ..............................................................................................

Content of display and problem that appears on machine for each failure code .....................................
TM-1
Failure code [1380MW] (Lock-up clutch: Slipping (MW)) .........................................................
TM-2
Failure code [1500LO] (Transmission clutch: * See the table in Contents. (LO)) .....................
TM-3
Failure code [15B0NX] (Transmission oil filter: Clogged (NX)) ................................................
TM-4
Failure code [15G0MW] (R clutch: Slipping (MW)) ..................................................................
TM-5
Failure code [15H0MW] (Hi clutch: Slipping (MW)) ..................................................................
TM-6
Failure code [15J0MW] (Lo clutch: Slipping (MW)) ..................................................................
TM-7
Failure code [15K0MW] (1st clutch: Slipping (MW)) .................................................................
TM-8
Failure code [15L0MW] (2nd clutch: Slipping (MW)) ................................................................
TM-9
Failure code [15M0MW] (3rd clutch: Slipping (MW)) ................................................................
TM-10 Failure code [15SBL1] (ECMV for R clutch: * See the table in Contents. (L1)) ........................
TM-11 Failure code [15SBMA] (ECMV for R clutch: Function impossible (MA)) .................................
TM-12 Failure code [15SCL1] (ECMV for Hi clutch: * See the table in Contents. (L1)) .......................
TM-13 Failure code [15SCMA] (ECMV for Hi clutch: Function impossible (MA)) ................................
TM-14 Failure code [15SDL1] (ECMV for Lo clutch: * See the table in Contents. (L1)) ......................
TM-15 Failure code [15SDMA] (ECMV for Lo clutch: Function impossible (MA)) ...............................
TM-16 Failure code [15SEL1] (ECMV for 1st clutch: * See the table in Contents. (L1)) .....................
TM-17 Failure code [15SEMA] (ECMV for 1st clutch: Function impossible (MA)) ...............................
TM-18 Failure code [15SFL1] (ECMV for 2nd clutch: * See the table in Contents. (L1)) ....................
TM-19 Failure code [15SFMA] (ECMV for 2nd clutch: Function impossible (MA)) ..............................
TM-20 Failure code [15SGL1] (ECMV for 3rd clutch: * See the table in Contents. (L1)) .....................
TM-21 Failure code [15SGMA] (ECMV for 3rd clutch: Function impossible (MA)) ..............................
TM-22 Failure code [15SJL1] (ECMV for lock-up clutch: * See the table in Contents. (L1)) ...............
TM-23 Failure code [15SJMA] (ECMV for lock-up clutch: Function impossible (MA)) ........................
TM-24 Failure code [15SKL1] (ECMV for inter-axle differential lock clutch:
* See the table in Contents. (L1)) .......................................................
TM-25 Failure code [15SKMA] (ECMV for inter-axle differential lock clutch:
Function impossible (MA)) ..................................................................
TM-26 Failure code [2B61MW] (Inter-axle differential lock clutch: Slipping (MW)) .............................
TM-27 Failure code [2F00KM] (Parking brake: Mistaken operation or mistaken setting (KM)) ...........
TM-28 Failure code [989A00] (Engine overrun prevention command signal: Actuated (00)) ..............
TM-29 Failure code [989AKZ] (Engine overrun prevention command signal:
Disconnection or short circuit (KZ)) ....................................................
TM-30 Failure code [989D00] (Rear overturn signal: Actuated (00)) ...................................................
TM-31 Failure code [AA10NX] (Air cleaner element: Clogged (NX)) ...................................................
TM-32 Failure code [AB00MA] (Alternator: Function impossible (MA)) ...............................................
TM-33 Failure code [B@BCZK] (Radiator coolant: Drop in level (ZK)) ...............................................
TM-34 Failure code [B@HAZK] (Hydraulic tank oil: Drop in level (ZK)) ..............................................
TM-35 Failure code [B@JANS] (Steering oil: Overheat (NS)) .............................................................
TM-36 Failure code [D1B0KZ] (Transmission cut relay: Disconnection or short circuit (KZ)) .............
TM-37 Failure code [D5ZBKX] (Inter-axle differential lock command signal:
Input signal outside range (KX)) .........................................................
TM-38 Failure code [D5ZCKZ] (Exhaust brake command signal: Disconnection or short circuit (KZ)) .
TM-39 Failure code [D5ZDL4] (Forced neutral demand signal: * See the table in Contents. (L4)) .....
TM-40 Failure code [D5ZEKX] (Engine load signal: Input signal outside range (KX)) ........................
TM-41 Failure code [DAQ0KK] (Transmission controller: Drop in power source voltage, input (KK)) .
TM-42 Failure code [DAQ1KK] (Transmission controller main power supply line:
Drop in power source voltage, input (KK)) .........................................
HM300-1
20-404
20-410
20-436
20-437
20-438
20-439
20-440
20-441
20-442
20-443
20-444
20-445
20-446
20-447
20-448
20-449
20-450
20-451
20-452
20-453
20-454
20-455
20-456
20-457
20-458
20-459
20-460
20-461
20-462
20-464
20-465
20-466
20-468
20-470
20-471
20-472
20-473
20-474
20-476
20-478
20-479
20-481
20-482
20-484
20-401
1 c
(9)
TROUBLESHOOTING
TM-43
TM-44
TM-45
TM-46
TM-47
TM-48
TM-49
TM-50
TM-51
TM-52
TM-53
TM-54
TM-55
TM-56
TM-57
TM-58
TM-59
TM-60
TM-61
TM-62
TM-63
TM-64
TM-65
TM-66
TM-67
TM-68
TM-69
TM-70
TM-71
TM-72
TM-73
TM-74
TM-75
TM-76
TM-77
TM-78
TM-79
TM-80
TM-81
TM-82
TM-83
TM-84
Failure code [DAQ2KK] (Transmission controller load power supply line:

Drop in power source voltage, input (KK)) .......................................... 20-485
Failure code [DAQ3KK] (Transmission controller battery direct power supply line:
Drop in power source voltage, input (KK)) .......................................... 20-486
Failure code [DAQ5KP] (Transmission controller power supply output 1:
Drop in output voltage (KP)) ............................................................... 20-487
Failure code [DAQ9KM] (Transmission controller wiring harness:
Mistaken operation or mistaken setting (KM)) .................................... 20-488
Failure code [DAQ9KQ] (Transmission controller wiring harness:
Non match in model selection signal (KQ)) ........................................ 20-489
Failure code [DAQAKQ] (Transmission controller rotary switch:
Non match in model selection signal (KQ)) ........................................ 20-490
Failure code [DAQSMA] (Transmission controller: Function impossible (MA) .......................... 20-490
Failure code [DDTFKA] (Fill switch for inter-axle differential lock clutch: Disconnection (KA)) . 20-491
Failure code [DDTGKA] (Fill switch for lock-up clutch: Disconnection (KA)) ............................ 20-492
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection (KA)) .................................... 20-493
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection (KA)) ..................................... 20-494
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection (KA)) ................................... 20-495
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection (KA)) .................................. 20-496
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection (KA)) .................................. 20-497
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection (KA)) ..................................... 20-498
Failure code [DF10KA] (Gearshift lever: Disconnection (KA)) .................................................. 20-499
Failure code [DF10KB] (Gearshift lever: Short circuit (KB)) ..................................................... 20-501
Failure code [DGF1KX] (Transmission valve oil temperature sensor:
Input signal outside range (KX)) ......................................................... 20-503
Failure code [DGR3L8] (Brake oil temperature sensor (center):
* See the table in Contents. (L8)) ....................................................... 20-505
Failure code [DGR4L8] (Brake oil temperature sensor (front):
Failure code [DGT1LX] (Torque converter oil temperature sensor:
Input signal outside range (KX)) ......................................................... 20-509
Failure code [DHT5KX] (Torque converter oil pressure sensor:
Input signal outside range (KX)) ......................................................... 20- 511
Failure code [DHT5L6] (Torque converter oil pressure sensor:
Failure code [DJF1KA] (Fuel level sensor: Disconnection (KA)) .............................................. 20-514
Failure code [DK11KX] (Throttle angle sensor: Input signal outside range (KX)) ..................... 20-515
Failure code [DLE2KA] (Engine speed sensor: Disconnection (KA)) ....................................... 20-517
Failure code [DLE2LC] (Engine speed sensor: * See the table in Contents. (LC)) ................... 20-518
Failure code [DLF1KA] (Transmission input shaft speed sensor:
Disconnection (KA)) ............................................................................ 20-519
Failure code [DLF1LC] (Transmission input shaft speed sensor:
* See the table in Contents. (LC)) ....................................................... 20-520
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:
Disconnection (KA)) ............................................................................ 20-521
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnection (KA)) ...... 20-523
Failure code [DLT3LC] (Transmission output shaft R speed sensor:
Failure code [DXH0KA] (Solenoid for inter-axle differential lock: Disconnection (KA)) ............ 20-526
Failure code [DXH0KB] (Solenoid for inter-axle differential lock: Short circuit (KB)) ................ 20-527
Failure code [DXH1KA] (Solenoid for lock-up clutch: Disconnection (KA)) .............................. 20-528
Failure code [DXH1KB] (Solenoid for lock-up clutch: Short circuit (KB)) .................................. 20-529
Failure code [DXH2KA] (Solenoid for Hi clutch: Disconnection (KA)) ...................................... 20-530
Failure code [DXH2KB] (Solenoid for Hi clutch: Short circuit (KB)) .......................................... 20-531
Failure code [DXH3KA] (Solenoid for Lo clutch: Disconnection (KA)) ...................................... 20-532
Failure code [DXH3KB] (Solenoid for Lo clutch: Short circuit (KB)) ......................................... 20-533
Failure code [DXH4KA] (Solenoid for 1st clutch: Disconnection (KA)) ..................................... 20-534
20-402
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-85
TM-86
TM-87
TM-88
TM-89
TM-90
TM-91
TM-92
TM-93
Failure code [DXH4KB] (Solenoid for 1st clutch: Short circuit (KB)) ........................................
Failure code [DXH5KA] (Solenoid for 2nd clutch: Disconnection (KA)) ...................................
Failure code [DXH5KB] (Solenoid for 2nd clutch: Short circuit (KB)) .......................................
Failure code [DXH6KA] (Solenoid for 3rd clutch: Disconnection (KA)) ....................................
Failure code [DXH6KB] (Solenoid for 3rd clutch: Short circuit (KB)) ........................................
Failure code [DXH7KA] (Solenoid for R clutch: Disconnection (KA)) .......................................
Failure code [DXH7KB] (Solenoid for R clutch: Short circuit (KB)) ..........................................
Backup lamp, backup buzzer do not work properly ..................................................................
Emergency steering does not operate .....................................................................................
20-535
20-536
20-537
20-538
20-539
20-540
20-541
20-542
20-545
Appendix: Table for Failure Phenomenon Code

Failure
Phenomenon
Code
Failure
Phenomenon
Code
Summary of Failure
Disconnection
L0
An impossible combination of clutch fill signals turn on more

than 2 channels simultaneously.
KB
Short-circuiting
L1
While the order current to ECMV is off, the fill signal is on.
KK
Power source voltage and

input lowered
L2
The fuel pressure exceeds the specified max. value.
KQ
Model selection signal

wrong
L3
The intended unit is out of control.
KR
Communication ineffective
L4
ON and OFF signals in two systems do not concur with each

other.
KT
Controller internally abnormal
L6
Signals from engine revolution, C terminal, hydraulic pressure

switch and coolant temperature sensor do not match up with
the respective actual condition.
KX
Input signal out of range
L8
Analog signals in two systems do not concur with each other.
KZ
Disconnection or short-circuiting
LC
Signals of revolution speed in two systems do not concur with

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
KA
HM300-1
Summary of Failure
20-403
1
(10)
TROUBLESHOOTING
TROUBLESHOOTING
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-404
c
1 c
HM300-1
TROUBLESHOOTING
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
TROUBLESHOOTING
20-406
!
1 !
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
HM300-1
20-407
1 !
TROUBLESHOOTING
TROUBLESHOOTING
20-408
!
1 !
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
HM300-1
20-409
1 c
TROUBLESHOOTING
TROUBLESHOOTING


Failure code
Nature of failure
Probable cause
Lock-up clutch:
Slipping (MW)
When there is output to the lockup clutch solenoid, there is an

abnormality in the value calculated from the signals from the
engine speed sensor, transmission input shaft speed sensor,
transmission intermediate shaft
speed sensor, and transmission
output shaft R speed sensor.
Defective lock-up clutch solenoid

Excessive resistance in solenoid (+) circuit wiring harness
Excessive resistance in solenoid () circuit wiring harness
Defective lock-up clutch, pressure control valve hydraulic, mechanical system
1500L0
(TM-2)
Transmission clutch:
* See Contents (LO)
Fill switch signals have been in- Other problem occurs at same time (failput from 2 clutches that do not
ure code [15S*L1] is displayed)
form a normal combination.
Defective pressure control valve hydraulic, mechanical system
15B0NX
(TM-3)
Transmission oil filter:

Clogged (NX)
When the torque converter oil

Clogged transmission oil filter (when actemperature is more than 50C,
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 wiring harness
15G0MW
(TM-4)
R clutch: Slipping (MW)
When there is output to the R

clutch solenoid, there is an abnormality in the value calculated
from the signals from the transmission input shaft speed sensor, intermediate shaft speed
sensor, and output shaft R
speed sensor.
Defective R clutch solenoid

Defective R clutch, pressure control
valve hydraulic, mechanical system
15H0MW
(TM-5)
Hi clutch: Slipping (MW)
When there is output to the Hi

speed sensor.
Defective Hi clutch solenoid

Defective Hi clutch, pressure control
15J0MW
(TM-6)
Lo clutch: Slipping (MW)
When there is output to the Lo

speed sensor.
Defective Lo clutch solenoid

Defective Lo clutch, pressure control
1380MW
(TM-1)
20-410
c
1 c
(9)
Location of failure
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

The code (TM-**) given below the failure code is the troubleshooting number.

Holds speed range during trav- Lock-up is canceled and transL/C-PS (male) (1) (2): 5 15 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
Action code
E03
Turns transmission cut relay

OFF.
Sets transmission to Neutral.
Suddenly shifts to Neutral when

traveling and cannot move off
again
E03

T03 (male) (1) (2):
When normal: Max. 1
Takes no action

as it is, there is danger that dirt will
circulate in transmission circuit
E01

R-PS (male) (1) (2): 5 15

traveling
E03

H-PS (male) (1) (2): 5 15

traveling
Cannot move off again unless machine is stopped
E03

L-PS (male) (1) (2): 5 15

traveling
E03
HM300-1
20-411
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
15K0MW
(TM-7)
1st clutch: Slipping (MW)
When there is output to the 1st

speed sensor.
Defective 1st clutch solenoid

Defective 1st clutch, pressure control
15L0MW
(TM-8)
2nd clutch: Slipping (MW)
When there is output to the 2nd

speed sensor.
Defective 2nd clutch solenoid

Defective 2nd clutch, pressure control
15M0MW
(TM-9)
3rd clutch: Slipping (MW)
When there is output to the 3rd

speed sensor.
Defective 3rd clutch solenoid

Defective 3rd clutch, pressure control
15SBL1
(TM-10)
ECMV for R clutch:

* See Contents (L1)
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.
Defective R clutch fill switch

switch circuit wiring harness
Defective R clutch pressure control valve
hydraulic, mechanical system
15SBMA
(TM-11)
ECMV for R clutch: Function Even when there is output to the Defective R clutch solenoid
Excessive resistance in solenoid (+) cirimpossible (MA)
R clutch solenoid, the signal
cuit wiring harness
from the fill switch stays OFF
Excessive resistance in solenoid () cirand the clutch is not engaged.
cuit wiring harness
Defective R clutch or pressure control
15SCL1
(TM-12)
ECMV for Hi clutch:

* See Contents (L1)
15SCMA
(TM-13)
ECMV for Hi clutch: Function Even when there is output to the Defective Hi clutch solenoid
impossible (MA)
Hi clutch solenoid, the signal
Excessive resistance in solenoid (+) cirfrom the fill switch stays OFF
cuit wiring harness
and the clutch is not engaged.
Defective Hi clutch pressure control
20-412
c

1 c
(9)
Even when the output to the Hi

disengaged.
Defective Hi clutch fill switch

Defective Hi clutch or pressure control
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

1-PS (male) (1) (2): 5 15

traveling
E03

2-PS (male) (1) (2): 5 15

traveling
E03

3-PS (male) (1) (2): 5 15

traveling
E03

R-SW (male) (1) ground:
When clutch is released:
Min. 1 M
When clutch is engaged:
Max. 1

traveling
E03

R-PS (male) (1) (2): 5 15

traveling
E03

H-SW (male) (1) ground:
Min. 1 M
Max. 1

traveling
E03

H-PS (male) (1) (2): 5 15

traveling
E03
HM300-1
20-413
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
15SDL1
(TM-14)
ECMV for Lo clutch:

* See Contents (L1)
Even when the output to the Lo

disengaged.
15SDMA
(TM-15)
ECMV for Lo clutch:

Even when there is output to the Defective Lo clutch solenoid

Lo clutch solenoid, the signal
cuit wiring harness
Defective Lo clutch or pressure control
15SEL1
(TM-16)
ECMV for 1st clutch:

* See Contents (L1)
Even when the output to the 1st Defective 1st clutch fill switch
Defective 1st clutch pressure control
disengaged.
15SEMA
(TM-17)
ECMV for 1st clutch:

Even when there is output to the Defective 1st clutch solenoid

1st clutch solenoid, the signal
Excessive resistance in solenoid () cirand the clutch is not engaged.
cuit wiring harness
Defective 1st clutch or pressure control
15SFL1
(TM-18)
ECMV for 2nd clutch:

* See Contents (L1)
Even when the output to the 2nd Defective 2nd clutch fill switch
Defective 2nd clutch pressure control
disengaged.
15SFMA
(TM-19)
ECMV for 2nd clutch:

Even when there is output to the Defective 2nd clutch solenoid

2nd clutch solenoid, the signal
Defective 2nd clutch or pressure control
15SGL1
(TM-20)
ECMV for 3rd clutch:

* See Contents (L1)
Even when the output to the 3rd Defective 3rd clutch fill switch
Defective 3rd clutch pressure control
disengaged.
20-414
c

1 c
(9)
Defective Lo clutch fill switch

Defective Lo clutch pressure control
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

L-SW (male) (1) ground:
Min. 1 M
Max. 1

traveling
E03

L-PS (male) (1) (2): 5 15

traveling
E03

1-SW (male) (1) ground:
Min. 1 M
Max. 1

traveling
E03

1-PS (male) (1) (2): 5 15

traveling
E03

Min. 1 M
Max. 1

traveling
E03

2-PS (male) (1) (2): 5 15

traveling
E03

Min. 1 M
Max. 1

traveling
E03
HM300-1
20-415
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
15SGMA
(TM-21)
ECMV for 3rd clutch:

Even when there is output to the Defective 3rd clutch solenoid

3rd clutch solenoid, the signal
cuit wiring harness
Defective 3rd clutch or pressure control
15SJL1
(TM-22)
ECMV for lock-up clutch:

* See Contents (L1)
Even when the output to the

Defective lock-up clutch fill switch
lock-up clutch solenoid is turned Short circuit with chassis ground in
OFF, the signal from the fill
switch stays ON and the clutch Defective lock-up clutch pressure control
is not disengaged.
15SJMA
(TM-23)
ECMV for lock-up clutch:

Even when there is output to the Defective lock-up clutch solenoid

lock-up clutch solenoid, the sig- Excessive resistance in solenoid (+) cirnal from the fill switch stays OFF
cuit wiring harness
Defective lock-up clutch or pressure control valve hydraulic, mechanical system
15SKL1
(TM-24)
ECMV for inter-axle differen- Even when the output to the dif- Defective differential lock clutch fill
switch
tial lock clutch:
ferential lock clutch solenoid is
* See Contents (L1)
turned OFF, the signal from the Short circuit with chassis ground in
fill switch stays ON and the
Defective differential lock clutch presclutch is not disengaged.
sure control valve hydraulic, mechanical
system
15SKMA
(TM-25)
ECMV for inter-axle differen- Even when there is output to the Defective differential lock clutch solenoid
tial lock clutch: Function im- differential lock clutch solenoid, Excessive resistance in solenoid (+) circuit wiring harness
possible (MA)
stays OFF and the clutch is not Excessive resistance in solenoid () cirengaged.
cuit wiring harness
Defective differential lock clutch or pressure control valve hydraulic, mechanical
system
2B61MW
(TM-26)
Inter-axle differential lock

clutch: Slipping (MW)
20-416
c

1 c
(9)
When there is output to the differential lock clutch solenoid,

there is an abnormality in the
value calculated from the signals from the transmission output shaft F speed sensor and
output shaft R speed sensor (retarder controller is responsible
for calculating value).
Defective differential lock clutch solenoid

Defective differential lock clutch or pressure control valve hydraulic, mechanical
system
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING


3-PS (male) (1) (2): 5 15
Action code

traveling
E03

L/C-SW (male) (1) ground:
Min. 1 M
Max. 1
Holds speed range when trav- Lock-up is canceled and it beeling and turns lock-up actuacomes impossible to shift gear
tion OFF
If gearshift lever is returned to N,
When gearshift lever is remachine cannot move off again
turned to N, holds in Neutral
until it is stopped
Lock-up pilot lamp does not give
display normally
E03

L/C-PS (male) (1) (2):
5 15
Holds speed range when trav- Lock-up is canceled and it beeling and turns lock-up actuacomes impossible to shift gear
tion OFF
machine cannot move off again
When gearshift lever is reuntil it is stopped
E03

D/L-SW (male) (1) ground:
Min. 1 M
Max. 1
Turns inter-axle differential

lock command OFF
Inter-axle differential lock does

not work
E01

D/L-PS (male) (1) (2) :
5 15

lock command OFF

not work
E02

D/L-PS (male) (1) (2) :
5 15

lock command OFF

not work
E01
HM300-1
20-417
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
2F00KM
(TM-27)
Parking brake: Mistaken op- Travel operation was carried out Forgot to release parking brake (when
eration or mistaken setting
when parking brake signal cirsystem is working normally)
(KM)
cuit was closed (connected with Defective fuse
ground)
Defective parking brake oil pressure
switch
Defective parking brake relay
Disconnection or short circuit with chassis ground in switch power source circuit
wiring harness
Disconnection or short circuit with chassis ground in switch signal circuit wiring
harness
Disconnection in relay GND circuit wiring
harness
Defective retarder controller(q1)
989A00
(TM-28)
Engine overrun prevention

command signal: Actuated
(00)
989AKZ
(TM-29)
Engine overrun prevention

Disconnection, short circuit with Defective retarder controller(q1)
command signal: Disconnec- ground, hot short occurred in
tion or short circuit (KZ)
overrun prevention command
ground, or hot short in signal circuit wircircuit, or did not match commu- ing harness
nications data (S-NET)
989D00
(TM-30)
Rear overturn signal: Actuat- Dump body was operated to

ed (00)
RAISE when machine was inclined more than 15
AA10NX
(TM-31)
Clogged air cleaner element (when sysAir cleaner element: Clogged Air cleaner clogging signal cir(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 sensor signal circuit wiring harness
Disconnection in relay signal circuit wiring harness
Disconnection in relay GND circuit wiring
harness
AB00MA
(TM-32)
Alternator: Function impossi- Electricity generation signal was Defective alternator

ble (MA)
not input from alternator when
Disconnection or short circuit with chasengine was running.
sis ground in alternator signal circuit
The transmission input shaft

Engine overrun
speed became more than 2450 Defective transmission controller
rpm when the speed range was
other than Neutral.
Dump operated when machine is inclined (when system is working normally)

Defective inclination sensor
Disconnection or hot short in sensor
power source circuit wiring harness
ground, or hot short in sensor signal circuit wiring harness
20-418
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
If the machine is used as it is,

there is danger that the parking
brake may be damaged
None
Issues order to retarder controller(q1) to apply brake (retarder)
Brake is applied, travel speed is

reduced
E02
Signal voltage
ATC1 (13) (8)(16)
When command is ON:
20 30 V
When command is OFF:
Max. 1 V
Continues control with signal

on S-NET
E01
A. Sensor power source voltage

T10 (1) (3): 11 13 V
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
Takes no action
User code is not displayed
If the dump RAISE operation is

continued in this condition, the
machine may tip over
None

T11 (male) (1) (2)
When normal: Min. 1 M
When clogged: Max. 1
R32 (male) (3) (6): Max. 1
Takes no action
If the machine is used as it is, the

engine air intake capacity may
drop
E01
Alternator generating voltage

Alternator R E: 27.5 29.5 V
Takes no action

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)
E03

Takes no action
B17 (male) (1) (2) :
User code is not displayed
Brake released: Min. 1 M
Brake applied: Max. 1
R32 (male) (1) (2) : 100 500
HM300-1
20-419
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Probable cause
B@BCZK
(TM-33)
Radiator coolant: Drop in lev- Radiator coolant level switch

Drop in radiator coolant level (when sysel (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 wiring harness
B@HAZK
(TM-34)
Hydraulic tank oil: Drop in lev- When the engine was stopped, Drop in hydraulic tank oil level (when
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)
harness
B@JANS
(TM-35)
Steering oil: Overheat (NS)
The signal circuit of the steering Steering oil temperature overheating

oil temperature switch became
open (shut off from GND)
Defective steering oil temperature switch
harness
D1B0KZ
(TM-36)
Transmission cut relay: Disconnection or short circuit

(KZ)
Abnormal voltage was generated in the transmission cut relay

circuit
When relay is actuated: 10 V
or more
When relay is stopped: Less
than 4 V
D5ZBKX
(TM-37)
The voltage in the differential

Inter-axle differential lock
command signal: Input signal lock signal circuit became less
than 0.5 V or more than 4.5 V
outside range (KX)
D5ZCKZ
(TM-38)
Exhaust brake command sig- A disconnection, short circuit

with ground, or hot short was
nal: Disconnection or short
generated in the exhaust brake
circuit (KZ)
ground, or hot short in signal circuit wircommand circuit, or there was a
ing harness
mismatch with the communica- Defective transmission controller
tion (S-NET) data
D5ZDL4
(TM-39)
Forced neutral demand signal: * See Contents (L4)
D5ZEKX
(TM-40)
Engine load signal: Input sig- The engine load signal circuit
nal outside range (KX)
was outside the correct range
20-420
c
Nature of failure
1
(9)
4 c
Defective transmission cut relay

wiring harness
ground, or hot short in relay output circuit
wiring harness
ground, or hot short in signal circuit wiring harness
There was a mismatch between Defective retarder controller(q1)

forced neutral demand signal 1 Disconnection, short circuit with chassis
and signal 2
ground, or hot short in signal 1 circuit wiring harness
ground, or hot short in signal circuit wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

T01 (male) (1) (2):
When normal: Max. 1
Takes no action

engine may overheat
E01

T06 (male) (1) ground:
When oil level is normal:
Max. 1
When oil level has dropped:
Min. 1 M
Takes no action
If the machine is used as it is, it

may become impossible to carry
out dump operations
E01

T04 (male) (1) ground:
When oil temperature is 25C:
Max 1
When oil temperature is
123C: Min. 1 M
Takes no action
If the machine is used as it is, oil

leakage may occur
E02
Controller inlet voltage

OFF.
ATC1 (15) (8)(16):
When relay actuated: Max. 1 V Sets transmission to Neutral.
When relay stopped: 20 30 V

traveling and machine cannot
move off again
E03
Signal voltage
ATC3A (8) (18): 0.7 4.3 V

lock command OFF

not work
E01
Signal voltage
ATC1 (14) (8)(16):
When command is OFF:
Max. 1 V
When command is ON:
20 30 V

on S-NET
E01

on S-NET
E01
Carries out control with load

taken as heavy load
Gearshift feeling may change

slightly
E01
Signal voltage
ATC3A (4) (16): 0 15 V
HM300-1
20-421
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DAQ0KK
(TM-41)
Transmission controller: Drop When the engine was running, Another problem is occurring at the
in power source voltage, in- both the main power supply volt- same time (failure code AB00MA is disput (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 chassis ground in power source circuit wiring
harness
DAQ1KK
(TM-42)
Transmission controller main

power supply line: Drop in
power source voltage, input
(KK)
The voltage difference between Disconnection or short circuit with chasthe main power supply voltage
sis ground in main power source circuit
circuit and the direct power sup- wiring harness
ply voltage circuit became more Defective transmission controller
than 5 V
DAQ2KK
(TM-43)
Transmission controller load

power source voltage, input
(KK)
When the controller power supply voltage circuit was normal,

the solenoid power supply voltage circuit became less than
18 V

wiring harness
Disconnection or short circuit with chassis ground in relay output circuit wiring
harness
DAQ3KK
(TM-44)
Transmission controller bat- The voltage in the direct power

tery direct power supply line: supply voltage circuit became
less than 5 V
Disconnection or short circuit with chassis ground in direct power source circuit
wiring harness
DAQ5KP
(TM-45)
Transmission controller pow- The voltage in the 12V power

er supply output 1: Drop in
supply circuit for the sensor beoutput voltage (KP)
came less than 6 V

Short circuit with chassis ground in sensor power source circuit wiring harness
DAQ9KM
(TM-46)
Transmission controller wir- When the starting switch is ON, Mistaken connection of connector ATC3
(A, B) and connector ATC5 (A, B) (when
ing harness: Mistaken opera- the input connector check signal
tion or mistaken setting (KM) does not match the setting inside the controller
harness
DAQ9KQ
(TM-47)
Transmission controller wiring harness: Non match in

model selection signal (KQ)
DAQAKQ
(TM-48)
Transmission controller rota- The model setting of the rotary

ry switch: Non match in mod- switch does not match the setel selection signal (KQ)
ting inside the controller
Defective setting of rotary switch

DAQSMA
(TM-49)
Transmission controller:
Another problem is occurring at the

same time (failure code DAQSKR is displayed)
Defective machine monitor
20-422
c

1 c
(9)
When the starting switch is ON, Disconnection in model selection signal

the input model selection signal
is different from the setting of the Defective transmission controller
controller
The communication (S-NET)

with the machine monitor is defective and the option setting
cannot be made
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

Main power source voltage
ATC1 (9)(17) (8)(16): 20 30 V
Direct power source voltage
ATC1 (7) (8)(16): 20 30 V

move off again
E03

Does not allow updating of inATC1 (9)(17) (8)(16): 20 30 V put related data
Condition before problem occurred is maintained
E03
Solenoid power source voltage

ATC2 (1)(12) ATC1 (8)(16):
20 30 V

OFF.

move off again
E03

ATC1 (7) (8)(16): 20 30 V

move off again
E03
Controller output voltage

ATC2 (14) ATC3A (16):
11 13 V
Shuts off output of sensor 12V Does not judge rear overturn
power supply
alarm
E03
Wiring harness resistance value

ATC5A (female) (1) ground:
Max. 1

Machine does not move off even
OFF.
when operation is carried out to
Holds transmission in Neutral.
move machine off
Does not record in trouble data.
E03

ATC5B (female) (14)(15)(16)
ground: Max. 1

OFF.
move machine off
E03
Rotary switch setting position

See TESTING AND ADJUSTING.

OFF.
move machine off
E03
E03
HM300-1

move machine off
20-423
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DDTFKA
(TM-50)
Fill switch for inter-axle differ- When the output is made to the
ential lock clutch: Disconnec- differential lock clutch solenoid,
tion (KA)
the clutch engages, but the signal from the fill switch does not
come ON
Defective differential clutch fill switch

Disconnection or hot short in switch circuit wiring harness
DDTGKA
(TM-51)
Fill switch for lock-up clutch: When the output is made to the
Disconnection (KA)
lock-up clutch solenoid, the
clutch engages, but the signal
from the fill switch does not
come ON
Defective lock-up clutch fill switch

Disconnection or hot short in switch circuit wiring harness
DDTHKA
(TM-52)
Fill switch for Hi clutch:

Disconnection (KA)
When the output is made to the Defective Hi clutch fill switch

Hi clutch solenoid, the clutch en- Disconnection or hot short in switch cirgages, but the signal from the fill
cuit wiring harness
switch does not come ON
DDTJKA
(TM-53)
Fill switch for Lo clutch:

Disconnection (KA)
When the output is made to the Defective Lo clutch fill switch

Disconnection or hot short in switch cirLo clutch solenoid, the clutch
engages, but the signal from the
cuit wiring harness
fill switch does not come ON
DDTKKA
(TM-54)
Fill switch for 1st clutch:

Disconnection (KA)
When the output is made to the Defective 1st clutch fill switch
Disconnection or hot short in switch cir1st clutch solenoid, the clutch
cuit wiring harness
DDTLKA
(TM-55)
Fill switch for 2nd clutch:

Disconnection (KA)
When the output is made to the Defective 2nd clutch fill switch
Disconnection or hot short in switch cir2nd clutch solenoid, the clutch
cuit wiring harness
DDTMKA
(TM-56)
Fill switch for 3rd clutch:

Disconnection (KA)
When the output is made to the Defective 3rd clutch fill switch
3rd clutch solenoid, the clutch
Disconnection or hot short in switch cirengages, but the signal from the
cuit wiring harness
DDTNKA
(TM-57)
Fill switch for R clutch:

Disconnection (KA)
When the output is made to the Defective R clutch fill switch

R clutch solenoid, the clutch en- Disconnection or hot short in switch cirgages, but the signal from the fill
cuit wiring harness
switch does not come ON
20-424
c

1 c
(9)
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
Fill switch resistance value

ATC5A (male) (17) ground:
Min. 1 M
Max. 1
Takes no action
Inter-axle differential lock is actuated, but pilot lamp does not light
up
E01

Min. 1 M
Max. 1
Holds speed range during trav- Cannot shift gear

el
until it is stopped
Lock-up pilot lamp does not light
up
E03

Min. 1 M
Max. 1

el
until it is stopped
E03

Min. 1 M
Max. 1

el
When gearshift lever is returned to N, holds in Neutral
until it is stopped
E03

Min. 1 M
Max. 1

el
E03

Min. 1 M
Max. 1

el
until it is stopped
E03

Min. 1 M
Max. 1

el
until it is stopped
E03

Min. 1 M
Max. 1

el
until it is stopped
E03
HM300-1
20-425
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DF10KA
(TM-58)
Gearshift lever: Disconnection (KA)
Nothing is input for the gearshift Defective gearshift lever

lever signal
Disconnection or short circuit with chassis ground in lever power source circuit
wiring harness
Disconnection in lever GND circuit wiring
harness
Disconnection or short circuit with chassis ground in lever signal circuit wiring
harness
DF10KB
(TM-59)
Gearshift lever: Short circuit

(KB)
The gearshift lever signal was

Defective shift lever
input at the same time from 2 or Hot short in lever signal circuit wiring harmore systems
ness
DGF1KX
(TM-60)
Transmission valve oil tem- The voltage of the signal circuit Defective transmission valve oil temperperature sensor: Input signal for the transmission valve oil
ature sensor
outside range (KX)
temperature sensor became
less than 0.97 V, or there was a
ground, or hot short in sensor signal cirbig difference from the torque
cuit wiring harness
converter oil temperature
DGR3L8
(TM-61)
Brake oil temperature sensor When the front brake oil temper- Defective center brake oil temperature
(center): * See Contents (L8) ature sensor signal and rear
sensor
brake oil temperature sensor
Disconnection or hot short in sensor sigsignal were more than 60C, the
nal circuit wiring harness
center brake oil temperature
Disconnection in sensor GND circuit wirsensor was less than 10C
ing harness
DGR4L8
(TM-62)
Brake oil temperature sensor When the center brake oil tem- Defective front brake oil temperature
(front): * See Contents (L8) perature sensor signal and rear
sensor
brake oil temperature sensor
Disconnection or hot short in sensor sigsignal were more than 60C, the
nal circuit wiring harness
front brake oil temperature sen- Disconnection in sensor GND circuit wirsor was less than 10C
ing harness
DGT1KX
(TM-63)
Torque converter oil tempera- The voltage of the signal circuit

ture sensor: Input signal out- for the torque converter oil temside range (KX)
perature sensor became less
than 0.97 V, or there was a big
difference from the transmission
valve oil temperature sensor signal
20-426
!

1 !
(9)
Defective torque converter oil temperature sensor

Disconnection in sensor GND circuit
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
Gearshift lever power source

voltage
SF1 (1) (2): 20 24 V
Gearshift lever signal voltage
SF1 (3)(4)(5)(6)(7)(8)(9)(10)
(11) (2):
Selected circuit: 20 24 V
Not selected circuit: Max. 1 V
Condition before abnormality

occurred is maintained
Shifts to higher speed range than

speed range set by gearshift lever
Stays in Neutral and machine cannot move off
Impossible to change direction of
travel between FORWARD and
REVERSE
All gearshift lever position lamps
go out
E03
Gearshift lever power source

voltage
SF1 (1) (2): 20 24V
Gearshift lever signal voltage
SF1 (3)(4)(5)(6)(7)(8)(9)(10)
(11) (2):
Selected circuit: 20 24 V
Not selected circuit: Max. 1 V
Controls using signal in order Shifts to higher speed range than

of high priority
speed range set by gearshift lever
(1): N > D > 5 > 4 > 3 > 2 > 1 Stays in Neutral and machine can(2): N > R2 > R1
not move off
If the signal for both system (1) Gearshift lever position lamps are
and system (2) are input at the
different from position of lever
same time, shifts transmission
to Neutral
E03
Transmission shock becomes ex Sensor resistance value

Controls clutch oil pressure
cessive
LUB-T (male) (1) (2):
with clutch oil temperature be When oil temperature is 25C:
fore abnormality occurred
37 50 k
3.5 4.0 k
E03

Takes no action
T14 (male) (1) (2):
37 50 k
3.5 4.0 k

does not give correct display
If it is used as it is, the braking effect may become weaker
E01

Takes no action
T15 (male) (1) (2):
37 50 k
3.5 4.0 k

does not give correct display
If it is used as it is, the braking effect may become weaker
E01

Takes no action
TC-SE (male) (1) (2):
37 50 k
3.5 4.0 k

gauge does not give correct display
E01
HM300-1
20-427
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DHT5KX
(TM-64)
Torque converter oil pressure The voltage in the signal circuit

sensor: Input signal outside of the torque converter oil presrange (KX)
sure sensor became less than
0.5 V or more than 4.5 V
DHT5L6
(TM-65)
Torque converter oil pressure When the engine is stopped, the Defective torque converter oil pressure
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
(TM-66)
Fuel level sensor:

Disconnection (KA)
The voltage of the signal circuit

of the fuel level sensor became
more than 4.0 V
Defective fuel level sensor

Disconnection or hot short in sensor signal circuit wiring harness
DK11KX
(TM-67)
Throttle angle sensor:

Input signal outside range
(KX)
The voltage in the signal circuit

of the acceleration sensor became less than 0.6 V or more
than 4.7 V
Defective accelerator sensor or defective

accelerator pedal
ground, or hot short in sensor power
source circuit wiring harness
DLE2KA
(TM-68)
Engine speed sensor:

Disconnection (KA)
There is a disconnection in the

signal circuit of the engine
speed sensor and the signal is
not input
Defective engine speed sensor or defective adjustment

Disconnection in sensor signal circuit
wiring harness
DLE2LC
(TM-69)
Engine speed sensor:

* See Contents (LC)
When the signal of the engine

Defective engine speed sensor
speed sensor is less than 350
rpm, the signal of the transmisshort in sensor signal circuit wiring harsion input shaft speed sensor in- ness
puts more than 500 rpm
20-428
!

1 !
(9)
Defective torque converter oil pressure

sensor
wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

TC-INT (2) (1): 20 30 V
TC-INT (3) (1): 0.8 2.0 V
Fixes torque converter oil pres- Excessive shock when lock-up is

sure to oil pressure set inside
actuated
controller and carries out control
E01

TC-INT (2) (1): 20 30 V
TC-INT (3) (1): 0.8 2.0 V
Fixes torque converter oil pres- Excessive shock when lock-up is

actuated
sure to oil pressure set inside
controller and carries out control
E01

T08 (male) (1) (2):
When full: Max. 12
When empty: 74 100
Takes no action
Fuel gauge does not give correct

display
E01

AS2 (1) (3): 4.6 5.4 V
AS3 (2) (3):
Lo position: 1.0 1.4 V
Hi position: 3.6 4.0 V
Carries out automatic shifting

in normal mode (but controls
with clutch oil pressure taken
as engine at full throttle)
Transmission shock becomes excessive

Immediately shifts up when traveling downhill
E03

EREV (male) (1) (2):
500 1000

el
Tachometer does not work (displays 0 rpm)
E03

EREV (male) (1) (2):
500 1000

el
until it is stopped
Tachometer does not go above
350 rpm
E03
HM300-1
20-429
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
DLF1KA
(TM-70)
Transmission input shaft

speed sensor:
Disconnection (KA)
There is a disconnection in the Defective transmission input shaft speed

signal circuit of the transmission
sensor or defective adjustment
input shaft speed sensor and the Disconnection in sensor signal circuit
signal is not input
wiring harness
DLF1LC
(TM-71)
Transmission input shaft

speed sensor:
* See Contents (LC)
There is an abnormality in the

Defective transmission input shaft speed
speed calculated from the ensensor
gine speed sensor signal, trans- Short circuit with chassis ground or hot
mission intermediate shaft
short in sensor signal circuit wiring harspeed sensor signal, and output
ness
shaft R speed sensor signal,
and the speed of the transmission input shaft sensor signal
DLF2KA
(TM-72)
shaft speed sensor:
Disconnection (KA)
There is a disconnection in the Defective transmission intermediate

shaft speed sensor or defective adjustsignal circuit of the transmission
ment
intermediate shaft speed sensor
Disconnection in sensor signal circuit
and the signal is not input
wiring harness
DLF2LC
(TM-73)
shaft speed sensor:
* See Contents (LC)

Defective transmission intermediate
speed calculated from the enshaft speed sensor
gine speed sensor signal, trans- Short circuit with chassis ground or hot
mission input shaft speed
short in sensor signal circuit wiring harsensor signal, and output shaft
ness
R speed sensor signal, and the Defective transmission controller
speed of the transmission intermediate shaft sensor signal
DLT3KA
(TM-74)

speed sensor:
Disconnection (KA)
There is a disconnection in the Defective transmission output shaft R

speed sensor or defective adjustment
signal circuit of the transmission
output shaft R speed sensor and Disconnection in sensor signal circuit
wiring harness
the signal is not input
DLT3LC
(TM-75)

speed sensor:
* See Contents (LC)

speed calculated from the engine speed sensor signal, transmission input shaft speed
sensor signal, and intermediate
shaft speed sensor signal, and
the speed of the transmission
output shaft R sensor signal
DXH0KA
(TM-76)
Defective differential lock clutch solenoid

Solenoid for inter-axle differ- No electric current flows when
ential lock:
there is output to the differential Disconnection in solenoid (+) circuit wirDisconnection (KA)
lock clutch solenoid
ing harness
Defective transmission output shaft R

short in sensor signal circuit wiring harness
Eefective retarder controller(q1)
20-430
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

Holds speed range during trav- Lock-up is canceled and transN1 (male) (1) (2): 500 1000 el and turns actuation of lockmission cannot be shifted
up OFF
until it is stopped
E03

Holds speed range during trav- Lock-up is canceled and transN1 (male) (1) (2): 500 1000
el and turns actuation of lockmission cannot be shifted
up OFF
until it is stopped
E03

N2 (male) (1) (2): 500 1000 el
E03

N2 (male) (1) (2): 500 1000
el
E03

Holds speed range during trav- Speedometer displays 0 km/h
N3 (male) (1) (2): 500 1000 el
Cannot shift gear
When gearshift lever is re If gearshift lever is returned to N,
until it is stopped
E03

N3 (male) (1) (2): 500 1000
el
Speedometer displays abnormal
speed
E03

Continues output as it is
D/L-PS (male) (1) (2): 5 15
E01
HM300-1

not work
20-431
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DXH0KB
(TM-77)
Solenoid for inter-axle differ- An extremely large electric cur- Defective differential lock clutch solenoid
ential lock: Short circuit (KB) rent flows when there is output Short circuit, short circuit with chassis
to the differential lock clutch soground, 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
(TM-78)
Solenoid for lock-up clutch:

Disconnection (KA)
No electric current flows when

there is output to the lock-up
clutch solenoid
DXH1KB
(TM-79)
Solenoid for lock-up clutch:

Short circuit (KB)
An extremely large electric cur- Defective lock-up clutch solenoid

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
harness
DXH2KA
(TM-80)
Solenoid for Hi clutch:

Disconnection (KA)

there is output to the Hi clutch
solenoid
DXH2KB
(TM-81)
Solenoid for Hi clutch:

Short circuit (KB)
An extremely large electric cur- Defective Hi clutch solenoid

to the Hi clutch solenoid or elec- ground, or hot short in solenoid (+) circuit
wiring harness
tric current flows when it is OFF
harness
DXH3KA
(TM-82)
Solenoid for Lo clutch:

Disconnection (KA)

there is output to the Lo clutch
solenoid
DXH3KB
(TM-83)
Solenoid for Lo clutch:

Short circuit (KB)
An extremely large electric cur- Defective Lo clutch solenoid

to the Lo clutch solenoid or elec- ground, or hot short in solenoid (+) circuit
wiring harness
tric current flows when it is OFF
harness
DXH4KA
(TM-84)
Solenoid for 1st clutch:

Disconnection (KA)

there is output to the 1st clutch
solenoid
20-432
c

1 c
(9)
Defective lock-up clutch solenoid

Disconnection in solenoid (+) circuit
Disconnection in solenoid () circuit



HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

D/L-PS (male) (1) (2): 5 15 lock command OFF

not work or is not canceled
E01

Turns lock-up actuation OFF
L/C-PS (male) (1) (2): 5 15
Lock-up is not actuated
E03

Holds speed range during trav- Lock-up is always canceled or alL/C-PS (male) (1) (2): 5 15 el and turns actuation of lockways actuated and transmission
up OFF
cannot be shifted
When gearshift lever is re If gearshift lever is operated to N,
until it is stopped (depending on
condition of failure, machine may
not be able to move off again)
E03

H-PS (male) (1) (2): 5 15
Shifts to Neutral during travel

If travel is not stopped, machine
cannot move off again
E03

H-PS (male) (1) (2): 5 15

cannot move off again (depending
on condition of failure, machine
may not be able to move off
again)
E03

L-PS (male) (1) (2): 5 15

E03

L-PS (male) (1) (2): 5 15

again)
E03

1-PS (male) (1) (2): 5 15

E03
HM300-1
20-433
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
Location of failure
Nature of failure
Probable cause
DXH4KB
(TM-85)
Solenoid for 1st clutch:

Short circuit (KB)
An extremely large electric current flows when there is output

to the 1st clutch solenoid or
OFF

Short circuit, short circuit with chassis
wiring harness
harness
DXH5KA
(TM-86)
Solenoid for 2nd clutch:

Disconnection (KA)

there is output to the 2nd clutch
solenoid
DXH5KB
(TM-87)
Solenoid for 2nd clutch:

Short circuit (KB)
An extremely large electric current flows when there is output

to the 2nd clutch solenoid or
OFF

wiring harness
harness
DXH6KA
(TM-88)
Solenoid for 3rd clutch: Disconnection (KA)

there is output to the 3rd clutch
solenoid
DXH6KB
(TM-89)
Solenoid for 3rd clutch: Short An extremely large electric curcircuit (KB)
rent flows when there is output
to the 3rd clutch solenoid or
OFF
DXH7KA
(TM-90)

Solenoid for R clutch: Discon- No electric current flows when
nection (KA)
there is output to the R clutch so- Disconnection in solenoid (+) circuit
lenoid
DXH7KB
(TM-91)
Solenoid for R clutch: Short

circuit (KB)
20-434
c

1 c
(9)



wiring harness
harness
An extremely large electric cur- Defective R clutch solenoid

to the R clutch solenoid or electric current flows when it is OFF
wiring harness
harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

1-PS (male) (1) (2): 5 15

again)
E03

2-PS (male) (1) (2): 5 15

E03

2-PS (male) (1) (2): 5 15

again)
E03

3-PS (male) (1) (2): 5 15

E03

3-PS (male) (1) (2): 5 15

again)
E03

R-PS (male) (1) (2): 5 15

E03

R-PS (male) (1) (2): 5 15

again)
E03
HM300-1
20-435
1 c
(9)
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 calculated from the signals from the engine speed sensor, transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed
sensor.
Cause
Remedy
1
Disconnect L/C-PS.
NO
Is resistance between L/C-PS

(male) (1) and (2) 5 15 ?
Defective lock-up clutch

solenoid
Replace
Excessive resistance in wiring

harness between ATC2 (female)
(10) and L/C-PS (female) (1) or
ATC2 (female) (20) and L/C-PS
(female) (2)
Repair or
replace
YES
2
Disconnect ATC2.
NO
Is resistance between ATC2

(female) (10) and (20) 5 15?
YES
3

when transmission controller is
replaced?
Defective hydraulic, mechanical

system of lock-up clutch or
pressure control valve
Carry out
troubleshooting for
mechanical
system
YES
Defective transmission
controller
Replace
TM-1 Related electrical circuit diagram
20-436
c
1 c
HM300-1
TROUBLESHOOTING
TM-2
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

time?
NO
YES
2
Does condition become normal

replaced?
NO
Other problem occurring at

same time
Go to
troubleshooting
of displayed
code

system of clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
HM300-1
Replace
20-437
1 c
TROUBLESHOOTING
TM-3
TM-3
FAILURE CODE [15B0NX] (TRANSMISSION OIL FILTER: CLOGGED (NX))
Nature of failure:When the torque converter oil temperature is more than 50C, the signal circuit of the transmission 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.
NO
Is transmission oil filter clogged?
YES
Clogged transmission oil filter
Clean or
replace
Defective transmission oil filter

clogging sensor
Replace
2
Disconnect T03.
Is resistance between T03 (male) NO

(1) and (2) less than 1 ?
YES
3
Disconnect T03.
Is resistance between T03

(female) (2) and ground less than
1 ?
contact or disconnection Repair or

NO Defective
in wiring harness between T03
replace
YES
4
Disconnect ATC5A.
Is resistance between ATC5A

1 ?
NO Defective contact or disconnection Repair or

in wiring harness between ATC5A
(female) (6) and T03 (female) (1)
replace
controller
Replace
YES
20-438
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-4
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect R-PS.
NO
Is resistance between R-PS

(male) (1) and (2) 5 15 ?
Replace
YES
2
Disconnect ATC2.
NO

(female) (5) and (15) 5 15?

Repair or
(5) and R-PS (female) (1) or ATC2 replace
(female) (15) and R-PS (female)
(2)
YES
3

replaced?
NO

system of R clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-439
1 c
(9)
TROUBLESHOOTING
TM-5
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect H-PS.
NO
Is resistance between H-PS

(male) (1) and (2) 5 15 ?
Replace
YES
2
Disconnect ATC2.
NO

(female) (4) and (15) 5 15?

Repair or
(4) and H-PS (female) (1) or ATC2 replace
(female) (15) and H-PS (female)
(2)
YES
3

replaced?
NO

system of Hi clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-440
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-6
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect L-PS.
NO
Is resistance between L-PS

(male) (1) and (2) 5 15 ?
Replace

(7) and L-PS (female) (1) or ATC2
(female) (17) and L-PS (female)
(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (7) and (17) 5 15?
YES
3

replaced?
NO

system of Lo clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-441
1 c
(9)
TROUBLESHOOTING
TM-7
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect 1-PS.
NO
Is resistance between 1-PS

(male) (1) and (2) 5 15 ?
Replace

(2) and 1-PS (female) (1) or ATC2
(female) (13) and 1-PS (female)
(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (2) and (13) 5 15?
YES
3

replaced?
NO

system of 1st clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-442
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-8
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect 2-PS.
NO

(male) (1) and (2) 5 15 ?
Replace

(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (9) and (19) 5 15?
YES
3

replaced?
NO

system of 2nd clutch or
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-443
1 c
(9)
TROUBLESHOOTING
TM-9
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 calculated from the signals from the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause
Remedy
1
Disconnect 3-PS.
NO

(male) (1) and (2) 5 15 ?
Replace

(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (3) and (13) 5 15?
YES
3

replaced?
NO
Carry out
troubleshootDefective hydraulic, mechanical ing for
system of 3rd clutch or pressure mechanical
system
control valve
YES
controller
Replace
20-444
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-10
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
Disconnect R-SW.
Is resistance between R-SW

(male) (1) and ground more than 1
M?
NO
Defective R clutch fill switch
Replace

(female) (16) and R-SW (female)
(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of R clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-445
1 !
TROUBLESHOOTING
TM-11
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
Cause
Remedy
1
Disconnect R-PS.
Is resistance between R-PS (male) NO

(1) and (2) 5 15 ?
Replace
YES
2
Disconnect ATC2.

(female) (5) and (15) 5 15?
NO

Repair or
(5) and R-PS (female) (1) or ATC2 replace
(2)
YES
3

replaced?
NO

system of R clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-446
!
1 !
HM300-1
TROUBLESHOOTING
TM-12
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
Disconnect H-SW.
Is resistance between H-SW

M?
NO
Defective Hi clutch fill switch
Replace

(female) (12) and H-SW (female)
(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of Hi clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-447
1 !
TROUBLESHOOTING
TM-13
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
Disconnect H-PS.
Is resistance between H-PS (male) NO

(1) and (2) 5 15?
Replace
YES
2
Disconnect ATC2.
NO

(female) (4) and (15) 5 15?

Repair or
(4) and H-PS (female) (1) or ATC2 replace
(2)
YES
3

replaced?
NO

system of Hi clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-448
!
1 !
HM300-1
TROUBLESHOOTING
TM-14
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
Disconnect L-SW.
Is resistance between L-SW

M?
NO
Defective Lo clutch fill switch
Replace

(female) (10) and L-SW (female)
(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of Lo clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-449
1 !
TROUBLESHOOTING
TM-15
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
Disconnect L-PS.
NO
Is resistance between L-PS (male)

(1) and (2) 5 15?
Replace

(7) and L-PS (female) (1) or ATC2
(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (7) and (17) 5 15?
YES
3

replaced?
NO

system of Lo clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-450
!
1 !
HM300-1
TROUBLESHOOTING
TM-16
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
Disconnect 1-SW.
Is resistance between 1-SW

M?
NO
Defective 1st clutch fill switch
Replace

(female) (13) and 1-SW (female)
(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of 1st clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-451
1 !
TROUBLESHOOTING
TM-17
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
Disconnect 1-PS.
NO
Is resistance between 1-PS (male)

(1) and (2) 5 15?
Replace

(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (2) and (13) 5 15?
YES
3

replaced?
NO

system of 1st clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-452
!
1 !
HM300-1
TROUBLESHOOTING
TM-18
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
Disconnect 2-SW.

M?
NO
Defective 2nd clutch fill switch
Replace

(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of 2nd clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-453
1 !
TROUBLESHOOTING
TM-19
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
Disconnect 2-PS.
NO

(1) and (2) 5 15?
Replace

(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (9) and (19) 5 15?
YES
3

replaced?
NO

system of 2nd clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-454
!
1 !
HM300-1
TROUBLESHOOTING
TM-20
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
Disconnect 3-SW.

M?
NO
Defective 3rd clutch fill switch
Replace

(1)
Repair or
replace
YES
2
Disconnect ATC5A.

than 1 M?
NO
YES
3

replaced?
NO

system of 3rd clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-455
1 !
TROUBLESHOOTING
TM-21
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
Disconnect 3-PS.
NO

(1) and (2) 5 15?
Replace

(2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (3) and (13) 5 15?
YES
3

replaced?
NO

system of 3rd clutch or pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-456
!
1 !
HM300-1
TROUBLESHOOTING
TM-22
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
Disconnect L/C-SW.
Is resistance between L/C-SW

(male) (1) and ground more than
1 M?
NO
Defective lock-up clutch fill

switch
Replace
YES
2
Disconnect ATC5A.

than 1 M?
NO

Repair or
wiring harness between ATC5A
(female) (11) and L/C-SW (female) replace
(1)
YES
3

replaced?
NO

system of lock-up clutch pressure
control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-457
1 !
TROUBLESHOOTING
TM-23
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
Disconnect L/C-PS.
NO

(male) (1) and (2) 5 15?

solenoid
Replace
YES
2
Disconnect ATC2.
NO

(female) (10) and (20) 5 15?

harness between ATC2 (female) Repair or
(10) and L/C-PS (female) (1) or replace
(female) (2)
YES
3

replaced?
NO

system of lock-up clutch or
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-458
!
1 !
HM300-1
TROUBLESHOOTING
TM-24
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
Disconnect D/L-SW.
Is resistance between D/L-SW

M?
NO
Defective differential lock

clutch fill switch
Replace
YES
2
Disconnect ATC5A.

than 1 M?
NO

Repair or
(female) (17) and D/L-SW (female) replace
(1)
YES
3

replaced?
NO

system of differential lock clutch
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-459
1 c
(9)
TROUBLESHOOTING
TM-25
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
Disconnect D/L-PS.
NO
Is resistance between D/L-PS

(male) (1) and (2) 5 15?

clutch solenoid
Replace
YES
2
Disconnect ATC2.
NO

(female) (8) and (18) 5 15?

(8) and D/L-PS (female) (1) or
ATC2 (female) (18) and D/L-PS
(female) (2)
Repair or
replace
YES
3

replaced?
NO

or pressure control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
20-460
c
1 c
HM300-1
TROUBLESHOOTING
TM-26
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 controller.)
Cause
Remedy
1
Disconnect D/L-PS.
NO

(male) (1) and (2) 5 15?

clutch solenoid
Replace

(8) and D/L-PS (female) (1) or
(female) (2)
Repair or
replace
YES
2
Disconnect ATC2.
NO

(female) (8) and (18) 5 15?
YES
3

replaced?
NO

or pressure control valve
Carry out
troubleshooting for
mechanical
system
YES
controller
Replace
HM300-1
20-461
1 c
(9)
TROUBLESHOOTING
TM-27
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
NO
Did machine travel with parking
brake switch at PARKING position?
YES
Mistaken operation of parking

brake switch
2
Start engine.
Operate gearshift lever.
Does condition become normal when

parking brake relay (R03) is
NO
YES
Defective parking brake relay

(R03)
Replace
3
Disconnect R03.
Start engine.
Parking brake switch: RELEASED
NO

(1) and ground 20 30 V?
YES
4
Disconnect R03.
Is resistance between R03

1 ?
NO

ground
YES
5
Disconnect R03 and
BRC5A.
NO
Is resistance between BRC5A

1 M?

in wiring harness between
BRC5A (female) (5) and R03
(female) (3)
Repair or
replace
Repair or
replace
YES
Defective retarder controller(q1) Replace
6
Disconnect B17.
Start engine.
Parking brake switch: RELEASED
NO
Is resistance between B17 (male)

(1) and (2) less than 1?
Defective parking brake

pressure switch
Replace
YES
7
Disconnect B17.
Is voltage between B17 (female)

YES
NO
Defective contact or disconnection Repair or

replace
BT3-16 outlet B17 (female) (1)
between B17 (female) (2) and
R03 (female) (1)
Repair or
replace
20-462
!
1 !
4
HM300-1
TROUBLESHOOTING
TM-27
HM300-1
20-463
1 !
TROUBLESHOOTING
TM-28
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
1
Did machine travel with
transmission input shaft speed at
more than 2450 rpm?
NO
controller
Remedy
Operate for
a short time
and watch
condition
YES
Engine overrun
20-464
!
1 !
HM300-1
TROUBLESHOOTING
TM-29
TM-29
FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL:

Nature of failure:Disconnection, short circuit with ground, hot short occurred in overrun prevention command circuit, or did not match communications data (S-NET)
Cause
1
Disconnect ATC1 and
BRC5B.
NO
Is voltage between ATC1 (female)


between ATC1 (female) (13) and
BRC5B (female) (5)
Remedy
Repair or
replace
YES
2
Disconnect ATC1 and
BRC5A.

(female) (13) and BRC5B (female)
(5) less than 1 ?
NO

Repair or
in wiring harness between ATC1
replace
(female) (13) and BRC5B
(female) (5)
YES
3
Disconnect ATC1 and
BRC5A.

than 1 M?
NO


(female) (5)
Repair or
replace
YES
4

replaced?
NO
YES
controller
Replace

HM300-1
20-465
1 !
4
(9)
TROUBLESHOOTING
TM-30
From 7
Cause
Remedy
8
Insert T-adapter to T10.
NO
Is voltage between T10 (2) and

ground 2.9 3.1 V?
between ATC3B (female) (16)
and T10 (female) (2)
Repair or
replace
NO

Repair or
replace
NO

in wiring harness between ATC3B Repair or
(female) (16) and T10 (female) (2) replace
YES
9
Disconnect ATC3B and
T10.
Is voltage between T10 (female)

YES
10
T10.

than 1 M
YES
Replace
HM300-1
20-467
1 !
(9)
TROUBLESHOOTING
TM-31
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
Is dust indicator red?
YES
Cause
Remedy
Clogged air cleaner element
Clean or
replace
Defective dust indicator relay

(R32)
Replace
Defective air cleaner clogging

switch
Replace

ground in wiring harness
T11 (female)
Repair or
replace
between ATC3A (female) (19)
and R32 (female) (3) or
Repair or
replace
controller
Replace
2
Start engine.

when dust indicator relay (R32)
is interchanged with other relay?
NO
YES
3
Disconnect R32.
Start engine.

than 1 M?
NO
YES
4
Disconnect T11.

(female) and T12 (male) less than
1 ?
YES
NO
5
Disconnect ATC3A.

(female) (19) and (16) less than
1 ?
YES
20-468
c
1 c
NO
HM300-1
TROUBLESHOOTING
TM-31
HM300-1
20-469
1 c
TROUBLESHOOTING
TM-32
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.
Start engine (mid-range
speed).
NO
Is voltage between ATC3B (female)

(1) and ground 27.5 - 29.5 V?
YES
controller
Replace

in wiring harness between ATC3B
(female) (1) and alternator terminal R
Repair or
replace
2
Disconnect alternator
terminal R.
speed).
Is voltage between alternator R and NO

E 27.5 - 29.5 V?
YES
3
Turn starting switch ON
Is voltage between alternator B and NO

E 20 - 30 V?
YES

Repair or
replace
in wiring harness between alternator
terminal B and battery relay terminal M
Defective alternator
Replace
20-470
c
1 c
4
HM300-1
TROUBLESHOOTING
TM-33
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 engine was running
If the level of the coolant in the radiator has dropped, check around the engine and radiator for signs of coolant leakage before adding coolant.
Cause
Remedy
1
Stop engine.
Has radiator coolant level dropped?
NO
YES
Drop in radiator coolant level
Check for
coolant
leakage, add
coolant
2
Disconnect T01.

Defective radiator coolant level

switch
Replace
YES
3
Disconnect T01.

1 ?
contact or disconnection Repair or

NO Defective
in wiring harness between T01
replace
YES
4
Disconnect ATC5A.

1 ?
NO Defective contact or disconnection Repair or

(female) (3) and T01 (female) (1)
replace
controller
Replace
YES
HM300-1
20-471
1 !
(9)
TROUBLESHOOTING
TM-34
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
Drop in hydraulic tank oil level
Check for oil

leakage, add
1
Stop engine.
NO
Has oil level in hydraulic tank

dropped?
YES
oil
2
Disconnect T06.

(1) and ground less than 1 ?
Defective hydraulic tank level

switch
Replace
YES
3
Disconnect ATC5A.

than 1?
NO
Repair or
replace
controller
Replace
YES
20-472
c
1 c
HM300-1
TROUBLESHOOTING
TM-35
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
NO
Did steering oil temperature go

above 120fC?
YES
Overheating of steering oil
2
Disconnect T04.
NO
Is resistance between T04 (male)

Defective steering oil

temperature switch
Replace
YES
3
Disconnect ATC3A.

1 ?
YES
NO

controller
Repair or
replace
Replace
HM300-1
20-473
1 !
TROUBLESHOOTING
TM-36
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

when transmission cut relay (R15)
NO
YES
2
Disconnect R15.
NO

(1) and ground 20 - 30 V?

(R15)
Replace
between fuse BT3 - 14 outlet R15 (female) (1)
Repair or
replace
YES
3
Disconnect ATC1 and R15.
Is voltage between ATC1

than 1 V?
NO
YES
4
Disconnect ATC1 and
R15.

NO
more than 1 M?
YES
5
Disconnect ATC1 and
R15.

(female) (15) and R15 (female)
(2) less than 1 ?
NO
Short circuit between wiring

harness at R15 (female) (1) end Repair or
replace
and wiring harness at R15
(female) (2) end
between ATC1 (female) (15)
Repair or
replace
Repair or
replace

Repair or
replace
controller
Replace
YES
6
Disconnect ATC1 and
R15.

than 1 M?
NO
YES
20-474
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-36
HM300-1
20-475
1 c
TROUBLESHOOTING
TM-38
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
1
Disconnect ATC1 and
BRC5B.
NO
Is voltage between ATC1 (female)


BRC5B (female) (4)
Remedy
Repair or
replace
YES
2
Disconnect ATC1 and
BRC5B.

(female) (14) and BRC5B (female)
(4) less than 1 ?
NO

Repair or
replace
(female) (4)
YES
3
Disconnect ATC1 and
BRC5B.

than 1 M?
NO


(female) (4)
Repair or
replace
YES
4

replaced?
NO
YES
controller
Replace

20-478
!
1 !
4
(9)
HM300-1
TROUBLESHOOTING
TM-41
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
Another problem is occurring at

the same time
Go to
troubleshoot
ing for
displayed
code
controller
Replace
between ATC1 (female) (8)(16)
and ground
Repair or
replace
Defective battery or defective

charging
Charge or
replace
between battery - battery relay transmission controller
Repair or
replace
1
Operate machine
monitor.
Is other failure code [AB00MA]

time?
NO
YES
2
Insert T-adapter to ATC1.
speed).
Is voltage between ATC1 (7) (8)(16) and between ATC1

(9)(17) - (8)(16) 20 - 30 V?
NO
YES
3
Disconnect ATC1.

(female) (8)(16) and ground less
than 1 ?
NO
YES
4
Is battery voltage more than 24

V and specific gravity more than
1.26?
YES
20-482
!
1 !
NO
HM300-1
TROUBLESHOOTING
TM-41
HM300-1
20-483
1 !
TROUBLESHOOTING
TM-43
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
and ATC2.
NO
Is voltage between ATC2 (1)(12)

and ATC1 (8)(16) 20 - 30 V?
YES
controller
Replace

(R15)
Replace
2

when transmission cut relay (R15)
is replaced with other relay?
NO
YES
3
Disconnect R15.
Is voltage between R15 (3) and

ground 20 - 30 V?
YES
NO
between fuse BT3-14 outlet R15 (female) (3)
ATC2 (female) (1)(12)
Repair or
replace
Repair or
replace
HM300-1
20-485
1 !
TROUBLESHOOTING
TM-46
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

ATC5 (A, B) connected at correct
place?
Mistaken connection of
controller connector
Connect
again
and ground
Repair or
replace
controller
Replace
YES
2
Disconnect ATC5A.

NO
1 ?
YES
20-488
!
1 !
HM300-1
TROUBLESHOOTING
TM-47
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
1
Disconnect ATC5B.
Remedy
NO

NO

Repair or
replace
Is resistance between ATC5B NO

than 1?

Repair or
replace
controller
Replace
Is resistance between ATC5B

than 1 ?
Repair or
replace
YES
2
Disconnect ATC5B.

than 1 M?
YES
3
Disconnect ATC5B.
YES
HM300-1
20-489
1 !
TROUBLESHOOTING
TM-58
TM-58
FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))
Nature of failure: Nothing is input for the gearshift lever signal

1
Is voltage between each pin of
ATC5B and ATC1 (8) as shown
in Table 1?
YES
Insert T-adapter to ATC1

and ATC5B.
Cause
NO
controller
Remedy
Replace
2
NO
Is voltage between SF1 (1) and

(2) 20 - 30 V?
Insert T-adapter to SF1.

YES
3
NO
Is voltage between SF1 (1) and

ground 20 - 30 V?
Insert T-adapter to SF1.

YES
between SF1 (female) (2) and
ATC1 (female) (8)
4
Is resistance between each pin of NO
ATC5B (female) and each pin of
SF1 (female) as shown in Table 2?

SF1.
disconnection in wiring harness Repair or
between fuse BT3-10 outlet and replace
SF1 (female) (1)
Repair or
replace
between SF1 (female) and
ATC5B (female) where
resistance value is not normal
Repair or
replace

between SF1 (female) and
ATC5B (female) where
resistance value is not normal
Repair or
replace
Defective gearshift lever
Replace
YES
5
Is resistance between each pin
of ATC5B (female) and ground

SF1.
NO
YES
Table 3
Table 2
Table 1
ATC5B (female),
SF1 (female)
Resistance
value
ATC5B, ATC1
Shift
position
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)
ATC5B(4) - SF1(5)
(4) - and ground
ATC5B(5) - ATC1(8)
ATC5B(5) - SF1(6)
ATC5B(6) - ATC1(8)
Voltage
20 - 30 V
ATC5B(6) - SF1(11)
ATC5B (female)
(5) - and ground

Max. 1
(6) - and ground
ATC5B(7) - ATC1(8)
ATC5B(7) - SF1(10)
(7) - and ground
ATC5B(8) - ATC1(8)
ATC5B(8) - SF1(9)
(8) - and ground
ATC5B(9) - ATC1(8)
ATC5B(9) - SF1(8)
(9) - and ground
ATC5B(10) - ATC1(8)
ATC5B(10) - SF1(7)
(10) - and ground
HM300-1
Resistance
value
Min. 1 M
20-499
1 !
TROUBLESHOOTING
TM-58
20-500
!
1 !
HM300-1
TROUBLESHOOTING
TM-59
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
Insert a T-adapter into
ATC1 and ATC5B
Turn the engine starting
switch ON.
Is the voltage between each pin of

ATC5B and ATC1 (8) as shown in
the Table 1?
NO
YES
defective
Replace
A wiring harness between

ATC5B (female) and SF1
(female) which shows abnormal
voltage is short-circuited
Repair or
replace
Gearshift lever defective
Replace
Separate ATC5B and

SF1.
Turn the engine starting
switch ON.
Is the voltage between each pin of

ATC5B (female) and grounding as
shown in the Table 2?
NO
YES
Table 1
Table 2
ATC5B (female)
ATC5B, ATC1
Shift
position
ATC5B(2) - ATC1(8)
R1
(3) - and ground
ATC5B(3) - ATC1(8)
R2
(4) - and ground
ATC5B(4) - ATC1(8)
(5) - and ground
ATC5B(5) - ATC1(8)
ATC5B(6) - ATC1(8)
ATC5B(7) - ATC1(8)
(8) - and ground
ATC5B(8) - ATC1(8)
(9) - and ground
ATC5B(9) - ATC1(8)
(10) - and ground
ATC5B(10) - ATC1(8)
HM300-1
Remedy
Voltage
Voltage
(2) - and ground
(6) - and ground

Max. 1 V
Max. 1 V
(7) - and ground
20-501
1 c
(9)
TROUBLESHOOTING
TM-59
20-502
c
1 c
HM300-1
TROUBLESHOOTING
TM-60
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 ADJUSTING.
Cause
Remedy
1
Disconnect ATC3A and
ATC3B.
Is voltage between ATC3B

NO
1 V?
YES
2
LUB-T.
Is voltage between ATC3B (female) NO

YES

ATC3B.
4
Is resistance between LUB-T
NO
(male) (1) - (2) and between (1) ground as shown in Table 2?
controller
Replace
Defective transmission valve oil

Replace
temperature sensor
Table 2
Table 1
Oil
temperature
Between ATC3B (female)

(9) and ATC3A (female)
(16)
25C
37 50 k
Between ATC3B
(female) (9) and
ground
Min. 1 M
HM300-1
Replace
Defective contact,
Repair or
replace
harness between ATC3B
(female) (9) and LUB-T (female)
(1), or defective contact or
and LUB-T (female) (2)
YES
100C
Defective transmission valve oil

temperature sensor
3
Is resistance between ATC3B (female) NO
(9) - ATC3A (female) (16) and between
(9) - ground as shown in Table 1?
YES
. Turn starting switch OFF.

. Disconnect LUB-T.

between ATC3B (female) (9) Repair or
replace
and LUB-T (female) (1)
3.5 4.0 k
Oil
Between LUB-T (male) (1)
temperature
and (2)
25C
37 50 k
100C
3.5 4.0 k
Between LUB-T
(male) (1) and
ground
Min. 1 M
20-503
1 c
(9)
TROUBLESHOOTING
TM-60
20-504
c
1 c
HM300-1
TROUBLESHOOTING
TM-61
TM-61
FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER):

Nature of failure:When the front brake oil temperature sensor signal were more than 60C, the center brake
oil temperature sensor was less than 10C
Cause
Remedy
1
ATC3B.

NO
1 V?
YES
2
T14.

than 1 V?
NO
YES

Repair or
replace
Defective center brake oil

temperature sensor
Replace
controller
Replace
Defective center brake oil

temperature sensor
Replace
between ATC3B (female) (8) T14 (female) (1) or between
ATC3A (female) (16) - T14
(female) (2)
Repair or
replace
3
ATC3B.

(female) (8) and ATC3A (female)
(16) as shown in Table 1?
NO
YES

Disconnect T14.
4
(1) and (2) as shown in Table 2?
YES
Table 2
Table 1
Oil
temperature
Between ATC3B (female) (8)

and ATC3A (female) (16)
25C
37 50 k
25C
37 50 k
100C
3.5 4.0 k
100C
3.5 4.0 k
HM300-1
Oil
Between T14 (male) (1) and (2)
temperature
20-505
1 c
(9)
TROUBLESHOOTING
TM-61
20-506
c
1 c
HM300-1
TROUBLESHOOTING
TM-62
TM-62
FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT):

Nature of failure:When the center brake oil temperature sensor signal were more than 60C, the front brake
oil temperature sensor was less than 10C
Cause
Remedy
1
ATC3B.

NO
1 V?
YES
2
T15.

than 1 V?
NO
YES

Repair or
replace
Defective front brake oil

temperature sensor
Replace
controller
Replace
Defective front brake oil

temperature sensor
Replace
between ATC3B (female) (3) T15 (female) (1) or between
ATC3A (female) (16) - T15
(female) (2)
Repair or
replace
3
ATC3B.

NO
YES

Disconnect T15.
4
YES
Table 2
Table 1
Oil
temperature

Oil
temperature
Between T15 (male) (1) and (2)
25C
37 50 k
25C
37 50 k
100C
3.5 4.0 k
100C
3.5 4.0 k
HM300-1
20-507
1 c
(9)
TROUBLESHOOTING
TM-62
20-508
c
1 c
HM300-1
TROUBLESHOOTING
TM-63
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
ATC3B.

NO
1 V?
YES
2
TC-SE.

than 1 V?
NO
YES

and TC-SE (female) (1)
Repair or
replace
Defective torque converter oil

temperature sensor
Replace
controller
Replace

temperature sensor
Replace
3
ATC3B.
Is resistance between ATC3B (female) (7) ATC3A (female) (16) and between(7) ground as shown in Table 1?
NO
YES

Disconnect TC-SE.
4
Is resistance between TC-SE
NO
Defective contact,
harness between ATC3B
(female) (7) and TC-SE
(female) (1), or defective
contact or disconnection in
(female) (16) and TC-SE
(female) (2)
YES
Table 2
Table 1
Oil
temperature
Between ATC3B (female)

(7) and ATC3A (female)
(16)
25C
37 50 k
Between ATC3B
(female) (7) and
ground
Oil
temperature
Between TC-SE (male)

(1) and (2)
25C
37 50 k
100C
3.5 4.0 k
Min. 1 M
100C
HM300-1
Repair or
replace
3.5 4.0 k
Between TC-SE
(male) (1) and
ground
Min. 1 M
20-509
1 c
(9)
TROUBLESHOOTING
TM-63
20-510
c
1 c
HM300-1
TROUBLESHOOTING
TM-64
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
ATC3A.
NO
Is voltage between ATC3A (7)

and (16)(17) 0.8 - 2.0 V?
YES
controller
Replace

TC-INT (female) (2)
Repair or
replace
2
Disconnect TC-INT.
Is voltage between TC-INT

(female) (2) and ground 20 - 30
V?
NO
YES
3
Disconnect ATC1 and
TC-INT.
Is resistance between TC-INT

than 1 M?
NO
YES
4
Insert T-adapter to ATC1.
Disconnect TC-INT.
Is voltage between ATC1 (3) and NO

ground 20 - 30 V?
YES
controller
TC-INT (female) (2)
Replace
Repair or
replace
5
Disconnect TC-INT.

than 1 ?
NO
YES
6
TC-INT.

(female) (16)(17) and TC-INT
(female) (3) less than 1 ?
NO
YES
(17) and TC-INT (female) (1)
Repair or
replace
controller
Replace

and TC-INT (female) (3)
Repair or
replace
7
Insert T-adapter to TCINT.
Is voltage between TC-INT (3) NO

YES
To 8
HM300-1
20-511
1 c
(9)
TROUBLESHOOTING
TM-64
From 7
Cause
8
TC-INT.
Is voltage between TC-INT

than 1 V?
NO

Remedy
Repair or
replace
YES
9
TC-INT.

than 1 M?
YES
NO

Repair or
replace

temperature sensor
Replace
20-512
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-65
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
ATC3A.
NO
Is voltage between ATC3A (7) and

(16) (17) 0.8 V?
YES
controller
Replace

between ATC3A (female) (7) and
TC-INT (female) (3)
Repair or
replace
2
TC-INT.
Is voltage between ATC3A (female) NO

YES
pressure sensor
Replace
HM300-1
20-513
1 c
(9)
TROUBLESHOOTING
TM-66
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
ATC3B.

NO
1 V?
YES
2
T08.

than 1 V?
NO
YES

Repair or
replace
Replace
controller
Replace
3
ATC3B.

(female) (4) - ATC3A (female)
NO
YES

Disconnect T08.
4
(1) (2) as shown in Table 2?
and T08 (female) (1) or
YES
Table 1
Replace
Repair or
replace
Table 2
Fuel tank

Fuel tank
Between T08 (male)

(1) and (2)
Full
Max. 12
Full
Max. 12
Empty
74 100
Empty
74 100
20-514
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-67
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
ATC3A and ATC3B.
NO
Is voltage between ATC3B (11)

and ATC3A (16) 1.0 - 4.0 V?
YES
controller
Replace

and AS2 (female) (1)
Repair or
replace

Repair or
replace
controller
Replace
Repair or
replace
2
Is voltage between AS2 (1) and NO

ground 4.6 - 5.4 V?
YES
3
AS2.
Is voltage between AS2 (female) NO

YES
4
AS2.
Is resistance between AS2

than 1 M?
NO
YES
Insert T-adapter to
ATC3A.
Disconnect AS2.
5
Is voltage between ATC3A (6) NO
YES
6
Disconnect AS2.

than 1 ?
NO
YES
7
AS2.

(female) (16) and AS2 (female)
(3) less than 1 ?
YES
NO
Repair or
replace
controller
Replace
To 8
HM300-1
20-515
1 c
(9)
TROUBLESHOOTING
TM-67
From 7
Cause
Remedy
8
NO
Is voltage between AS2 (2) and

ground 1.0 - 4.0 V?
YES
9
AS2.
Is voltage between AS2 (female)

NO
Repair or
replace

Repair or
replace

Repair or
replace
Defective accelerator sensor or

defective accelerator pedal
Replace
YES
10
AS2.

than 1 M?
YES
NO
20-516
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-68
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
Disconnect ATC3A.

NO
(female) (13) and (14) 500 - 1000
?
YES
2
Disconnect EREV.
NO
Is resistance between EREV
(male) (1) and (2) 500 - 1000 ?
and EREV (female) (1) or
and EREV (female) (2)
YES
3
See TESTING AND
ADJUSTING.
Start engine.

when engine speed sensor is
adjusted?
NO
Replace
Repair or
replace
controller
Replace
Defective adjustment of engine

speed sensor
Adjust
YES
HM300-1
20-517
1 c
TROUBLESHOOTING
TM-69
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 transmission input shaft speed sensor inputs more than 500 rpm
Cause
Remedy
1
Disconnect ATC3A.
Is voltage between ATC3A

than 1 V?
NO
YES
2
EREV.

than 1 V?
NO

Repair or
replace
Replace
controller
Replace
Replace

Repair or
replace
YES
3
Disconnect ATC3A.

than 1 M?
NO
YES

Disconnect EREV
4
Is resistance between EREV
NO
(male) (1) and ground more than
1 M?
YES
20-518
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-70
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
Cause
Remedy
1
Disconnect ATC3A.

(female) (2) and (14) 500 - 1000
?
NO
YES
2
Disconnect N1.
NO
Is resistance between N1 (male)

(1) and (2) 500 - 1000 ?
and N1 (female) (1) or between
ATC3A (female) (14) and N1
(female) (2)
YES
3
See TESTING AND
ADJUSTING.
Start engine.

when transmission input shaft
speed sensor is adjusted?
YES
Defective transmission input

shaft speed sensor
NO
Replace
Repair or
replace
controller
Replace
Defective adjustment of
transmission input shaft speed
sensor
Adjust
HM300-1
20-519
1 c
(9)
TROUBLESHOOTING
TM-71
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
Cause
Remedy
1
Disconnect ATC3A.

NO
1 V?
YES
2
N1.

than 1 V?
NO
YES

and N1 (female) (1)
Repair or
replace

shaft speed sensor
Replace
controller
Replace

shaft speed sensor
Replace

and N1 (female) (1)
Repair or
replace
3
Disconnect ATC3A.

than 1 M?
NO
YES

Disconnect N1.
4
Is resistance between N1 (male) NO
YES
20-520
!
1 !
(9)
HM300-1
TROUBLESHOOTING
TM-72
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
Cause
Remedy
1
Disconnect ATC3A.

NO
(female) (12) and (14) 500 - 1000
?
YES
2
Disconnect N2.
NO

(1) and (2) 500 - 1000 ?
(female) (2)
YES
3
See TESTING AND
ADJUSTING.
Start engine.

when transmission intermediate
shaft speed sensor is adjusted?
YES

Replace
shaft speed sensor
NO
Repair or
replace
controller
Replace
transmission intermediate shaft
speed sensor
Adjust
HM300-1
20-521
1 c
(9)
TROUBLESHOOTING
TM-73
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, transmission input shaft speed sensor signal, and output shaft R speed sensor signal, and the
speed of the transmission intermediate shaft sensor signal
Cause
Remedy
1
Disconnect ATC3A.

than 1 V?
NO
YES
2
N2.

than 1 V?
NO
YES

and N2 (female) (1)
Repair or
replace

shaft speed sensor
Replace
controller
Replace

shaft speed sensor
Replace

and N2 (female) (1)
Repair or
replace
3
Disconnect ATC3A.

than 1 M?
NO
YES
4
Disconnect N2.

YES
20-522
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-74
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 sensor and the signal is not input
Cause
Remedy
1
BRC3A.

(female) (3) and (14) 500 - 1000
?
NO
YES
2
Disconnect N3.

(1) and (2) 500 - 1000 ?
NO
YES
See TESTING AND

ADJUSTING.
Start engine.
3
NO
when transmission output shaft R
speed sensor is adjusted?
YES
Defective transmission output

(female) (2)
Replace
Repair or
replace
controller
Replace
transmission output shaft R
speed sensor
Adjust
HM300-1
20-523
1 c
(9)
TROUBLESHOOTING
TM-75
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, transmission input shaft speed sensor signal, and intermediate shaft speed sensor signal, and
the speed of the transmission output shaft R sensor signal
Cause
Remedy
1
BRC3A.

than 1 V?
NO
YES
2
Disconnect ATC3A,
BRC3A, and N3.

than 1 V?
NO
YES

between ATC3A (female) (3) BRC3A (female) (13) - N3
(female) (1)
Repair or
replace

Replace
3
BRC3A.

than 1 M?
NO
YES

Disconnect N3.
4
YES
5
replaced?

between ATC3A (female) (3) BRC3A (female) (13) - N3
(female) (1)
Replace
Repair or
replace
YES
controller
Replace
20-524
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TM-75
HM300-1
20-525
1 !
TROUBLESHOOTING
TM-76
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
Disconnect ATC2.
NO

(female) (8) and (18) 5 15 ?
YES
2
Disconnect D/L-PS.

(male) (1) and (2) 5 15 ?
YES
NO
controller
Replace
Defective differential lock clutch

solenoid
Replace

(female) (8) and D/L-PS (female)
(1) or between ATC2 (female) (18)
and D/L-PS (female) (2)
Repair or
replace
20-526
!
1 !
HM300-1
TROUBLESHOOTING
TM-77
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
NO
YES

Disconnect D/L-PS.
2
NO
YES
3
Disconnect ATC2 and
D/L-PS.

(female) (8) - (18) - ground less
than 1 V?
NO
YES
Table 1
ATC2 (female)
Defective differential lock clutch

solenoid
Replace

(female) (8) and D/L-PS (female)
(1) or short circuit in wiring
(18) and D/L-PS (female) (2)
Repair or
replace

D/L-PS (female) (1) or between
(female) (2)
Repair or
replace
controller
Replace
Table 2
Resistance value
D/L-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-527
1 c
(9)
TROUBLESHOOTING
TM-78
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
Disconnect ATC2.
NO

(female) (10) and (20) 5 15 ?
YES
controller
Replace

solenoid
Replace
2
Disconnect L/C-PS.

(male) (1) and (2) 5 15 ?
YES
NO

(female) (10) and L/C-PS (female)
(1) or between ATC2 (female) (20)
and L/C-PS (female) (2)
Repair or
replace
20-528
c
1 c
HM300-1
TROUBLESHOOTING
TM-79
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.

NO
(female) (10) - (20) and between
YES

Disconnect L/C-PS.
2
NO
YES
3
Disconnect ATC2 and
L/C-PS.

(female) (10)(20) - ground less
than 1 V?
NO
YES

solenoid
Replace

Repair or
(female) (10) and L/C-PS (female)
replace
(20) and L/C-PS (female) (2)
L/C-PS (female) (1) or between
(female) (2)
Repair or
replace
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
L/C-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-529
1 c
(9)
TROUBLESHOOTING
TM-80
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
Disconnect ATC2.
NO

(female) (4) and (15) 5 15 ?
YES
controller
Replace
Replace

(female) (4) and H-PS (female) (1)
or between ATC2 (female) (15)
and H-PS (female) (2)
Repair or
replace
2
Disconnect H-PS.
Is resistance between H-PS (male) NO

(1) and (2) 5 15 ?
YES
20-530
c
1 c
HM300-1
TROUBLESHOOTING
TM-81
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.

NO
(female) (4) - (15) and between (4)
YES

Disconnect H-PS.
2
Is resistance between H-PS
NO
YES
3
Disconnect ATC2 and HPS.

than 1 V?
NO
YES

(15) and H-PS (female) (2)
Replace
Repair or
replace

between ATC2 (female) (4) and H- Repair or
PS (female) (1) or between ATC2 replace
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
H-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-531
1 c
(9)
TROUBLESHOOTING
TM-82
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
Disconnect ATC2.
NO

(female) (7) and (17) 5 15 ?
YES
controller
Replace
Replace

(female) (7) and L-PS (female) (1)
and L-PS (female) (2)
Repair or
replace
2
Disconnect L-PS.
Is resistance between L-PS (male)

(1) and (2) 5 15 ?
YES
NO
20-532
c
1 c
HM300-1
TROUBLESHOOTING
TM-83
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
Disconnect ATC2.

NO
YES

Disconnect L-PS.
2
Is resistance between L-PS
NO
YES
3
Disconnect ATC2 and LPS.

than 1 V?
NO
YES
Replace

Repair or
(female) (7) and L-PS (female) (1)
replace
or short circuit in wiring harness
L-PS (female) (2)
between ATC2 (female) (7) and L- Repair or
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
L-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-533
1 c
(9)
TROUBLESHOOTING
TM-84
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
Disconnect ATC2.
NO

(female) (2) and (13) 5 15 ?
YES
controller
Replace
Replace

(female) (2) and 1-PS (female) (1)
and 1-PS (female) (2)
Repair or
replace
2
Disconnect 1-PS.

(1) and (2) 5 15 ?
YES
NO
20-534
c
1 c
HM300-1
TROUBLESHOOTING
TM-85
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
Disconnect ATC2.

NO
YES

Disconnect 1-PS.
2
NO
YES
3
Disconnect ATC2 and 1PS.

than 1 V?
NO
YES
Replace

Repair or
replace
1-PS (female) (2)
between ATC2 (female) (2) and 1- Repair or
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
1-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-535
1 c
(9)
TROUBLESHOOTING
TM-86
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
Disconnect ATC2.
NO

(female) (9) and (19) 5 15 ?
YES
controller
Replace
Replace

Repair or
replace
2
Disconnect 2-PS.

(1) and (2) 5 15 ?
YES
NO
20-536
c
1 c
HM300-1
TROUBLESHOOTING
TM-87
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
Disconnect ATC2.

NO
YES

Disconnect 2-PS.
2
NO
YES
3

than 1 V?
NO
YES
Replace

Repair or
replace
2-PS (female) (2)
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
2-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-537
1 c
(9)
TROUBLESHOOTING
TM-88
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
Disconnect ATC2.
NO

(female) (3) and (13) 5 15 ?
YES
controller
Replace
Replace

Repair or
replace
2
Disconnect 3-PS.

(1) and (2) 5 15 ?
YES
NO
20-538
c
1 c
HM300-1
TROUBLESHOOTING
TM-89
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
Disconnect ATC2.

NO
YES

Disconnect 3-PS.
2
NO
YES
3

than 1 V?
NO
YES
Replace

Repair or
replace
3-PS (female) (2)
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
3-PS (male)
Resistance value
5 15
Between (1) and (2)
5 15
Min. 1 M
Min. 1 M
HM300-1
20-539
1 c
(9)
TROUBLESHOOTING
TM-90
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
Disconnect ATC2.
NO

(female) (5) and (15) 5 15 ?
YES
controller
Replace
Replace

(female) (5) and R-PS (female) (1)
and R-PS (female) (2)
Repair or
replace
2
Disconnect R-PS.
Is resistance between R-PS (male) NO

(1) and (2) 5 15 ?
YES
20-540
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-91
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
Disconnect ATC2.

NO
YES

Disconnect R-PS.
2
Is resistance between R-PS
NO
YES
3
Disconnect ATC2 and RPS.

than 1 V?
NO
YES
Replace

(15) and R-PS (female) (2)
Repair or
replace

between ATC2 (female) (5) and R- Repair or
(2)
controller
Replace
Table 2
Table 1
ATC2 (female)
Resistance value
R-PS (male)
Resistance value
5 - 15
Between (1) and (2)
5 - 15
Min. 1 M
Min. 1 M
HM300-1
20-541
1 c
(9)
TROUBLESHOOTING
TM-92
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)
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.
a)
Cause
Remedy
1
Does condition become normal when

backup lamp and buzzer relay (R05) is
NO
YES
2
Disconnect R05.
Gearshift lever: R1, R2

(5) and ground 20 - 30 V?
Defective backup lamp, buzzer

relay (R05)
Replace
wiring harness at dividing point
Repair or
replace
ground
Repair or
replace
between BT1-16 outlet and R05
(female) (2) (4)
Repair or
replace
between CJK (female) (6) and
ground
Repair
replace
YES
3
Disconnect R05.

than 1 ?
NO
YES
4
Disconnect R05.

(2)(4) - ground 20 - 30 V?
YES
NO
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
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TM-92
d) Backup lamp do not work (Backup buzzer works normally)
Cause
Remedy
1
Do back-up lamps light up normally,

NO
if the back-up lamp and alarm buzzer
relay (R05) is replaced with another?
YES
Back-up lamp and alarm buzzer
relay (R05) faulty
Replace
Wiring harness between R05

(female) (1) and BL47 (female) (1)
either disconnected or connected
defectively
Repair or
replace
2
NO
Is voltage between BL47 (1) and

grounding 20 30 V?
YES
3
Disconnect BL47 and CJK.
Is resistance value of the wiring harness NO

between BL47 (female) (2) and CJK
(female) (5) less than 1?
YES
Wiring harness between BL47

(female) (2) and CJK (female) (5)
either disconnected or connected
defectively
Repair or
replace
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

the back-up lamp and alarm buzzer relay
(R05) is replaced with another?
YES
Back-up lamp and alarm buzzer

relay (R05) faulty
Replace
Wiring harness between R05 (female)

(3) and CJK (female) (8) either
disconnected or connected defectively
Repair or
replace
Wiring harness between back-up

alarm buzzer terminal 49 and CJK
(female) (1) either disconnected or
connected defectively
Repair or
replace
Wiring harness between back-up

alarm buzzer terminal 41 and CJK
(female) (7) either disconnected or
connected defectively
Repair or
replace
Back-up alarm buzzer faulty
Replace
2
Is voltage between the back-up alarm NO

buzzer terminal (49) and grounding 20
30 V?
YES
3
NO
Is voltage between CJK (8) and

grounding 20 30 V?
YES
4
Disconnect terminal 41
and CJK.
Is resistance value of the wiring harness

NO
between back-up lamp and buzzer terminal 41
and CJK (female) (7) less than 1 ?
YES
HM300-1
20-543
1 c
(9)
TROUBLESHOOTING
f)
TM-92
Gearshift lever is not operated to R1 or R2, but backup lamp and backup buzzer are actuated
Cause
YES
Disconnect R05.
Gearshift lever: Other
than R1, R2
Remedy
1
backup lamp and buzzer relay (R05)
Defective backup lamp, buzzer
relay (R05)
Replace
2
Is voltage between R05
than 1 V?
NO

R05 (female) (5) - D05 (female) (1) Repair or
replace
- D06 (female) (1)
NO

R05 (female) (1) and BL47 (female) Repair or
replace
(1)
YES
3
Disconnect R05.

YES
Hot short in wiring harness between Repair or

R05 (female) (3) and backup buzzer replace
20-544
!
1 !
(9)
HM300-1
TROUBLESHOOTING
TM-93
TM-93
EMERGENCY STEERING DOES NOT OPERATE
Failure content (1) When steering pump stops, automatic emergency steering does not operate.
General
information
Check that the parking brake is released.

Causes
1 Defective fuse (16)
Standard values when normal and remarks for troubleshooting

If fuse (16) is broken, circuit probably has ground fault. (Check it in
item 8.)
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Connect T-adapter to B17 (male).
Defective parking brake

switch (Internal contact)
B17 (male)
Between (1) (2)
Operation of parking brake
Resistance
Released (Closed)
Max. 1 z
Operated (Open)
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Connect T-adapter to E02 (male).
3
Defective flow switch

(Internal contact)
E02 (male)
Between (1) (2)
Steering pump
Resistance
Operated (Open)
Min. 1 Mz
Stopped (Closed)
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
Possible causes
and the
standard values
when normal
Defective emergency
4
steering timer
1) Between relay terminal (7) ground
Voltage
20 30V
Voltage
20 30V
Voltage
20 30V
If voltage is normal in 1) above and abnormal 2) and 3), timer is

defective.
If voltage is abnormal in 1), carry out troubleshooting in item 7.
Defective emergency
5
steering relay
Voltage
20 30V
Voltage
20 30V
Voltage
20 30V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
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
Defective emergency
6
steering motor
Voltage
20 30V
Between motor terminal E-2 ground
Voltage
20 30V
If result of above troubleshooting is normal, starting motor is

defective.
HM300-1
20-545
1
(10)
TROUBLESHOOTING
TM-93
Causes

Disconnection in wiring
7 harness (Disconnection in
wiring or defective contact)
Possible causes
and the
standard values
when normal
Wiring harness between fuse (16) B17

(female) (1)
Resistance
Max. 1 z
Wiring harness between B17 (female) (2)

CJR (female) (1)
Resistance
Max. 1 z
Wiring harness between CJR (female) (2)

E02 (female) (2)
Resistance
Max. 1 z
Wiring harness between E02 (female) (1)

timer terminal (7)
Resistance
Max. 1 z
Wiring harness between timer terminal (8)

relay terminal (61)
Resistance
Max. 1 z
Wiring harness between relay terminal (77)

motor terminal M-2
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between motor terminal e-2

ground
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

battery (+)
Resistance
Max. 1 z
Ground fault in wiring

8 harness
(Contact with GND circuit)
20-546
1
(10)
Between wiring harness fuse (16) B17

Resistance
Min. 1 Mz
Between wiring harness B17 (female) (2)

CJR (female) (1) and ground
Resistance
Min. 1 Mz
Between wiring harness CJR (female) (2)

E02 (female) (2) and ground
Resistance
Min. 1 Mz
Between wiring harness E02 (female) (1)

timer terminal (7) and ground
Resistance
Min. 1 Mz
Between wiring harness timer terminal (8)

relay terminal (61) and ground
Resistance
Min. 1 Mz
Between wiring harness relay terminal (77)

motor terminal M-2 and ground
Resistance
Min. 1 Mz
Between wiring harness timer terminal (6)

manual switch terminal ST1 and ground
Resistance
Min. 1 Mz
HM300-1
TROUBLESHOOTING
TM-93
Failure content (2) When steering pump stops, emergency steering cannot be operated manually.
General
information
Carry out following troubleshooting when automatic emergency steering operates. (If automatic emergency steering does not operate either, carry out troubleshooting for trouble (1) first.)
Causes

1
Possible causes
and the
standard values
when normal
HM300-1
Defective manual switch

(Internal contact)
Manual switch
terminal
Operation of manual
switch
Resistance
Between ST1 ST2

(Switch unit)
Switch (Pressed)
Max. 1 z
Switch (Released)
Min. 1 Mz
Disconnection in wiring
harness (Disconnection in
Resis2
Max. 1 z
wiring or defective contact in manual switch terminal ST1
tance
connector)
Wiring harness between manual switch terResisMax. 1 z
minal ST2 relay terminal (61)
tance
20-547
1
(10)
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF
RETARDER CONTROLLER(q1)
SYSTEM (BK MODE)
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ......................................................................

BK-1
Failure code [2G42ZG] (Accumulator (front): Drop in oil pressure (ZG)) .................................
BK-2
Failure code [2G43ZG] (Accumulator (rear): Drop in oil pressure (ZG)) ..................................
BK-3
Failure code [D1C0KZ] (Brake cut relay: Disconnection or short circuit (KZ)) .........................
BK-4
Failure code [D5ZFKZ] (Neutral signal 1: Disconnection or short circuit (KZ)) ........................
BK-5
Failure code [D5ZGKZ] (Neutral signal 2: Disconnection or short circuit (KZ)) ........................
BK-6
Failure code [DB10KK] (Retarder controller: Drop in power supply voltage, input (KK)) .........
BK-7
Failure code [DB11KK] (Retarder controller main power supply line: Drop in power supply
voltage, input (KK)) ............................................................................
BK-8
Failure code [DB12KK] (Retarder controller load power supply line:
Drop in power supply voltage, input (KK)) .........................................
BK-9
Failure code [DB13KK] (Retarder controller battery direct power supply line:
Drop in power supply voltage, input (KK)) .........................................
BK-10 Failure code [DB19KM] (Retarder controller wiring harness:
Mistaken operation or mistaken setting (KM)) ...................................
BK-11 Failure code [DB1SKQ] (Retarder controller S-NET line:
Model selection signal mismatch (KQ)) ............................................
BK-12 Failure code [DHU2KX] (Accumulator oil pressure sensor (front):
Input signal outside range (KX)) ........................................................
BK-13 Failure code [DHU3KX] (Accumulator oil pressure sensor (rear):
Input signal outside range (KX)) ........................................................
BK-14 Failure code [DK51L5] (Retarder lever potentiometer: * See separate table (L5)) ..................
BK-15 Failure code [DK52KX] (Dump lever potentiometer 1: Input signal outside range (KX)) ..........
BK-16 Failure code [DK53L8] (Dump lever potentiometer 2: * See the table in Contents. (L8)) .........
BK-17 Failure code [DK54KX] (Body positioner sensor: Input signal outside range (KX)) .................
BK-18 Failure code [DLF4KA] (Transmission output shaft F speed sensor: Disconnection (KA)) ......
BK-19 Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnection (KA)) ......
BK-20 Failure code [DW71KZ] (Exhaust brake solenoid: Disconnection or short circuit (KZ)) ...........
BK-21 Failure code [DW72KZ] (Dump lever kick-out solenoid: Disconnection or short circuit (KZ)) ..
BK-22 Failure code [DW73KZ] (Dump selector valve solenoid: Disconnection or short circuit (KZ)) .
BK-23 Failure code [DX11KA] (Rear brake pressure reducing valve
solenoid: Disconnection (KA)) ...........................................................
BK-24 Failure code [DX11KB] (Rear brake pressure reducing valve solenoid:
Short circuit (KB)) ..............................................................................
BK-25 Failure code [DX11KY] (Rear brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) .............................................
BK-26 Failure code [DX12KA] (Front brake pressure reducing valve solenoid: Disconnection (KA)) .
BK-27 Failure code [DX12KB] (Front brake pressure reducing valve solenoid: Short circuit (KB)) ....
BK-28 Failure code [DX12KY] (Front brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) .............................................
BK-29 Failure code [DX13KA] (Dump EPC valve solenoid: Disconnection (KA)) ...............................
BK-30 Failure code [DX13KB] (Dump EPC valve solenoid: Short circuit (KB)) ..................................
BK-31 Failure code [DX13KY] (Dump EPC valve solenoid: Short circuit in power supply line (KY)) ..
BK-32 Parking brake does not work properly ......................................................................................
HM300-1
20-604
20-610
20-622
20-622
20-623
20-625
20-626
20-627
20-629
20-630
20-631
20-632
20-633
20-634
20-636
20-638
20-641
20-643
20-644
20-646
20-647
20-648
20-649
20-651
20-653
20-654
20-655
20-656
20-657
20-658
20-659
20-660
20-661
20-662
20-601
1 c
(9)
4
TROUBLESHOOTING
* Failure phenomena of L Series problem codes (L*)*

Problem code
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
L6
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch, 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
20-602
c
Nature of problem (phenomenon, nature of problem that occurs)
1 c
(9)
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-604
!
1 !
HM300-1
TROUBLESHOOTING
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)
TROUBLESHOOTING
TROUBLESHOOTING
20-606
c
1 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
HM300-1
20-607
1 !
TROUBLESHOOTING
TROUBLESHOOTING
20-608
!
1 !
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING


Failure code
Location of failure
Probable cause
2G42ZG
(BK-1)
Accumulator (front):
Defective hydraulic, mechanical system

With engine running (continuof front accumulator
ously for at least 30 seconds), oil
pressure of less than 6.86 MPa
{70 kg/cm2} was input for front
accumulator oil pressure sensor
signal
2G43ZG
(BK-2)
Accumulator (rear): Drop in

oil pressure (ZG)
With engine running (continu Defective hydraulic, mechanical system

ously for at least 30 seconds), oil
of rear accumulator
pressure of less than 6.86 MPa
{70 kg/cm2} was input for rear
signal
D1C0KZ
(BK-3)
Brake cut relay: Disconnection or short circuit (KZ)
When output is sent to brake cut Defective brake cut relay

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
(BK-4)
Neutral signal 1: Disconnec- When output is sent to neutral

signal 1 circuit, excessive electric current flows; when there is
output, no electric current flows

Disconnection or short circuit with chassis ground in signal 1 circuit wiring harness
D5ZGKZ
(BK-5)
Neutral signal 2: Disconnec- When output is sent to neutral

signal 2 circuit, excessive electric current flows; when there is
output, no electric current flows

DB10KK
(BK-6)
Retarder controller(q1): Drop Both main power source voltage Other problem occurs at same time (failin 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
Disconnection or short circuit with chassis ground in power source circuit
wiring harness
DB11KK
(BK-7)
Retarder controller(q1) main

power supply voltage, input
(KK)
Voltage difference between

main power source voltage circuit and direct power source
voltage went below 5 V (main
power source < direct power
source)
DB12KK
(BK-8)
Retarder controller(q1) load

power supply voltage, input
(KK)
When controller power source

Defective brake cut relay
voltage circuit was normal, sole- Disconnection or short circuit with chasnoid power source voltage cirsis ground in relay power source circuit
cuit went below 17 V
wiring harness
Disconnection or short circuit with chassis ground in relay output circuit wiring
harness
20-610
c
Nature of failure
1
(9)
4 c
Disconnection or short circuit with chassis ground in main power source circuit
wiring harness
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
Takes no action

there is danger that the brake will
lose its effect
E03
Takes no action

there is danger that the brake will
lose its effect
E03

Turns output to brake cut relay The whole system of the retarder
R14 (male) (1) (2): 100 500 OFF
controller(q1) stops working (retarder, inter-axle differential lock,
dump, exhaust brake, neutral signal)
Failure codes (DB12KK,
DHU2KX, DHU3KX) are displayed at same time
E03
Turns neutral signal 1 and sig- Even when transmission output

nal 2 OFF
shaft F speed goes above 4200
rpm, the transmission does not
shift to N
E01
Turns neutral signal 1 and sig- Even when transmission output

nal 2 OFF
shift to N
E01

Takes no action (moves as
BRC1 (9)(17) (8)(16): 20 30 V long as it is possible to actuate)
BRC1 (7) (8)(16): 20 30 V
E03

Takes no action
BRC1 (9)(17) (8)(16): 20 30 V
E03
The whole system of the retarder

controller(q1) stops working (retarder, inter-axle differential lock,
Failure codes (DHU2KX,
DHU3KX) are displayed at same
time
E03
Solenoid power source voltage

BRC2 (1)(12) BRC1 (8)(16):
20 30 V
Turns all output circuits OFF

Turns 24V power supply of
sensor OFF
HM300-1
20-611
1 c
(9)
4
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
DB13KK
(BK-9)
Retarder controller(q1) bat- Voltage of direct power source

tery direct power supply line: voltage circuit went below 5 V
Drop in power supply voltage,
input (KK)
DB19KM
(BK-10)
Retarder controller(q1) wir- When starting switch is ON, in- Mistaken connection of connector BRC3
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
harness
DB1SKQ
(BK-11)
Retarder controller(q1) SCommunication (S-NET) with

Other problem occurs at same time (failNET line: Model selection sig- transmission controller is defecure 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
(BK-12)
Accumulator oil pressure

sensor (front): Input signal
outside range (KX)
Voltage of signal circuit of front Defective front accumulator oil pressure

sensor
went below 0.5 V or above 4.5 V Disconnection or short circuit with chassis ground in sensor power source circuit
wiring harness
DHU3KX
(BK-13)
Accumulator oil pressure

sensor (rear): Input signal
outside range (KX)
Defective rear accumulator oil pressure

Voltage of signal circuit of rear
sensor
went below 0.5 V or above 4.5 V Disconnection or short circuit with chassis ground in sensor power source circuit
wiring harness
Disconnection or short circuit with chassis ground in direct power source circuit
wiring harness
20-612
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING


Action code

BRC1 (7) (8)(16): 20 30 V
Takes no action
E03

BRC5A (female) (1) ground:
Max. 1
Turns all outputs OFF

Does not record in trouble data controller(q1) stops working (retarder, inter-axle differential lock,
E03
Only inter-axle differential lock Inter-axle differential lock system

system is not controlled
does not work
E03

B25 (2) (1): 20 30 V
B25 (3) (1): 000 000 V
Takes no action
E01

B24 (2) (1): 20 30 V
B24 (3) (1): 1.8 3.5 V
Takes no action
E01
HM300-1
20-613
1 c
(9)
4
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
DK51L5
(BK-14)
Retarder lever potentiometer: Signal voltage of potentiometer Defective retarder lever(q2) (potentiom* See separate table (L5)
of retarder lever circuit went beeter, 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 circuit wiring harness
ground, or hot short in potentiometer signal signal circuit wiring harness
ground, or hot short in switch 1 circuit
wiring harness
ground, or hot short in switch 2 circuit
wiring harness
DK52KX
(BK-15)
Dump lever potentiometer 1: Voltage of potentiometer 1 sig- Defective dump lever (potentiometer)
Input signal outside range
nal circuit or potentiometer 2 sig- Disconnection, short circuit with chassis
ground, or hot short in power source cir(KX)
nal circuit went below 0.3 V or
above 4.7 V
cuit wiring harness
DK53L8
(BK-16)
Dump lever potentiometer 2: Total voltage of potentiometer 1 Defective dump lever (potentiometer)
* See Contents (L8)
signal circuit and potentiometer Disconnection, short circuit with chassis
ground, or hot short in power source cir2 signal circuit went below 4.4 V
or above 5.6 V
cuit wiring harness

q2. The lever is not installed in E-SPEC.
20-614
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

voltage
RTL (1) (3): 4.1 4.8 V
Potentiometer signal voltage
RTL (2) (3): 0.3 4.7 V
(lever at RELEASED position)
RTL (male) (4) (6):
Max. 1
RTL (male) (5) (6):
Min. 1 M
Switch resistance value (lever
at APPLIED position)
RTL (male) (4) - (6):
Min. 1 M
RTL (male) (5) - (6): Max. 1
Depending on condition of occurrence of failure

Carries out control with potentiometer signal
Limits output to solenoid to
70%
Turns output to solenoid OFF
Depending on nature of action

Fine control of retarder is impossible (which is not used in E-SPEC)
Retarder does not work (foot
brake works) (which is not used in
E-SPEC)
E03

voltage
HSL (4) (1): 4.6 5.4 V
HSL (3) (1) (signal 1):
0.3 4.7 V
HSL (2) (1) (signal 2):
0.3 4.7 V
Recognizes dump lever position as HOLD
Dump body does not move
E03

voltage
HSL (4) (1): 4.6 5.4 V
HSL (3) (1) (signal 1):
0.3 4.7 V
HSL (2) (1) (signal 2):
0.3 4.7 V
Recognizes dump lever position as HOLD
E03
HM300-1
20-615
1 c
(9)
4
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
DK54KX
(BK-17)
Body positioner sensor: Input Voltage of body positioner sen- Defective body positioner sensor
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
DLF4KA
(BK-18)
Transmission output shaft F Disconnection has occurred in

Defective transmission output shaft F
speed sensor: Disconnection signal circuit of transmission
(KA)
output shaft F speed sensor and Disconnection in sensor signal wiring
signal is not input
harness
DLT3KA
(BK-19)
Defective transmission output shaft R

Transmission output shaft R Disconnection has occurred in
speed sensor: Disconnection signal circuit of transmission
(KA)
output shaft R speed sensor and Disconnection in sensor signal wiring
signal is not input
harness
DW71KZ
(BK-20)
Exhaust brake solenoid: Disconnection or short circuit

(KZ)
(Machine with exhaust brake)
DW72KZ
(BK-21)
Dump lever kick-out solenoid: When output is sent to dump le- Defective dump lever (kick-out solenoid)
Disconnection or short circuit ver kick-out solenoid circuit, ex- Disconnection, short circuit with chassis
cessive electric current flows;
(KZ)
ground, or hot short in solenoid signal cirwhen 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
(BK-22)
Dump selector valve solenoid: Disconnection or short

circuit (KZ)
When output is sent to exhaust Defective exhaust brake solenoid

brake solenoid circuit, excessive Disconnection, short circuit with chassis
electric current flows; when
ground, or hot short in solenoid signal cirthere is output, no electric curcuit wiring harness
rent flows; when output is OFF, Disconnection in solenoid GND circuit
electric current flows
wiring harness
When output is sent to dump se- Defective dump pilot valve (selector solector valve solenoid circuit, exlenoid)
cessive electric current flows;
when there is output, no electric
ground, or hot short in solenoid signal circurrent flows; when output is
cuit wiring harness
Disconnection in solenoid GND circuit
OFF, electric current flows
wiring harness
20-616
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

B34 (3) (1): 4.6 5.4 V
B34 (2) (1)
When seated: 0.30 0.46 V
When fully raised: 4.00 4.70 V

Carries out dump control ac There is a big shock when dump

cording to signal from dump le- body is seated
ver
Dump lever positioner function
Recognizes that dump body is
does not work
not seated when carrying out Maximum travel speed range is
control
limited
Machine cannot travel in reverse
if dump lever is not at FLOAT
Action code
E03

Cancels inter-axle differential Inter-axle differential lock does
FE1 (male) (1) (2): 500 1000 lock command
not work
Does not output neutral signal Even when transmission output
shift to N
E01

Cancels inter-axle differential
N3 (male) (1) (2): 500 1000 lock command

not work
E01

B29 (male) (1) (2): 20 60
Exhaust brake does not work
E01

Turns output to dump lever
LKO (male) (1) (2): 39 5% kick-out solenoid OFF
Dump lever is not locked in detent
E01

B31 (male) (1) (2): 15 35
E03
HM300-1
Turns output to exhaust brake

solenoid OFF
Turns output to dump selector

valve solenoid OFF
Turns output to dump EPC
valve solenoid OFF
20-617
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
Probable cause
When output is sent to rear

brake pressure reducing valve
solenoid circuit, no electric current flows
Defective rear brake pressure reducing

valve solenoid
DX11KA
(BK-23)
Rear brake pressure reducing valve solenoid: Disconnection (KA)
DX11KB
(BK-24)
Rear brake pressure reduc- When output is sent to rear

Defective rear brake pressure reducing
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 harness
DX11KY
(BK-25)
Rear brake pressure reduc- When output to rear brake pres- Hot short in solenoid (+) circuit wiring
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
(BK-26)
Front brake pressure reducing valve solenoid: Disconnection (KA)
DX12KB
(BK-27)
Front brake pressure reduc- When output is sent to front

Defective front brake pressure reducing
valve solenoid
ing valve solenoid: Short cir- brake pressure reducing valve
solenoid circuit, excessive elec- Short circuit or short circuit with chassis
cuit (KB)
ground in solenoid (+) circuit wiring hartric current flows
ness
DX12KY
(BK-28)
Front brake pressure reduc- When output to front brake pres- Hot short in solenoid (+) circuit wiring
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
(BK-29)
Dump EPC valve solenoid:

Disconnection (KA)
When output is sent to front

brake pressure reducing valve
solenoid circuit, no electric current flows
When output is sent to dump

EPC valve solenoid circuit, no
Defective front brake pressure reducing

valve solenoid
Defective dump pilot valve (EPC solenoid)

20-618
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code

B18 (male) (1) (2): 10 30
Turns output to rear brake

pressure reducing valve solenoid OFF
Rear brake (center brake) does

not work
E03

B18 (male) (1) (2): 10 30

Rear brake (center brake) does

not work
E03

pressure reducing valve solecontroller(q1) stops working (renoid OFF
tarder, inter-axle differential lock,
Turns output to brake cut relay
dump, exhaust brake, neutral sigOFF
nal)
E03

B19 (male) (1) (2): 10 30
Turns output to front brake

Front brake does not work
E03

B19 (male) (1) (2): 10 30

Front brake does not work
E03

B32 (male) (1) (2): 5 20

pressure reducing valve solecontroller(q1) stops working (renoid OFF
tarder, inter-axle differential lock,
Turns output to brake cut relay
left and right differential lock,
OFF
E03
Turns output to dump selector Dump body does not work

valve solenoid OFF
valve solenoid OFF
E03
HM300-1
20-619
1 !
4
(9)
TROUBLESHOOTING
TROUBLESHOOTING
Failure code

Location of failure
Nature of failure
When output is sent to dump
EPC valve solenoid circuit, excessive electric current flows
Probable cause
DX13KB
(BK-30)

Short circuit (KB)
Defective dump pilot valve (EPC solenoid)

Short circuit or short circuit with chassis
ground in solenoid (+) circuit wiring harness
DX13KY
(BK-31)

When output to dump EPC valve Hot short in solenoid (+) circuit wiring
Short circuit in power source solenoid circuit is OFF, electric
harness
line (KY)
current flows
harness
20-620
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

B32 (male) (1) (2): 15 20
HM300-1

Action code

valve solenoid OFF
valve solenoid OFF
Dump body does not work
E03

valve solenoid OFF
valve solenoid OFF
Dump body does not work
E03
20-621
1 c
(9)
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
See TESTING AND
ADJUSTING.
NO
Has accumulator oil pressure

(brake oil pressure) dropped?
Defective retarder controller(G1)
Repair
Carry out
Defective hydraulic, mechanical troubleshooting
system of accumulator oil of mechanical
pressure (brake oil pressure)
system
YES
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
See TESTING AND
ADJUSTING.
Has accumulator oil pressure

(brake oil pressure) dropped?
YES
NO
Repair
Defective hydraulic, mechanical Carry out

system of accumulator oil troubleshooting
of mechanical
pressure (brake oil pressure)
system
20-622
!
1 !
4
(9)
HM300-1
TROUBLESHOOTING
BK-3
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
Disconnect BRC1.
Remedy
1
Is resistance between BRC1 (female) NO
(13) and ground 100 - 500 M?
YES

Disconnect BRC1 and
R14.
2
brake cut relay (R14) is interchanged
with other relay?
YES
3
Defective brake cut relay (R14)
Replace

ground in wiring harness between BRC1 (female) (13) and
R14 (female) (1)
Repair or
replace
YES
4
Disconnect R14.
.
NO

(2) and ground less than 1 M?
YES
Defective contact or disconnection in wiring harness between

R14 (female) (2) and ground
between BRC1 (female) (13) and
R14 (female) (1)
Repair or
replace
Repair or
replace
5
Disconnect BRC1
Is voltage between BRC1 (female)

YES
NO

between BRC1 (female) (13)
Repair or
replace
Replace
HM300-1
20-623
1 c
(9)
4
TROUBLESHOOTING
BK-3
BK-3 Related electrical circuit diagram
20-624
c
1 c
HM300-1
TROUBLESHOOTING
BK-4
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
1
Disconnect BRC1 and
ATC5A.
Is resistance between BRC1

(female) (6) and ATC5A (female) (7)
less than 1 ?
YES

Disconnect BRC1 and
ATC5A.

1 M?
YES
Remedy
disconnection in wiring
harness between BRC1
(female) (6) and ATC5A
(female) (7)
Repair or
replace

between BRC1 (female)
Repair or
replace
NO

Repair or
replace
NO
controller
Repair
NO
2
NO
3
Disconnect BRC1 and
ATC5A.

YES
4

when retarder controller(G1) is
replaced?
YES
Defective retarder controller(G1) Repair

HM300-1
20-625
1 c
(9)
4
TROUBLESHOOTING
BK-5
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
1
Disconnect BRC1 and
ATC5A.

(8) less than 1 ?
YES

Disconnect BRC1 and
ATC5A.

1 M?
YES
disconnection in wiring
harness between BRC1
(female) (15) and ATC5A
(female) (8)
Repair or
replace

between BRC1 (female)
Repair or
replace
NO

Repair or
replace
NO
controller
Repair
NO
2
NO
3
Disconnect BRC1 and
ATC5A.

Remedy
YES
4

when retarder controller(G1) is
replaced?
YES

20-626
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-6
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

the same time
displayed
code
1
Operate machine
monitor.
NO
Is other failure code [AB00MA]

displayed or recorded at same time?
YES
2
Insert T-adapter to BRC1.
speed).
Is voltage between BRC1 (7) and (8) (16)

and between BRC1 (4)(17) and (8) (16)
20 30 V?
NO
YES

Disconnect BRC1.
Defective retarder controller(G1) Replace
3
(8)(16) and ground less than 1 ?
YES

BRC1 (female) (8) (16) and
ground
Repair or
replace
Defective battery or defective

charge
Charge or
replace
between battery - battery relay retarder controller(G1) BRC1
(female) (7) (4) (17)
Repair or
replace
4
Is voltage of battery more than 24V

and gravity more than 1.26?
YES
NO
HM300-1
20-627
4 !
(9)
1
TROUBLESHOOTING
BK-6
20-628
c
1 c
HM300-1
TROUBLESHOOTING
BK-7
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
Insert T-adapter to
BRC1.
Remove fuse BT3-12.

ON.
Remedy
1
Is voltage between BRC1 (4)(17) NO
and (8)(16) 20 - 30 V?
YES
Replace
2
Is voltage between fuse BT3-12 NO
inlet and ground 20 - 30 V?

BT3-12 inlet - circuit breaker battery relay terminal M
Repair or
replace
YES

BT3-12 outlet and BRC1 (female)
(4) (17
Repair or
replace

HM300-1
20-629
1 c
(9)
4
TROUBLESHOOTING
BK-8
BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER(q

q1) LOAD POWER SUPPLY
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

the same time
Go to
troubleshooting for
displayed
code
1
Operate machine
monitor.
NO
Is other failure code [D1C0KZ]

displayed or recorded at same time?
YES
2
Insert T-adapter to BRC1
and BRC2.
NO
Is voltage between BRC2 (1)(12) - BRC1

(8)(16) 20 - 30 V?
YES
3
brake cut relay (R14) is interchanged
with other relay?
YES
Defective brake cut relay (R14)
4
Disconnect R14.

YES
NO
between fuse BT3-12 outlet
BRC2 (female) (1) (12)
Replace
Repair or
replace
Repair or
replace

20-630
!
1 !
4
HM300-1
TROUBLESHOOTING
BK-9
BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER(q

q1) BATTERY DIRECT POWER
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

OFF.
NO
Is voltage between BRC1 (7)

and (8)(16) 20 - 30 V?
YES
2
Remove fuse BT2-22.
OFF.
Is voltage between fuse BT2-22

YES
NO
Replace
between fuse BT2-22 inlet fusible link - battery relay
terminal B
Repair or
replace

BT2-22 outlet and BRC1 (female)
(7)
Repair or
replace

HM300-1
20-631
1 c
4
TROUBLESHOOTING
BK-10
BK-10
FAILURE CODE [DB19KM] (RETARDER CONTROLLER(q

q1) 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
Are connectors BRC3 (A, B) and NO

BRC5 (A, B) connected in correct
position?
Remedy
Mistaken connection of
controller connector
Connect
again

in wiring harness between BRC5A
Repair or
replace
YES

Disconnect BRC5A.

NO
1?
YES

20-632
c
1 c
4
HM300-1
TROUBLESHOOTING
BK-11
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 impossible to obtain the model selection data
Cause
Operate machine
monitor.
1
Is other failure code [DAFSKQ] NO
[DAQAKQ] [DAQSKR] displayed
or recorded at same time?
YES
ON.
2
when retarder controller is
replaced?
YES
Remedy

the same time
Go to
troubleshooting for
displayed
code
Replace
Replace
HM300-1
20-633
1 c
(9)
4
TROUBLESHOOTING
BK-12
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
BRC3A and BRC3B.
NO
Is voltage between BRC3B (5) and

BRC3A (16) 0.5 - 4.5 V?
YES

2
Disconnect B25.
NO
Is voltage between B25 (female) (2)

YES
3
Disconnect BRC1 and
B25.
NO
Is resistance between B25 (female)


ground in wiring harness between BRC1 (female)
(1) and B25 (female) (2)
Repair or
replace
YES
4
Disconnect B25
NO
Is voltage between BRC1 (1) and

ground 20 - 30 V?
Replace
B25 (female) (2)
Repair or
replace
between BRC3A (female) (16)
and B25 (female) (1)
Repair or
replace
Replace
between BRC3B (female) (5)
Repair or
replace
NO

Repair or
replace
NO

wiring harness between BRC3B
(female) (5) and B25 (female) (3)
Repair or
replace
Defective front accumulator oil

pressure sensor
Replace
YES
5
Disconnect B25.
NO

YES
6
Disconnect BRC3A and
B25.

less than 1 ?
NO
YES
7
Insert T-adapter to B25.
NO
Is voltage between B25 (3) and

ground 0.5 - 4.5 V?
YES
8
Disconnect BRC3B and
B25.

YES
9
B25.

20-634
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-12
HM300-1
20-635
1 c
TROUBLESHOOTING
BK-13
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
Insert T-adapter to
BRC3A and BRC3B.
NO

BRC3A (16) 0.5 - 4.5 V?
YES

2
Disconnect B24.
NO

YES
3
Disconnect BRC1 and
B24.
NO


ground in wiring harness between BRC1 (female)
Repair or
replace
YES
4
Disconnect B24.
NO

ground 20 - 30 V?
YES
Replace
B24 (female) (2)
Repair or
replace
Repair or
replace
Replace
Repair or
replace

Repair or
replace

BRC3B (female) (6) and B24
(female) (3)
Repair or
replace
Defective rear accumulator oil

pressure sensor
Replace
5
Disconnect B24.
NO

YES
6
B24.

less than 1 ?
NO
YES
7
NO

ground 0.5 - 4.5 V?
YES
8
B24
NO

YES
9
B24.

20-636
c
1
(9)
4 c
NO
HM300-1
TROUBLESHOOTING
BK-13
HM300-1
20-637
1 c
TROUBLESHOOTING
BK-14
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
Insert T-adapter to
BRC3A and BRC3B.
NO

BRC3A (16) 0.3 - 4.7 V?
YES
2
Insert T-adapter to RTL.
NO
Is voltage between RTL (1) and

ground 4.1 - 4.8 V?
YES
3
Disconnect BRC2 and
RTL.
NO
Is voltage between RTL (female) (1)

Hot short in wiring harness between BRC2 (female) (16) and Repair or
replace
RTL (female) (1)
YES
4
Disconnect BRC2 and
RTL.
NO
Is resistance between RTL (female)


in wiring harness between BRC2
(female) (16) and RTL (female)
(1)
Repair or
replace
YES
5
Disconnect RTL.
NO

ground 4.1 - 4.8 V?
YES

(female) (16) and RTL (female) (1)
(includes resistor)
Repair or
replace
and RTL (female) (3)
Repair or
replace
Replace
Repair or
replace

Repair or
replace

BRC3B (female) (16) and RTL
(female) (2)
Repair or
replace
Defective retarder lever

potentiometer
Replace
6
Disconnect RTL.
NO

YES
7
RTL.

(female) (16) and RTL (female) (3)
less than 1 ?
YES
NO
8
Insert T-adapter to RTL.
NO
Is voltage between RTL (2) and

ground 4.1 - 4.8 V?
YES
9
RTL.
Is voltage between RTL (female) (2)

NO
YES
RTL.

YES
20-638
c
1
(9)
4 c
10
NO
HM300-1
TROUBLESHOOTING
BK-14
Cause
Insert T-adapter to
BRC5A.
YES

Disconnect RTL.
Remedy
11
Is voltage between BRC5A (female) NO
(6) and ground, and between (7)
and ground as shown in Table 1?
Is resistance between RTL (male) (4) and

(6), and between (5) and (6) as
shown in Table 2?
12
NO
Defective retarder lever switch
Replace
YES

Disconnect RTL.

13
NO
YES

RTL (female) (6) and ground
short circuit with chassis ground,
between BRC5A (female) (6) and
RTL (female) (4) or between
BRC5A (female) (7) and RTL
(female) (5)
Repair or
replace
Repair or
replace
Table 1
Table 2
BRC5A (female)
Lever at
RELEASED
position(q2)
Lever at
APPLIED
position(q2)
RTL (male)
Lever at RELEASED
position(q2)
Lever at
APPLIED
position(q2)
Between (6) and

ground
Max. 1 V
20 30V
Between (4)
and (6)
Max. 1
Max. 1M
Between (7) and

ground
20 30V
Max. 1 V
Between (5)
and (6)
Max. 1M
Max. 1
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
1 !
4
(9)
TROUBLESHOOTING
BK-14
20-640
c
1 c
HM300-1
TROUBLESHOOTING
BK-15
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.
NO
Is voltage between HSL (4) and (1)

4.6 - 5.4 V?
YES
2
Disconnect HSL.
NO
Is voltage between HSL (4) and

ground 4.6 - 5.4 V?
YES

HSL.
3
Is voltage between HSL (female) (4) NO
Hot short in wiring harness between BRC3A (female) (6) and

HSL (female) (4)
Repair or
replace

BRC3A (female) (6) and HSL
(female) (4)
Repair or
replace
YES
4
HSL.
NO
Is resistance between HSL (female)

YES
5
Insert T-adapter to BRC3A.
Disconnect HSL.
NO
Is voltage between BRC3A (6) and

ground 4.6 - 5.4 V?
YES

(female) (6) and HSL (female) (4)
Repair or
replace
Defective dump lever

(potentiometer)
Replace

Repair or
replace
Replace

BRC3B (female) (12) and HSL
(female) (3)
Repair or
replace
10
NO
and HSL (female) (3)
Repair or
replace
11
NO

(female) (3)
(potentiometer)
6
Disconnect HSL.
NO
Is resistance between HSL (female)

YES
7

HSL.

less than 1 ?
YES
NO
8
Insert T-adapter to
BRC3A and BRC3B.
NO

BRC3A (16) 0.3 - 4.7 V?
YES
9


ground 0.3 - 4.7 V?
NO
YES

HSL.

YES

HSL.
Is resistance between HSL (3) and

ground more than 1 M?
YES

HM300-1
Repair or
replace
Replace
20-641
1 c
(9)
4
TROUBLESHOOTING
BK-15
Cause
Insert T-adapter to
BRC3A and BRC3B.
Remedy
12
Is voltage between BRC3B (14) and NO
BRC3A (16) 0.3 - 4.7 V?
YES
13
Is voltage between HSL (2) and ground 0.3 - NO

4.7 V?
YES

HSL .
14
NO


(female) (2)
Repair or
replace
Hot short in wiring harness between BRC3B (female) (14)

and HSL (female) (2)
Repair or
replace
YES
HSL .
Is resistance between HSL (2) and

groung more than 1 M?
YES
15
NO

Repair or
replace
(female) (2)
(potentiometer)
Replace

20-642
!
1 !
4
(9)
HM300-1
TROUBLESHOOTING
BK-16
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
Is other failure code [DK52KX]

time?
YES
HM300-1
NO
Remedy

(potentiometer)
Replace

the same time
Go to
troubleshooting
for displayed
code
20-643
1 c
TROUBLESHOOTING
BK-17
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
SEE TESTING AND
ADJUSTING.
1
Is trouble repaired by adjusting NO
installation of potentiometer?
Cause
Remedy
YES
Defective adjustment
2
Insert T-adapter to
BRC3A and BRC3B.
NO

BRC3A (16) 0.3 - 4.7 V?
YES

3

NO

ground 4.6 - 5.4 V?
YES
4
B34.
NO

Hot short in wiring harness between BRC3A (female) (6) and

B34 (female) (3)
Repair or
replace

BRC3A (female) (6) and B34
(female) (3)
Repair or
replace
YES
5
B34.
NO

YES
6
Insert T-adapter to BRC3A.
Disconnect B34.
NO
Is voltage between BRC3A (6) and

ground 4.6 - 5.4 V?
YES

Repair or
replace

Repair or
replace
7
Disconnect B34.
NO

YES
8
B34.

less than 1 ?
YES
20-644
c
1
(9)
4 c
NO
HM300-1
TROUBLESHOOTING
BK-17
Cause
Remedy
9
NO

ground 0.3 - 4.7 V?
YES

(female) (2)
Repair or
replace
Hot short in wiring harness between BRC3B (female) (13)

Repair or
replace
10
B34.

NO
YES
11
B34.

(2) and groung more than 1 M?
NO

Repair or
replace
(female) (2)
YES
Defective body positioner sensor Repair
HM300-1
20-645
1 !
(9)
TROUBLESHOOTING
BK-18
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
Disconnect BRC3A.
Remedy
1
NO
(female) (12) and (14) 500 - 1000 ?
YES

Disconnect FE1.
2
Is resistance between FE1 (male) (1) NO
and (2) 500 - 1000 ?
YES
See TESTING AND

ADJUSTING.
Start engine.
3
transmission output shaft F speed
sensor is adjusted?
YES

shaft F speed sensor
BRC3A (female) (12) and
B09 (female) (1) or between
BRC3A (female) (14) and
B09 (female) (2)
Replace
Repair or
replace

transmission output shaft F
speed sensor
Adjust

20-646
!
1 !
4
(9)
HM300-1
TROUBLESHOOTING
BK-19
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
BRC3A.

(14) 500 - 1000 ?
NO
YES
2
Disconnect N3.
Is resistance between N3 (male) (1)

and (2) 500 - 1000 ?
NO
YES
See TESTING AND

ADJUSTING.
Start engine and travel.
3
transmission output shaft R speed
sensor is adjusted?
YES

Replace

BRC3A (female) (13) and N3
(female) (1)
Repair or
replace

transmission output shaft R
speed sensor
Adjust

HM300-1
20-647
1 !
4
(9)
TROUBLESHOOTING
BK-20
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
Disconnect BRC1.
Remedy
1
(3) and ground 20 - 60 ?
YES
2
Disconnect B29.
Is resistance between B29 (male) (1) and

(2), and between (1) and ground as shown
in Table 1?
NO
Defective exhaust brake

solenoid
Replace
Defective contact, disconnection, or short circuit with chassis

ground in wiring harness between BRC1 (female) (3) and
B29 (female) (1)
Repair or
replace
between B29 (female) (2) and
ground
Repair or
replace

B29 (female) (1)
Repair or
replace
YES
3
Disconnect B29.
NO

YES
4
Disconnect BRC1.

YES
NO

Table 1
B29 (male)
Resistance
Between (1) and (2)
20 60
Min. 1 M
20-648
!
1 !
4
(9)
HM300-1
TROUBLESHOOTING
BK-21
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 current flows
Cause
Disconnect BRC1.
Remedy
1
(11) and ground 39 5%?
YES
2
Disconnect LK0.
Is resistance between LK0 (male) (1)

and (2), and between (1) and ground
NO
Defective dump lever (kick-out

solenoid)
Replace
YES
3
Disconnect LK0.
NO
Is resistance between LK0 (female)

4
YES
Repair or
replace
Defective contact,
Repair or
harness between BRC1(female) replace
(11) and LK0 (female) (1)
YES
Disconnect BRC1.

LK0 (female) (2) and ground
NO

and LK0 (female) (1)
Repair or
replace
Table 1
LK0 (male)
Resistance
Between (1) and (2)
39 5%
Min. 1 M
HM300-1
20-649
1 !
4
(9)
TROUBLESHOOTING
BK-21
20-650
c
1 c
HM300-1
TROUBLESHOOTING
BK-22
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 current flows
Cause
Disconnect BRC1.
Remedy
1
(12) and ground 15 - 35 ?
YES
2
Disconnect B31.
Is resistance between B31 (male) (1)

NO
Defective dump selector valve

solenoid
Replace
YES
3
Disconnect B31.
NO

4
YES
Repair or
replace
Defective contact,
Repair or
replace
harness between BRC1(female)
YES
Disconnect BRC1.

B31 (female) (2) and ground
NO

Repair or
replace
Table 1
B31 (male)
Resistance
Between (1) and (2)
15 35
Min. 1 M
HM300-1
20-651
1 !
4
(9)
TROUBLESHOOTING
BK-22
20-652
c
1 c
HM300-1
TROUBLESHOOTING
BK-23
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
OFF.
Disconnect BRC2.
1
(9) and (19) 10 - 30 ?
YES
OFF.
Disconnect B18.
Remedy
2
Is resistance between B18 (male) (1) NO
and (2) 10 - 30 ?
YES
Replace
Defective rear brake pressure

reducing valve solenoid
Replace

Repair or
(female) (9) and B18 (female) (1) or replace
B18 (female) (2)

HM300-1
20-653
1 c
(9)
4
TROUBLESHOOTING
BK-24
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
Cause
Remedy
1
OFF.
Disconnect BRC2.

NO
(female) (9) and (19), and between
(9) and ground as shown in Table 1?
YES
OFF.
Disconnect B18.
2
YES
Replace
Defective rear brake pressure

Replace

wiring harness between BRC2
B18 (female) (2)
Repair or
replace

Table 2
Table 1
BRC2 (female)
Resistance value
B18 (male)
Resistance value
10 30
Between (1) and (2)
10 30
Min. 1M
Min. 1M
20-654
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-25
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
Disconnect BRC2.
Is voltage between BRC2

than 1 V?
NO

B18 (female) (1)
Repair or
replace
NO

B18 (female) (2)
Repair or
replace
Replace
YES
2
Disconnect BRC2.
ON.

than 1 V?
YES

HM300-1
20-655
1 !
4
(9)
TROUBLESHOOTING
BK-26
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
OFF.
Disconnect BRC2.
NO

(female) (8) and (18) 10 - 30 ?
YES
Replace
Defective front brake pressure

Replace
2
OFF.
Disconnect B19.
Is resistance between B19

(male) (1) and (2) 10 - 30 ?
YES
NO

Repair or
(female) (8) and B19 (female) (1) or replace
B19 (female) (2)

20-656
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-27
BK-27
FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))
Nature of failure: When output is sent to the front brake pressure reducing valve solenoid circuit, excessive
Cause
Remedy
1
OFF.
Disconnect BRC2.

NO
(female) (8) and (18), and between
(8) and ground as shown in Table 1?
YES
Replace
Defective front brake pressure

Replace
2
OFF.
Disconnect B19.

YES

B19 (female) (2)
Repair or
replace

Table 1
Table 2
BRC2 (female)
Resistance value
B19 (male)
Resistance value
10 30
Between (1) and (2)
10 30
Min. 1M
Min. 1M
HM300-1
20-657
1 c
(9)
4
TROUBLESHOOTING
BK-28
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
Disconnect BRC2.

NO
1 V?

Repair or
replace

B19 (female) (2)
Repair or
replace
YES
2
Disconnect BRC2.

than 1 V?
YES
NO

20-658
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-29
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.
Disconnect BRC2.
NO

(female) (10) and (20) 5 - 20?
YES
Replace
2
OFF.
Disconnect B32.
Is resistance between B32 (male) NO

(1) and (2) 5 - 20?
YES
Defective dump EPC valve

Replace
solenoid
(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
TROUBLESHOOTING
BK-30
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
Disconnect BRC2.
YES

Disconnect B32.
Remedy
1
2
IIs resistance between B32 (male) (1) NO
and (2), and between (1) and ground as
shown in Table 2?
Defective dump pilot valve (EPC Replace

solenoid)
YES
Short circuit with chassis ground in Repair or

replace
B32 (female) (2)

Table 2
Table 1
BRC2 (female)
Resistance value
B32 (male)
Resistance value
5 20
Between (1) and (2)
5 20
Min. 1M
Min. 1M
20-660
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
BK-31
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
Disconnect BRC2.
1
Is voltage between BRC2 (female) (10) NO
Remedy

B32 (female) (1)
Repair or
replace

B32 (female) (2)
Repair or
replace
Replace
YES
Disconnect BRC2.
2
Is voltage between BRC2 (female) NO
YES

HM300-1
20-661
1 c
(9)
4
TROUBLESHOOTING
BK-32
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 starting the engine. If it is not turned to PARKING, the parking brake cannot be released.
Cause
Remedy

parking brake safety relay (R19) is
YES
Defective parking brake safety Replace
relay (R19)

Disconnect B14.
Is resistance between B14 (male) (1) and NO

(2), and between (1) and ground as
shown in Table 1?
Defective parking brake solenoid
Replace
Defective parking brake switch
Replace
YES

Disconnect R33.
Is resistance between R33 (male) (1) and NO

(2), and between (1) and (3) as shown in
Table 2?
YES
Disconnect B21.
Start engine.
Cancel parking brake switch.
Is voltage between B21 (female) (1) NO

YES
Disconnect R33.
Start engine.


in wiring harness between fuse Repair or
replace
BT2-6 and R33 (female) (3)
YES
Disconnect R19.
Start engine.

(1)(3) and ground 20 - 30 V?

in wiring harness between R33 Repair or
(female) (1) and R19 (female) replace
(1)(3)
YES
Go to 9
20-662
c
1 c
Go to 7
HM300-1
TROUBLESHOOTING
BK-32
From 4
From 6
Cause
Disconnect R19.

Remedy
NO

NO

BT2-6 and R19 (female) (5)
Repair or
replace
YES
Disconnect R19.
Start engine.

YES
Disconnect B20.
Start engine.

Repair or
replace
Repair or
replace
NO
YES
Disconnect B21.
Start engine..

and (2) less than 1 ?
YES
Disconnect B14.
Start engine.

Replace

in wiring harness between B21
Repair or
replace

Repair or
replace
Defective rear accumulator oil

pressure switch
Replace

Repair or
replace
NO
YES
Disconnect B20.
Start engine.
Defective front accumulator oil

pressure switch

and (2) less than 1?
YES
Table 2
Table 1
When parking
When parking
brake switch is at
brake switch OFF
PARKING
B14 (male)
Resistance
R33 (male)
Between (1) and (2)
30 50
Between (1) and (2)
Min. 1 M
Max. 1
Min. 1 M
Between (1) and (3)
Max. 1
Min. 1 M
HM300-1
20-663
1 c
TROUBLESHOOTING
BK-32
b) Even when parking brake switch is at PARKING position, parking brake is not applied
Cause
Disconnect R33.
Start engine.
Set parking brake switch to
PARKING.
Does parking brake work when R33 NO

is disconnected?
YES
Disconnect B21.
Start engine.
PARKING.
Disconnect B20.
Start engine.
PARKING.
Remedy
Defective parking brake switch
Replace
Does parking brake work when B21 NO

is disconnected?
YES
Hot short in wiring harness between Repair or

R33 (female) (2) and B21 (female) replace
(1)
Does parking brake work when B20 is NO

disconnected?

B20 (female) (2) and B14 (female) Repair or
replace
(1)
YES

B21 (female) (2) and B20 (female) Repair or
replace
(1)
20-664
c
1 c
(9)
HM300-1
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF
(MON MODE)
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...................................................................

MON-1 Failure code [B@C6NS] (Front brake oil: Overheat (NS)) .....................................................
MON-2 Failure code [B@C8NS] (Center brake oil: Overheat (NS)) ...................................................
MON-3 Failure code [B@CENS] (Torque converter: Overheat (NS)) .................................................
MON-4 Failure code [DAF0KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ........
MON-5 Failure code [DAF9KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ........
MON-6 Failure code [DAFSKQ] (Monitor panel: Non match in model selection signal (KQ)) ............
MON-7 Failure code [DAQSKR] (Transmission controller S-NET: Defective communication,
abnormality in corresponding component system (KR)) ................
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)) .....................................................
MON-11 When starting switch is turned ON, machine monitor gives no display ..................................
MON-12 When starting switch is OFF, machine monitor cannot be operated ......................................
MON-13 Alarm buzzer does not sound ................................................................................................
MON-14 Gauges, caution lamps, character display on machine monitor do not give correct display ..
MON-15 Actuation check of machine monitor cannot be performed properly ......................................
MON-16 Character display cannot be switched properly .....................................................................
MON-17 Power mode selector function does not work properly ..........................................................
MON-18 AISS function does not work properly ....................................................................................
MON-19 Exhaust brake does not work properly (machines equipped with exhaust brake) .................
MON-20 Seat belt caution lamp display is not shown properly ............................................................
MON-21 Turn signal lamp, hazard lamp do not work properly .............................................................
MON-22 Night lighting is not normal .....................................................................................................
20-702
20-706
20-710
20-710
20-710
20- 711
20-712
20-713
20-714
20-716
20-718
20-720
20-721
20-722
20-723
20-724
20-725
20-726
20-729
20-730
20-731
20-733
20-735
20-740
HM300-1
20-701
1 c
(9)
4
TROUBLESHOOTING
TROUBLESHOOTING
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-702
c
1 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
This circuit diagram has been made by extracting the machine monitor related circuits from the overall electrical circuit diagram.
HM300-1
20-703
1 !
TROUBLESHOOTING
TROUBLESHOOTING
20-704
!
1 !
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
HM300-1
20-705
1 c
TROUBLESHOOTING
TROUBLESHOOTING


Failure code
B@C6NS
(MON-1)
B@C8NS
(MON-2)
B@CENS
(MON-3)
DAF0KM
(MON-4)
DAF9KM
(MON-5)
Location of failure
Nature of failure
Probable cause
Front brake oil: Overheat

(NS)
Front brake cooling oil is overheated
Front brake cooling oil is overheated

Center brake oil: Overheat

(NS)
Center brake cooling oil is over- Center brake cooling oil is overheated
heated
Torque converter: Overheat

(NS)
Torque converter is overheated
Monitor panel: Mistaken operation or mistaken setting

(KM))
Option setting of rotary switch at Defective setting of rotary switch,

rear of machine monitor and
dipswitch, or option connector (when
dipswitches does not match sig- system is working normally)
nal from option setting connec- Disconnection or short circuit with chastor
sis ground in option connector circuit wiring harness
Monitor panel: Mistaken operation or mistaken setting

(KM))
Check signal of connector does Mistaken connection of connector DPC2

not match internal setting of ma- (A, B) and connector DPC3 (A, B) (when
chine monitor
Torque converter oil is overheated (when

DAFSKQ
(MON-6)
Monitor panel: Non match in Communication (S-NET) with

model selection signal (KQ) transmission controller is defective and model selector information cannot be received, or
setting of transmission controller
rotary switch is not correct
DAQSKR
(MON-7)
Transmission controller SS-NET data cannot be received Disconnection, short circuit with chassis
NET: Defective communica- from transmission controller
ground, or hot short in S-NET (+) circuit
tion, abnormality in correwiring harness
sponding component system
(KR)
DB1SKR
(MON-8)
Retarder controller(q1) SS-NET data cannot be received Disconnection, short circuit with chassis
NET: Defective communica- from retarder controller(q1)
tion, abnormality in correwiring harness
sponding component system
(KR)

wiring harness
Disconnection in S-NET () circuit
20-706
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

The code (MON-**) given below the failure code is the troubleshooting number.
Takes no action
Takes no action
Takes no action
Action code

as it is, there is danger that front
brake will brake
E02

as it is, there is danger that center
brake will brake
E02

as it is, there is danger that torque
converter will brake
E02
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
Max. 1
not match
When connector is disconnect- Does not record as trouble
ed: Min. 1 M
data
Signal voltage
DPC2A (female) (5) ground:
20 30 V
Holds abnormal condition until

Does not record as trouble
data
E03
E03
Holds abnormal condition until No meters or gauges give display

Some panel switches and lamps
do not work
Controls as HM300
E03
Holds condition existing when

S-NET voltage
problem occurred
Between DPC4 (1)(2) and (4)(5):
69V
Between ATC4 (6)(12) and (10):
69V
Meters, gauges, cautions, special

function receiving data from transmission controller do not work or
give any display
E03
S-NET voltage
problem occurred
Between DPC4 (1)(2) and (4)(5):
69V
Between BRC4 (6)(12) and (10):
69V
Cautions, special function receiving data from retarder controller(q1) do not work or give any
display
E03
HM300-1
20-707
1 c
(9)
4
TROUBLESHOOTING
TROUBLESHOOTING
Failure code
DB2SKR
(MON-9)
DV00KB
(MON-10)
20-708
c
1 c
(9)

Location of failure
Nature of failure
Probable cause
Engine controller S-NET:

Unable to receive S-NET inforDefective communication,
mation from engine controller
abnormality in corresponding
component system (KR)
Wiring harness in S-NET (+) circuit disconnected or connected defectively or

short-circuited
Engine controller faulty
Machine monitor faulty
Alarm buzzer:
Short-circuiting (KB)
Alarm buzzer faulty

Wiring harness in alarm buzzer output
circuit short-circuited
Machine monitor faulty
Alarm buzzer output circuit

short-circuited
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING

Action code
S-NET voltage
Between DPC4 (1)(2) and
(4)(5):
69V
Between CN2 (8)(18) and (6):
69V

problem occurred
Cautions, special function receiving data from engine controller do

not work or give any display
E03
Output circuit voltage

DPC1 (13) (9)(10):
When buzzer is stopped:
20 30 V
When buzzer is sounding:
Max. 1 V
Holds abnormal condition until Alarm buzzer does not sound

Turns buzzer output circuit
OFF
HM300-1
E01
20-709
1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING
MON-1
MON-1
MON-1, MON-2, MON-3
FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))
Nature of failure: The front brake cooling oil is overheated
Cause
Remedy
1
Stop engine
NO
Is front brake cooling oil

overheated?
YES
MON-2
Front brake cooling oil is

overheated
Replace
FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))
Nature of failure: The center brake cooling oil is overheated
Cause
Remedy
1
Stop engine
NO
Is center brake cooling oil

overheated?
YES
MON-3
Center brake cooling oil is

overheated
Replace
FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))
Nature of failure: The torque converter is overheated
Cause
Remedy
1
Stop engine.
Is torque converter overheated?
NO
Replace
YES
Torque converter is overheated
20-710
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-4
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
ADJUSTING.
Is setting of rotary switch,

dipswitch, or option connector
normal?
NO
Defective setting of rotary

switch, dipswitch, or option
connector
Set again
between DPC3A (female)
(4)(6)(7)(13)(14)(15)(16) and
ground
Repair or
replace
YES
Disconnect DPC3A.
OP connector connection
circuit
2
Is resistance between DPC3A
(female)(4)(6)(7)(13)(14)(15)
NO
YES
Disconnect DPC3A.
OP connector
disconnection circuit
3
Is resistance between DPC3A NO
(female)(4)(6)(7)(13)(14)(15)(16)
and ground more than 1 M?

Repair or
DPC3A(female) (4)(6)(7)(13)
replace
(14)(15)(16) and ground
YES
Replace
MON-4 Related electrical circuit diagram
HM300-1
20-711
1 c
(9)
TROUBLESHOOTING
MON-5
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 monitor
Cause
Remedy
1
Are connectors DPC2A, DPC3A NO

and DPC2B, DPC4 connected at
correct position?
Mistaken connection of machine Connect

monitor connectors
again
YES
2
Insert T-adapter to DPC2A.
Is voltage between DPC2A (5)

and ground 20 30 V?
NO
between DPC2A (female) (5)
and fuse BT2-2
Repair or
replace
Replace
YES
20-712
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-6
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 selector information cannot be received, or the setting of the transmission controller rotary
switch is not correct
Cause
Remedy
1
Is other failure code [DAQAKQ]

also displayed or recorded at
same time?
NO
YES
Other problem is occurring at

same time
Go to
troubleshooting of
displayed
code
Defective S-NET
communication circuit between
machine monitor and
transmission controller
Repair or
replace
2
When troubleshooting for failure
code [DAQSKR] is carried out, is
NO
condition normal (S-NET
communication circuit between
machine monitor and transmission
controller)?
YES
3

when machine monitor is
replaced?
NO
Defective transmission controller Replace
YES
HM300-1
Replace
20-713
1 c
(9)
TROUBLESHOOTING
MON-7
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

and [DB2SKR] also displayed or
recorded at same time?
YES
2
Disconnect ATC4.

(female) (6)(12) and ground 6
9 V?
NO
YES
3
Disconnect DPC4,
BRC4, ATC4,and CN2.
Is voltage between DPC4

than 1V?
NO

(female) (6) JCB (female) (3) and
ATC4 (female) (12) JCD (female)
(3)
Repair or
replace
Replace

between DPC4 (female) (1) - JCD
(female) (1)(2) - BRC4 (female)
(12), ATC4 (female) (12), CN2
(female) (18) and between DPC4
(female) (2) - JCB (female) (1)(2) BRC4 (female) (6), ATC4 (female)
(6), CN2 (female) (8)
Repair or
replace
YES
4
Disconnect DPC4, BRC4,
ATC4,and CN2.
Is resistance between DPC4

(female) (1)(2) and ground more
than 1 M?
NO
YES
5
Disconnect JCD and JCB.
Is voltage between JCD (female)

(1), JCB (female) (1) and ground
6 9 V?
YES
NO

wiring harness between DPC4
(female) (1) - JCD (female) (1)(2) - Repair or
BRC4 (female) (12), ATC4 (female) replace
(12), CN2 (female) (18) and
between DPC4 (female) (2) - JCB
(female) (1)(2) - BRC4 (female) (6),
ATC4 (female) (6), CN2 (female) (8)

in wiring harness between DPC4
(female) (1) - JCD (female) (1) and
between DPC4 (female) (2) - JCB (2)
One of machine monitor, retarder
controller(q1), transmission
controller, or engine controller is
defective
Repair or
replace
Replace
20-714
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
MON-7
HM300-1
20-715
1 c
TROUBLESHOOTING
MON-8
MON-8
FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(q1) S-NET: DEFECTIVE COMMUNICATION, 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

and [DBQSKR] also displayed or
YES
2
Disconnect ATC4.

(female) (6)(12) and ground 6 9 V?
NO
YES
3
Disconnect DPC4,
BRC4, ATC4,and CN2.

BRC4 (female) (12) JCD (female)
(2)

than 1V?
NO

DPC4 (female) (1) - JCD (female)
(1)(2) - BRC4 (female) (12), ATC4
(female) (12), CN2 (female) (18)
and between DPC4 (female) (2) JCB (female) (1)(2) - BRC4 (female)
(6), ATC4 (female) (6), CN2 (female)
(8)
Repair or
replace
Replace
Repair or
replace
YES
4
ATC4,and CN2.

than 1 M?
NO
YES

(female) (1) - JCD (female) (1)(2) BRC4 (female) (12), ATC4 (female)
Repair or
replace
5

6 9 V?
YES
NO

defective
Repair or
replace
Replace
20-716
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
MON-8
HM300-1
20-717
1 c
TROUBLESHOOTING
MON-9
MON-9
FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, 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

and [DB1SKR] also displayed or
YES
2
Disconnect ATC4.
Is voltage between CN2

(female) (8)(18) and ground 6
9 V?
NO
YES
3
Disconnect DPC4,
BRC4, ATC4,and CN2.

than 1V?
NO

CN2 (female) (18) JCD (female) (4)
Repair or
replace
Replace

DPC4 (female) (1) - JCD (female)
(1)(2) - BRC4 (female) (12), ATC4
(female) (12), CN2 (female) (18)
and between DPC4 (female) (2) JCB (female) (1)(2) - BRC4
(female) (6), ATC4 (female) (6),
CN2 (female) (8)
Repair or
replace
YES
4
ATC4,and CN2.

than 1 M?
NO
YES

(female) (1) - JCD (female) (1)(2) BRC4 (female) (12), ATC4 (female)
Repair or
replace
5

6 9 V?
YES
NO

defective
Repair or
replace
Replace
20-718
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
MON-9
HM300-1
20-719
1 c
TROUBLESHOOTING
MON-10
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
DPC1.
Is voltage between DPC1 (female) NO

(13) - (9)(10) less than1 V?
YES
2
Disconnect fuse BT2-2
and DPC1.
Is voltage between DPC1 (female) NO

(13) - (9)(10) less than 1 V?
Defective alarm buzzer
Replace

between DPC1 (female) (13)
and BZ2 (female) (2)
Repair or
replace
Replace
YES
20-720
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-11
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.
NO
Is voltage between DPC1 (6)(7)

(9)(10) 20 30 V?
YES
Replace
between DPC1 (female) (9)(10)
and ground
Repair or
replace
2
NO
Is voltage between DPC1 (6)(7)

and ground 20 30 V?
YES
3
Disconnect fuse BT2-1.

YES
NO
between fuse BT2-1 inlet starting switch - BT2-20 - battery
relay B
and fuse BT2-2 outlet
Repair or
replace
Repair or
replace
HM300-1
20-721
1 c
(9)
TROUBLESHOOTING
MON-12
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

ON, does machine monitor give
normal display?
NO
Defective main power source

system
Carry out
troubleshoo
ting MON12.
Replace
between fuse BT2-21 inlet and
J01 (female)
Repair or
replace
and fuse BT2-22 outlet
Repair or
replace
YES
2
Is voltage between DPC1 (4)(5) NO

(9)(10) 20 30 V?
YES
3
Disconnect fuse BT2-22.

inlet and ground 20 30 V?
YES
NO
20-722
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-13
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.

NO
(female) (13) and ground 20 30
V?
YES
2
Disconnect BZ2.
NO
Is voltage between BZ2 (female)

Replace
between fuse BT2-2 outlet and
BZ2 (female) (1)
Repair or
replace
between DPC1 (female) (13)
and BZ2 (female) (2)
Repair or
replace
Defective alarm buzzer
Replace
YES
3
Disconnect DPC1 and
BZ2.

(female) (13) and BZ2 (female)
(1) less than 1 ?
NO
YES
HM300-1
20-723
1 c
(9)
TROUBLESHOOTING
MON-14
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

machine monitor check switch is
operated?
Replace
Defective signal system of

applicable sensor
Carry out
troubleshooting for signal
system
Replace
YES
2
Operate machine
monitor.
When input condition of

NO
applicable signal is monitored, is
it found to be normal?
YES
b) Caution lamp display is different from condition of machine
Cause
Remedy
1
Do lamps light up and go off

when machine monitor check
switch is operated?
NO
Replace
YES
2
Operate machine
monitor.
When input condition of

applicable signal is monitored, is
it found to be normal?
NO
Defective switch or signal

system of applicable sensor
Carry out
troubleshooting for
signal
system
YES
Replace
c) Nothing is displayed on character display, or display is not correct
Cause
Remedy
1
When machine monitor check

switch is operated, does display
give normal display?
NO
Replace
Replace
YES
20-724
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-15
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
Insert T-adapter to
DPC2A.
Is voltage between DPC2A (10) NO

YES
Replace
NO

check switch
Replace
NO

Repair or
BT2-2 outlet and CK1 (female) (3) replace
2
Disconnect CK1.
Is resistance between CK1 (male)

YES
3
Disconnect CK1.
Is voltage between CK1 (female)


and CK1 (female) (6)
YES
Table 1
DPC2A
Between (10)
and ground
Repair or
replace
Table 2
Machine monitor
check switch
Voltage
CK1 (male)
Release
Max. 1 V
Press
20 30 V
Between (3)
and (6)
Machine monitor
Resistance value
check switch
Release
Min. 1 M
Press
Max. 1
HM300-1
20-725
1 c
(9)
TROUBLESHOOTING
MON-16
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
DPC2A.
NO
YES
2
Disconnect CH1.
NO
Is resistance between CH1 (male)


mode selector switch 1
Replace
CH1 (female) (3)
Repair or
replace

hot short in wiring harness between
DPC2A (female) (8) and CH1
(female) (2)
Repair or
replace
Replace
NO Defective machine monitor
Replace
YES
3
Disconnect CH1.
NO
Is voltage between CH1 (female)

YES
4
Insert T-adapter to
DPC2A.
NO

YES
5
Disconnect CH1.


and CH1 (female) (1)
YES
Machine monitor
mode selector
switch 1
Voltage
CH1 (male)
Between (8)
and ground
Press [ ]
20 30 V
Neutral
Max. 1 V
Between (14)
and ground
Neutral
Max. 1 V
Press [ ]
20 30 V
20-726
c
1 c
(9)
Repair or
replace
Table 2
Table 1
DPC2A
Machine monitor
mode selector
switch 1
Resistance value
Between (2)
and (3)
Press [ ]
Max. 1
Neutral
Min. 1 M
Between (1)
and (3)
Neutral
Min. 1 M
Press [ ]
Max. 1
HM300-1
TROUBLESHOOTING
MON-16
b) Machine monitor mode selector switch 2 system is not normal
Cause
Remedy
1
Insert T-adapter to
DPC2A.
NO
YES
2
Disconnect CH2.
NO


Replace
CH2 (female) (3)
Repair or
replace

DPC2A (female) (6) and CH1
(female) (2)
Repair or
replace
Replace
NO Defective machine monitor
Replace
YES
3
Disconnect CH2.
NO
Is voltage between CH2 (female)

YES
4
Insert T-adapter to
DPC2A.
NO

YES
5
Disconnect CH2.


and CH2 (female) (1)
YES
Machine monitor
mode selector
switch 2
Voltage
CH2 (male)
Between (6)
and ground
Press [>]
20 30 V
Neutral
Max. 1 V
Between (15)
and ground
Neutral
Max. 1 V
Press [<]
20 30 V
HM300-1
Repair or
replace
Table 4
Table 3
DPC2A
Machine monitor
mode selector
switch 2
Resistance value
Between (2)
and (3)
Press [>]
Max. 1
Neutral
Min. 1 M
Between (1)
and (3)
Neutral
Min. 1 M
Press [<]
Max. 1
20-727
1 c
(9)
TROUBLESHOOTING
MON-16
20-728
c
1 c
HM300-1
TROUBLESHOOTING
MON-17
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 function 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
NO
Insert T-adapter to
DPC2A.
YES
2
Disconnect PWM.
Is resistance between PWM

(male) (1) and (3) as shown in
Table 2?
NO
Defective power mode selector

switch
Replace
PWM (female) (1)
Repair or
replace

DPC2A (female) (13) and PWM
(female) (3)
Repair or
replace
Defective control system of

engine controller
Go to
troubleshooting for
applicable
circuit
Replace
YES
3
NO
Is voltage between PWM (female)

Disconnect PWM.
YES
4
NO
replaced?
YES
Table 2
Table 1
DPC2A
Between (13)
and ground
Power mode selector switch
Voltage
PWM (male)
Up
Max. 1 V
Down
20 30 V
Between (1)
and (3)
Power mode selector switch
Resistance value
Up
Min. 1 M
Down
Max. 1
HM300-1
20-729
1 c
(9)
TROUBLESHOOTING
MON-18
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
NO
Insert T-adapter to
DPC2A.
YES
2
Disconnect AISS.
Is resistance between AISS

(male) (1) and (3) as shown in
Table 2?
NO
Defective AISS LOW switch
Replace
AISS (female) (1)
Repair or
replace

DPC2A (female) (2) and AISS
(female) (3)
Repair or
replace

engine controller
Go to
troubleshooting for
applicable
circuit
Replace
YES
3
NO
Is voltage between AISS (female)

Disconnect AISS.
YES
4
NO
replaced?
YES
Table 2
Table 1
DPC2A
AISS LOW switch
Voltage
AISS (male)
Between (2)
and ground
Up
Max. 1 V
Down
20 30 V
Between (1)
and (3)
AISS LOW switch Resistance value

Up
Min. 1 M
Down
Max. 1
20-730
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-19
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 normally, or the exhaust brake pilot lamp does not light up and go out normally (no failure code
is displayed).
Cause
Remedy
1
NO
Insert T-adapter to
DPC2A.
YES
2
NO
Is resistance between EXH (male)

. Turn starting switch OFF.

. Disconnect EXH.
Defective exhaust brake switch
Replace
EXH (female) (1)
Repair or
replace

DPC2A (female) (11) and EXH
(female) (2)
Repair or
replace
Defective exhaust brake switch
Replace

between DPC2A (female) (3) and
EXH (female) (3)
Repair or
replace
YES
3
NO
Is voltage between EXH (female)
Disconnect EXH.
YES
4
Insert T-adapter to
DPC2A.
NO
Is voltage between DPC2A (3) and

YES
5
Disconnect EXH.
NO
Is resistance between EXH (male)

YES
6
when machine monitor is replaced?
NO

retarder controller
Go to
troubleshooting for
applicable
circuit
YES
Table 1
DPC2A
Between (11)
and ground
Between (3)
and ground
HM300-1
Replace
Table 2
Exhaust brake
switch
Voltage
EXH (male)
Up
20 30 V
Neutral
Max. 1 V
Between (1)
and (2)
Neutral
Max. 1 V
Down
20 30 V
Between (1)
and (3)
Exhaust brake
switch
Resistance value
Up
Max. 1
Neutral
Min. 1 M
Neutral
Min. 1 M
Down
Max. 1
20-731
1 c
(9)
TROUBLESHOOTING
MON-19
20-732
c
1 c
HM300-1
TROUBLESHOOTING
MON-20
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
DPC2B.
NO
Is voltage between DPC2B (11)

and ground 20 30 V?
YES
Replace
Defective seat belt switch
Replace
between fuse BT4-2 and SBS
(female) (1)
Repair or
replace
between DPC2B (female) (11)
and SBS (female) (2)
Repair or
replace
2
Disconnect SBS.
NO
Is resistance between SBS (male)

YES
3
Disconnect SBS.
NO
Is voltage between SBS (female)

YES
b) Seat belt is not fitted, but lamp does not light
Cause
Remedy
1
Insert T-adapter to
DPC2B.
NO
Is voltage between DPC2B (11)

YES
Replace
Defective seat belt switch
Replace

DPC2B (female) (11) and SBS
(female) (2)
Repair or
replace
2
Disconnect SBS.
Is resistance between SBS (male) NO

(1) and (2) more than 1 M?
YES
HM300-1
20-733
1 c
(9)
TROUBLESHOOTING
MON-20
20-734
c
1 c
HM300-1
TROUBLESHOOTING
MON-21
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 (between 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

when hazard relay 2 (R17) is
NO
YES
2
Disconnect FBL.
NO
Is voltage between FLB (wiring

harness end) and ground 20 30 V?
Defective hazard relay 2 (R17)
Replace
FLB
Repair or
replace
YES
3
Disconnect FLL, CM,
and R16.
Is resistance between FLL (wiring

harness end) CM (female) (6),
R16 (female) (1)(3) less than 1 ?
NO
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,
and R16.
Is voltage between FLL (wiring

harness end) and ground less
than 1 V?
NO

between FLL - CM (female) (6) R16 (female) (1)(3)
Repair or
replace
Defective flasher
Replace
YES
HM300-1
20-735
1 c
(9)
TROUBLESHOOTING
MON-21
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

NO
YES
2
Disconnect R17.
NO

Replace
between fuse BT1-4 and R17
(female) (6)
Repair or
replace
between CM (female) (6) and
wiring harness dividing point
Repair or
replace
Defective turn signal lever
Replace
YES
3
Disconnect CM.
Is voltage between CM (female)
NO
YES
20-736
c
1 c
HM300-1
TROUBLESHOOTING
MON-21
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
NO
YES
2
NO

Disconnect R17.

or hazard relay 2 (R17)
Replace
(female) (5)
Repair or
replace
between FLL and R16 (female)
(1)(3)
Repair or
replace

(female) (6) ground or between
R17 (female) (2) ground
Repair or
replace
Defective hazard lamp switch
Replace
YES
3
NO

(1)(3) and ground 20 30 V?
Disconnect R16.
YES
4
Disconnect R16 and R17.
Turn hazard switch ON.

(5) ground and between R17
(female) (1) ground 20 30 V?
NO
YES
5
Disconnect HAZ.
NO
Is resistance between HAZ (male)

YES
6
Disconnect HAZ.
Is voltage between HAZ (female)

YES
contact or
NO Defective
between fuse BT2-24 and HAZ
(female) (1)
Repair or
replace

Repair or
in wiring harness between HAZ
(female) (3) R16 (female) (5) or replace
R17 (female) (1)
Table 1
HAZ (male)
Between (1)
and (3)
HM300-1
Hazard lamp
switch
Resistance value
OFF
Min. 1 M
ON
Max. 1
20-737
1 c
TROUBLESHOOTING
MON-21
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
NO
YES
Replace
Defective hazard lamp switch
Replace

HAZ (female) (3) R16 (female) (5)
or R17 (female) (1)
Repair or
replace
2
NO
Is resistance between HAZ (male)


Disconnect HAZ.
YES
Table 1
HAZ (male)
Hazard lamp
switch
Resistance value
OFF
Min. 1 M
ON
Max. 1
Between (1) and (3)
f)
Turn signal pilot lamp does not flash normally (turn signal lamps flash normally)
Cause
1
Insert T-adapter to
DPC2A.

NO
ground and between (16) ground
Remedy

in wiring harness between DPC2A
(female) (7) R16 (female) (4) or Repair or
replace
R16 (female) (2)
YES
Replace
Table 2
DPC2A
Turn signal lever
Voltage
Remarks
Right
Max. 1 V/20 30 V
Voltage varies in turn
Neutral
Max. 1 V
Neutral
Max. 1 V
Left
Max. 1 V/20 30 V
20-738
c
1 c
(9)
Voltage varies in turn
HM300-1
TROUBLESHOOTING
MON-21
HM300-1
20-739
1 c
TROUBLESHOOTING
MON-22
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 normally (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
1
Disconnect CM.
NO
Is voltage between CM (female)

Remedy

Repair or
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.
Disconnect CM.
Is resistance between CM (male) NO

YES
Replace
Repair or
replace
Table 1
CM (male)
Lamp Switch
Resistance Value
OFF
Max. 1 M
1st stage
Min. 1
Between (1) and (2)
20-740
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-22
c) Lamp switch is turned OFF, but side lamps and night lighting light up
Cause
Remedy
1
OFF.
Disconnect CM.

YES
Replace

CM (female) (2) and side lamp,
machine monitor, night lighting
dimmer switch
Repair or
replace
Table 1
CM (male)
Between (1) and (2)
Lamp Switch
Resistance Value
OFF
Max. 1 M
1st stage
Min. 1
d) Even when night lighting dimmer switch is operated, brightness of night lighting cannot be adjusted
Cause
Remedy
1
Insert T-adapter to LS.
Set lamp switch to 1st stage.
NO
Is voltage between LS (1) and

(3) 20 30 V?
YES
2
Disconnect LS.
NO
Is resistance between LS (female)

YES

in wiring harness between LS
Repair or
replace
Defective contact or disconnection in

wiring harness between LS (female)
(1) and wiring harness dividing point
Repair or
replace
3
Insert T-adapter to LS.
Set lamp switch to 1st stage.
Is voltage between LS (2) and

YES
NO Defective night lighting dimmer

switch (rheostat)
Defective contact or disconnection in
wiring harness between LS (female)
(2) and wiring harness dividing point
Replace
Repair or
replace
Table 2
LS
Between (2) and (3)
HM300-1
Switch position
Voltage
Left end
6 10 V
Right end
18 27 V
20-741
1 !
(9)
TROUBLESHOOTING
MON-22
e) Even when lamp switch is operated to 2nd stage, head lamps do not light up
Cause
Remedy
1
Disconnect CM.

Replace
YES
2
Disconnect R31.
Set lamp switch to 2nd stage.

(1)(2)(3)(4) and ground 20 30 V?
NO
Repair or
between CM (female) (3) and R31 replace
(female) (1)(2)(3)(4)
YES
Defective passing relay
Replace
Table 3
CM (male)
Lamp Switch
Resistance Value
OFF
Max. 1 M
2nd stage
Min. 1
Between (1) and (2)
20-742
c
1 c
(9)
HM300-1
TROUBLESHOOTING
f)
MON-22
Head lamp Hi beam does not light up (Lo beam lights up)
Cause
1
Disconnect R29.
NO disconnection in wiring harness

(1)(3) and ground 20 30 V?
Remedy

(female) (1)(3)
Repair or
replace
YES
2
Disconnect R29.
NO

YES
3
Disconnect R29.
NO


Repair or
replace
Defective passing switch
Replace
YES
4
Disconnect CM.
NO
Is resistance between CM (male)

YES
5
Insert T-adapter to CM.
Is voltage between CM (4) and

ground 20 30 V?

YES

in wiring harness between CM
6

when head lamp Hi relay (R29)
NO
between R29 (female) (2)(4)

and head lamp
Repair or
replace
Repair or
replace
Repair or
replace
YES
Defective head lamp Hi relay
Replace
Table 4
R29 (female)
Dimmer switch
Voltage
Remarks
Between (5) and (6)
Operate between
Hi and Lo
Min. 1 V/20 30 V
Each time switch is operated,

voltage changes
CM (male)
Dimmer switch
Voltage
Remarks
Between (4) and (5)
Operate between
Hi and Lo
Min. 1 /
Max. 1 M

resistance changes
Table 5
HM300-1
20-743
1 c
(9)
TROUBLESHOOTING
MON-22
g) Head lamp Lo beam does not light up (Hi beam lights up)
Cause
1
Disconnect R30.
Defective passing relay or defective
NO contact or disconnection in wiring

Remedy
harness between fuse R31 (female)

(5)(7) and R30 (female) (3)
Repair or
replace
YES
2
Disconnect R30.
NO

YES
3
Disconnect R30.
NO


Repair or
replace
Defective passing switch
Replace
YES
4
Disconnect CM.
NO
Is resistance between CM (male)

YES
5
Insert T-adapter to CM.
Is voltage between CM (4) and

ground 20 30 V?

YES
6

when head lamp Lo relay (R30)
NO
Repair or
replace

between CM (female) (5) and R30
(female) (1)
Repair or
replace
head lamp
Repair or
replace
Defective head lamp Lo relay
Replace
YES
Table 6
R30 (female)
Passing switch
Voltage
Remarks
Between (1) and (2)
Operate between Hi
and Lo
Min. 1 V/20 30 V

voltage changes
CM (male)
Passing switch
Voltage
Remarks
Between (4) and (5)
Operate between Hi
and Lo
Min. 1 /
Max. 1 M

resistance changes
Table 7
20-744
c
1 c
(9)
HM300-1
TROUBLESHOOTING
MON-22
h) When head lamp is operated to Hi beam, machine monitor pilot lamp does not light up (Hi beam
lights up)
Cause
1
Insert T-adapter to DPC2A.
NO
Remedy

in wiring harness between DPC2A Repair or
(female) (5) and wiring harness
replace
dividing point
YES
Replace
Table 8
DPC2A
Passing switch
Voltage
Lo
Min. 1 V
Hi
20 30 V
HM300-1
20-745
1 c
(9)
TROUBLESHOOTING
MON-22
20-746
c
1 c
HM300-1
20 TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING OF
HYDRAULIC, MECHANICAL
SYSTEM (H MODE)
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
H-15
H-16
H-17
Machine does not start ................................................................................................................

Machine does not travel smoothly (machine jerks) .....................................................................
Lock-up clutch cannot be disengaged (engine stalls) .................................................................
Excessive shock when starting or shifting ...................................................................................
Transmission does not shift up ....................................................................................................
Machine lacks power or speed when traveling ............................................................................
Time lag is excessive when starting or shifting gear ...................................................................
Torque converter oil temperature is high .....................................................................................
Torque converter oil pressure is low ............................................................................................
Front brake is ineffective, or effective only on one side ...............................................................
Center brake is ineffective, or effective only on one side ............................................................
Steering wheel is heavy ...............................................................................................................
Steering wheel does not work .....................................................................................................
Steering wheel vibrates ...............................................................................................................
Dump body lifting speed is slow, or lacks power .........................................................................
Dump does not work ...................................................................................................................
Excessive hydraulic drift of dump body .......................................................................................
Remedy symbol
Remedy
Replace
20-802
20-803
20-803
20-804
20-805
20-806
20-809
20-810
20- 811
20-812
20-813
20-814
20-815
20-816
20-817
20-818
20-819
Repair
A
Adjust
Clean
HM300-1
20-801
1 c
TROUBLESHOOTING
Remedy
No. Problems
1
Defective function of speed sensor
Defective speed clutch
Breakage inside torque converter
Seized speed clutch
Drop in set pressure of power train main relief valve
Defective speed clutch shaft seal ring
Defective speed clutch piston sealing, groove
Defective operation of speed clutch ECMV valve
Defective operation of speed clutch ECMV solenoid
Causes
g h i
Breakage inside transmission
Defective power train pump
Checks before troubleshooting

Is the oil level in the transmission case correct?
Is the torque converter, transmission input shaft broken? (Monitor with the transmission input shaft
speed sensor.)
Is the drive shaft broken?
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
RELEASE position? (E-SPEC)
Is any failure code related to the power train displayed?
Air sucked in at suction side of power train pump
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
Clogged power train pump strainer
MACHINE DOES NOT START
Defective power train pump drive system (PTO)
H-1
H-1
Abnormal noise comes from between power train pump and filter
Machine does not start in any speed range (Item 1 normal)
Machine starts normally in certain speed range
Machine does not start when torque converter oil temperature rises
2
3
4
5
Measure power
train main relief
pressure
6
7
Low at every speed range

Becomes lower at certain speed range
Oil pressure gauge is unstable and fluctuates excessively
When pressure pickup port plug is removed and engine is

cranked, no oil comes out
8
9
10
Clutch oil pressure is abnormal

Power train main relief pressure is low
Clutch used
Hi
Lo
1st
2nd
3rd
R2
Speed range
R1
N
F1
F2
F3
F4
F5
F6
20-802
c
1
(9)
4 c
HM300-1
TROUBLESHOOTING
TROUBLESHOOTING
MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)

There is hunting.
Lock-up pilot lamp flashes
Causes
a
b
No.
H-3
Problems
Does not travel smoothly

Remedy
Worn speed clutch seal ring
H-2
H-2
H-2, H-3
See H-6
LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)

Causes
b
Defective operation of lock-up ECMV solenoid

Defective operation of lock-up ECMV valve
Seized lock-up clutch
No.
Problems
Remedy
When lock-up clutch pressure is measured, it does not become 0
2
3
4
When lock-up clutch pressure is measured, it becomes 0, but lock-up clutch is not disengaged
Operation of lock-up ECMV valve is normal
Operation of lock-up ECMV solenoid is normal
HM300-1
20-803
1 c
(9)
TROUBLESHOOTING
H-4
H-4
EXCESSIVE SHOCK WHEN STARTING OR SHIFTING
Judgement standard
There is some shock, but it is difficult to judge if the shock is
excessive or not, so judge that it is excessive in the following
cases.
It is clear that the shock has suddenly become excessive.
The shock is excessive compared with other machines of
the same class.
Causes

No.
Problems
Defective operation of speed clutch ECMV pressure control valve spool

Defective operation of speed clutch ECMV flow detection valve spool
Defective operation of speed clutch ECMV solenoid
Remedy
C C
Excessive shock when starting or shifting
20-804
c
1 c
HM300-1
TROUBLESHOOTING
H-5
H-5
Transmission does not shift up

Causes
b c d
1st
2nd
3rd
R2
Speed range
R1
N
F1
F2
F3
F4
F5
F6
Defective speed clutch piston seal ring, groove
Lo
Defective operation of speed clutch ECMV
Clutch used
Hi
Slipping or damage of lock-up clutch
q This is the most probable cause, but for details, see H-6.
C
No.
Problems
Remedy
Shifts up when traveling downhill

Does not shift up, regardless of road surface
HM300-1
20-805
1 c
(9)
TROUBLESHOOTING
Causes
e f g
Torque converter lock-up does not engage (carry out troubleshooting for H-6b)
Defective torque converter outlet piping, cooler
Defective torque converter freewheel
Defect inside torque converter (turbine rivet broken)
Drop in performance of engine
a) Abnormality at all speed ranges
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
MACHINE LACKS POWER OR SPEED WHEN TRAVELING
No. Problems
1
Abnormal noise comes from between power train pump and filter
Torque converter stall speed is high
2
3
4
5
6
7
8
Torque converter stall speed is low

Measure power Low at every speed range (Item 2 normal)
Oil pressure gauge is unstable and fluctuates excessively
train main relief
pressure
Becomes low when lock-up is engaged
Hydraulic pressure at torque converter inlet port is low (Items 4 - 6 normal)

Hydraulic pressure at torque converter outlet port is low (Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of transmission case
10
11
Hydraulic pressure at power train pump outlet port is low

When carrying out troubleshooting for Item 10, if oil temperature rises, oil pressure drops
20-806
c
Remedy

Is there any external oil leakage from the piping or valve
connections (joints)?
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 RELEASE position? (E-SPEC)
Defective operation of torque converter relief valve, deteriorated spring
H-6
H-6
1
(9)
4 c
HM300-1
TROUBLESHOOTING
H-6
b) Abnormality at some speed ranges
Causes
a b c d e f g h i j k l
F4
F5
F6
No. Problems
DefectiveoperationofRclutchECMV
F3
Defectiveoperationof3rdclutchECMV
F2
Defectiveoperationof2ndclutchECMV
N
F1
Defectiveoperationof1stclutchECMV
Speedrange
R1
DefectiveoperationofLoclutchECMV
Rclutchdiscwornorseized,sealringworn
3rd
DefectiveoperationofHiclutchECMV
2nd
3rdclutchdiscwornorseized,sealringworn
1st
R2
1stclutchdiscwornorseized,sealringworn
Lo
2ndclutchdiscwornorseized,sealringworn
Hiclutchdiscwornorseized,sealringworn
Clutchused
Hi
Loclutchdiscwornorseized,sealringworn

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 RELEASE position? (E-SPEC)
Remedy
1F2,F4,andF6areabnormal,butotherspeedrangesarenormal
SameasItem1,butconditionreturnstonormalwhenECMVforHi
2
clutchisreplacedwithECMVforRclutch
3F1,F3,andF4areabnormal,butotherspeedrangesarenormal
SameasItem3,butconditionreturnstonormalwhenECMVforLo
5F1,F2,andR1areabnormal,butotherspeedrangesarenormal
SameasItem5,butconditionreturnstonormalwhenECMVfor1st
6
7F3,F4,andR2areabnormal,butotherspeedrangesarenormal
SameasItem7,butconditionreturnstonormalwhenECMVfor2nd
8
9F5andF6areabnormal,butotherspeedrangesarenormal
SameasItem9,butconditionreturnstonormalwhenECMVfor3rd
10
R1andR2areabnormal,butotherspeedrangesarenormal
11
SameasItem11,butconditionreturnstonormalwhenECMVforR
12
clutchisreplacedwithECMVforHiclutch
4
HM300-1
20-807
1 c
(9)
4
TROUBLESHOOTING
H-6
c) Torque converter lock-up does not engage
Causes
a b c d e f g
No. Problems
Crackedlock-upclutchcase
Wornlock-upclutchdisc
Wornlock-upclutchpistonsealring
Defectiveoperationoflock-upECMVvalvespool
Defectiveoperationoflock-upECMVsolenoidspool

Is there any external oil leakage from piping or valve connections (joints)?
Defectivelock-upECMVsolenoid
Dropinsetpressureofpowertrainmainreliefvalve

Did the problem suddenly happen?
Yes = Internal seizure, damage
When this happened, was there any abnormal noise?
Yes = Broken part
Remedy
1Powertrainmainreliefpressureislow
2WithItem1normal,lock-upclutchpressureislowor0
WithItem2abnormal,nodisconnection,shortcircuit,orshortcircuitwithgroundis
3
foundinlock-upECMVsolenoid
WithItem2abnormal,disconnection,shortcircuit,orshortcircuitwith
4
groundisfoundinlock-upECMVsolenoid
5WithItems1-4normal,lock-upoilpressureislow
6WithItems1-4normal,lock-upoilpressureisnormal
7Whenoilpressureismeasured,mainreliefpressureandlock-upclutchpressurearebothlow
8Lock-uptakestimetoengage
20-808
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR
Defective oil tightness of speed clutch
Defective shaft seal ring of speed clutch
Hi clutch disc worn or defective seal ring, worn seal ring
Lo clutch disc worn or defective seal ring, worn seal ring
1st clutch disc worn or defective seal ring, worn seal ring
2nd clutch disc worn or defective seal ring, worn seal ring
3rd clutch disc worn or defective seal ring, worn seal ring
R clutch disc worn or defective seal ring, worn seal ring
Clutch used
Hi
Lo
1st
2nd
3rd
R2
Speed range
R1
N
F1
F2
F3
F4
F5
F6
No. Problems
Abnormal noise comes from around power train pump

There is time lag in any speed range
There is time lag when shifting to F2, F4, F6
There is time lag when shifting to F1, F3, F4
There is time lag when shifting to F1, F2, R1
There is time lag when shifting to F3, F4, R2
There is time lag when shifting to F5, F6
There is time lag when shifting to R1, R2
Clutch pressure is low when placed in any speed range

Torque converter oil temperature goes above
operating range
HM300-1
Remedy C
1
2
10
Defective operation of R clutch ECMV
Defective operation of 3rd clutch ECMV
Defective operation of 2nd clutch ECMV
Defective operation of 1st clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Causes

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?
H-7
H-7
20-809
1 c
TROUBLESHOOTING
TORQUE CONVERTER OIL TEMPERATURE IS HIGH

Does oil temperature go up when torque converter is
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,
crack in pump or turbine)
Defective operation of torque converter relief valve
Causes
a
H-8
H-8
No. Problems
1
2
3
Power train pump makes abnormal noise when oil temperature is low
Low idle and high idle speeds are low
Torque converter outlet port oil pressure is low
4
5
6
Torque converter inlet port oil pressure is low

Clutch pressure is low
Excessive leakage inside torque converter
Remedy
Clogged power train filter

Is oil level in transmission case correct?
If the results of all troubleshooting items are normal, this is the probable cause.
20-810
c
1 c
(9)
HM300-1
TROUBLESHOOTING
TORQUE CONVERTER OIL PRESSURE IS LOW

Is there any external oil leakage from the piping or
valve connections (joints)?
No. Problems
1
2
3
4
5
Remedy
Drop in set pressure of torque converter relief valve
Excessive leakage inside torque converter
Causes
H-9
H-9
C C
Abnormal noise comes from power train pump

Power train main relief pressure is low
Torque converter inlet port pressure is low
Torque converter inlet pressure is low (lock-up pressure and clutch pressure are normal)
When torque converter relief valve is adjusted, inlet pressure becomes high
HM300-1
20-811
1 c
TROUBLESHOOTING
FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE
No. Problems
Brake has no effect only when brake pedal is depressed

When brake pedal is depressed, it is light
When brake pedal is depressed, it is heavy
Even when retarder lever is pulled, retarder has no effect

(This is not related to E-SPEC)
Extremely large operating effort is needed to obtain
specified braking effect
6
7
8
9
10
Defective PPC pump
Defective accumulator charge valve
Drop in accumulator gas pressure (gas leakage, defective piston seal)
Defective brake valve (front)
Defective slack adjuster
Defective wheel brake piston seal
Defective operation of wheel brake piston
Breakage inside wheel brake
Worn wheel brake disc
Improper axle oil
Air in brake circuit
Defective rear brake pressure reducing valve
Abnormal noise is heard from around transmission oil pan

or PPC pump
When oil is drained from inside axle case, large amounts
of metal particles are found
13
14
15
16
Brake oil pressure is low

Brake disc wear amount is high
When air is bled from brake system, air comes out
20-812
c
When brakes are applied, abnormal noise is heard from brake portion of axle
Hydraulic and steering do not work
Abnormal noise is heard from around PTO
Accumulator charge pressure is low

Brake immediately loses power after engine is stopped
There is time lag before brake starts to take effect
11
12
Remedy
1
2
3
Causes
Air sucked in at suction side of PPC pump

Is the brake pedal play correct?
Is there any leakage of oil from the brake piping or
deformation of the piping?
Is the tire inflation and tread condition normal?
Is any failure code related to the brakes displayed?
Defective PPC pump drive system (PTO)
H-10
H-10
1 c
4
HM300-1
TROUBLESHOOTING
CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE
No. Problems
Brake has no effect only when brake pedal is depressed

When brake pedal is depressed, it is light
When brake pedal is depressed, it is heavy
Even when retarder lever is pulled, retarder has no effect
Extremely large operating effort is needed to obtain

specified braking effect
When brakes are applied, abnormal noise is heard from

brake portion of axle
Hydraulic and steering do not work
8
9
Abnormal noise is heard from around PTO

Abnormal noise is heard from around transmission oil pan
or PPC pump
10
When oil is drained from inside axle case, large amounts

of metal particles are found
13
14
15
16
Defective PPC pump
Defective accumulator charge valve
Drop in accumulator gas pressure (gas leakage, defective piston seal)
Defective brake valve (center, rear)
Defective slack adjuster
Defective wheel brake piston seal
Defective operation of wheel brake piston
Breakage inside wheel brake
Worn wheel brake disc
Improper axle oil
Air in brake circuit
Defective retarder solenoid valve
Remedy
1
2
3
4
11
12
Causes
a
Air sucked in at suction side of PPC pump

Is the brake pedal play correct?
Is there any leakage of oil from the brake piping or deformation of the piping?
Is the tire inflation and tread condition normal?
Is any failure code related to the brakes displayed?
Defective PPC pump drive system (PTO)
H-11
H-11
Accumulator charge pressure is low

Brake immediately loses power after engine is stopped
There is time lag before brake starts to take effect
Brake oil pressure is low
Brake disc wear amount is high
When air is bled from brake system, air comes out
HM300-1
20-813
1 c
(9)
TROUBLESHOOTING
STEERING WHEEL IS HEAVY

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?
No. Problems
1
Remedy
Clogged hydraulic and steering pump strainer
Air sucked in at suction end of hydraulic and steering pump
Damaged suction tube of hydraulic and steering pump
Defective hydraulic and steering pump
Drop in set pressure of flow amplifier valve relief valve or defective oil tightness
Defective operation of flow amplifier valve spool or stuck spool
Defective steering valve
Defective steering cylinder
A
C
Dump cylinder also does not work

When pressure pickup port plug is removed and engine is cranked, no oil comes out
Dump is normal
2
3
4
Steering oil pressure is low at end of cylinder stroke

(Item 3 normal)
5
6
7
Item 4 is abnormal, relief noise is heard from relief valve

Abnormal noise comes from between hydraulic, steering pump - filter
Steering wheel works when engine is at low idle
8
9
10
When steering cylinder is turned fully to right (left), and hose on opposite side is
disconnected, oil flows out continuously
Hydraulic and steering pump discharge amount is too low
Excessive play in steering wheel
20-814
c
Causes
Defective hydraulic and steering pump drive system (PTO)
H-12
H-12
1 c
(9)
HM300-1
TROUBLESHOOTING
STEERING WHEEL DOES NOT WORK

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?
No. Problems
Remedy
1
2
Dump cylinder also does not work

Dump is normal
Steering oil pressure is low at end of cylinder stroke
(Item 3 normal)
Abnormal noise comes from between hydraulic, steering pump - filter
4
5
6
7
8
9
10
Damaged suction tube of hydraulic and steering pump
Defective steering valve
Defective steering cylinder
Causes
H-13
H-13
A
C
Steering wheel works when engine is at low idle

When steering cylinder is turned fully to right (left), and hose on opposite side is
disconnected, oil flows out continuously
Hydraulic and steering pump discharge amount is too low
Excessive play in steering wheel
HM300-1
20-815
1 c
(9)
4
TROUBLESHOOTING
STEERING WHEEL VIBRATES

Air in hydraulic oil
Causes
a
b
No.
Problems
Steering wheel vibrates
20-816
c
1 c
Remedy
Leakage of air inside steering cylinder
H-14
H-14
HM300-1
TROUBLESHOOTING
DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER

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?
No. Problems
1
2
3
4
5
6
7
8
9
10
11
12
Broken hydraulic and steering pump suction tube
Defective dump EPC pump
Drop in dump EPC valve or defective operation
Remedy
C
Defective dump cylinder
Defective operation of check valve of dump valve
Drop in set pressure of dump valve relief valve or defective oil tightness
Air sucked in at suction side of hydraulic and steering pump
Causes
H-15
H-15
Steering also does not work normally

Steering works normally
Steering relief pressure and dump relief pressure is low
Dump relief pressure is too high at engine high idle
Dump relief pressure is low
Dump body does not rise smoothly (moves irregularly)
Hydraulic and steering pump discharge amount is low
Items 1 - 9 are normal but dump body lifting speed is slow
Abnormal noise comes from between hydraulic and steering pump - filter
Dump EPC valve oil pressure is low
HM300-1
20-817
1 c
(9)
4
TROUBLESHOOTING
DUMP DOES NOT WORK
No. Problems
1
2
3
Steering also does not work normally

Steering works normally
Item 2 is abnormal, steering relief pressure and dump relief pressure
is low
Dump relief pressure is low
Dump relief pressure is low at engine high idle
Normal when engine is at low idle
Hydraulic and steering pump discharge amount is low
When dump body is raised, and hose at head end of dump cylinder is
disconnected, oil flows out
4
5
6
7
8
9
10
11
20-818
c
Remedy
1
(9)
4 c
Broken suction tube of hydraulic and steering pump
Defective dump EPC pump
Drop in dump EPC valve or defective operation
A
C
Defective dump cylinder
Defective operation of check valve of dump valve
Drop in set pressure of dump valve relief valve or defective oil tightness
Causes
a

Is signal value of dump lever within normal range?
Is the battery charge circuit caution lamp lighting up?
(If the alternator signal R is not output normally, the dump
controller does not operate.)
H-16
H-16
HM300-1
TROUBLESHOOTING
EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY

Causes
a b
No.
1
2
HM300-1
Remedy
Problems
Raise dump body and disconnect hose at head
end of dump cylinder
Slipping or damage of lock-up clutch
H-17
H-17
Oil flows out

Oil does not flow out
20-819
1 c
(9)
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF THE ENGINE BODY

(S MODE)
Points to remember when troubleshooting ..............................................................................................

Method of using troubleshooting charts ...................................................................................................
S-1 Starting performance is poor (starting always takes time) ..............................................................
S-2 Engine does not start .....................................................................................................................
S-3 Engine does not pick up smoothly (follow-up is poor) ....................................................................
S-4 Engine stops during operations ......................................................................................................
S-5 Engine does not rotate smoothly (hunting) .....................................................................................
S-6 Engine lacks output (or lacks power) .............................................................................................
S-7 Exhaust smoke is black (incomplete combustion) ..........................................................................
S-8 Oil consumption is excessive (or exhaust smoke is blue) ..............................................................
S-9 Oil becomes contaminated quickly .................................................................................................
S-10 Fuel consumption is excessive .......................................................................................................
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ............................................
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ..............................................................
S-13 Oil level rises (water, fuel in oil) ......................................................................................................
S-14 Coolant temperature becomes too high (overheating) ...................................................................
S-15 Abnormal noise is made .................................................................................................................
S-16 Vibration is excessive .....................................................................................................................
HM300-1
20-902
20-903
20-907
20-908
20- 911
20-912
20-913
20-914
20-915
20-916
20-917
20-918
20-919
20-920
20-921
20-922
20-923
20-924
20-901
(5)
(9)
TROUBLESHOOTING

k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied.
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
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 questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not
hurry to disassemble the components
If components are disassembled immediately
any failure occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred before?
3. Checks before troubleshooting

1) Is there any sign of abnormality in the machine or engine?
2) Always carry out the Checks before starting.
3) Carry out other checks if necessary.
4) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
5) Check for any error display on the controller.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to re-enact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting matrix or
flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
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 problem occurred. Then, remove the root cause.
20-902
(5)
(9)
HM300-1
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users 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 probability 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 necessary 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)
TROUBLESHOOTING
<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 because an error has occurred in the electrical
system.)
20-904
(5)
HM300-1
TROUBLESHOOTING
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 injection 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
(5)
HM300-1
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 engine does not start
Lack of rotating force due to defective electrical system
20-910
(5)
HM300-1
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
Engine overheating
Failure in power train
a Carry out troubleshooting of the machine.
20-912
(5)
HM300-1
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
Engine overheating
(The injection amount (output) is limited because an error has occurred in the electrical system.)
20-914
(5)
(9)
HM300-1
TROUBLESHOOTING
S-7
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
There is excessive fuel.
Engine overheating
(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 operation is not allowed).
External leakage of oil
Wear of lubrication system
20-916
(5)
(9)
HM300-1
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
(5)
(9)
HM300-1
TROUBLESHOOTING
S-11
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)
TROUBLESHOOTING
S-12
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
(5)
(9)
HM300-1
TROUBLESHOOTING
S-13
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 coolant.
HM300-1
20-921
(5)
(9)
TROUBLESHOOTING
S-14
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
(5)
(9)
HM300-1
TROUBLESHOOTING
S-15
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 becomes slightly louder because it is operated in the low temperature 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)
TROUBLESHOOTING
S-16
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 troubleshooting also for Abnormal noise is made.
20-924
(5)
HM300-1
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL..................30- 3
Removal and installation of assemblies..30- 3
Disassembly and assembly of
assemblies ............................................30- 4
PRECAUTIONS WHEN CARRYING
OUT OPERATION.......................................30- 5
SPECIAL TOOL LIST ..................................30- 6-1
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY ............30- 7
Special tool ............................................30- 7
Removal ................................................30- 7
Installation .............................................30- 8
FUEL INJECTOR ASSEMBLY ....................30- 10
Removal ................................................30- 10
Installation .............................................30- 11
NOZZLE TIP................................................30- 14
SPECIAL TOOL ....................................30- 14
Removal ................................................30- 14
Installation .............................................30- 15
Sketches of special tools .......................30- 16
CYLINDER HEAD ASSEMBLY ...................30- 17
Special tool ............................................30- 17
Removal ................................................30- 17
Installation .............................................30- 21
ENGINE ASSEMBLY ..................................30- 25
Special tool ............................................30- 25
Removal ................................................30- 25
Installation .............................................30- 29
RADIATOR ASSEMBLY..............................30- 30
Removal ................................................30- 30
Installation .............................................30- 32
OUTPUT SHAFT ASSEMBLY.....................30- 33
Removal ................................................30- 33
Installation .............................................30- 34
ASSEMBLY AND DISASSEMBLY OF
OUTPUT SHAFT ASSEMBLY.....................30- 36
Disassembly ..........................................30- 36
Assembly ...............................................30- 37
HM300-1

TRANSMISSION AND
FRONT DIFFERENTIAL ASSEMBLY........... 30- 39
Special tool ............................................. 30- 39
Removal.................................................. 30- 39
Installation............................................... 30- 44
CONNECTION AND DISCONNECTION OF
FRONT DIFFERENTIAL ASSEMBLY AND
TRANSMISSION ASSEMBLY ...................... 30- 46
Disconnection ......................................... 30- 46
Connection.............................................. 30- 47
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY........... 30- 48
Special tool ............................................. 30- 48
Disassembly............................................ 30- 48
Assembly ................................................ 30- 51
Sketches of special tools ........................ 30- 56
TRANSMISSION ASSEMBLY ...................... 30- 57
Special tool ............................................. 30- 57
Disassembly............................................ 30- 57
Assembly ................................................ 30- 74
Sketches of special tools ........................ 30-100
FRONT DIFFERENTIAL ASSEMBLY........... 30-103
Special tool ............................................. 30-103
Disassembly............................................ 30-103
Assembly ................................................ 30-107
CENTER DIFFERENTIAL
ASSEMBLY................................................... 30-118
Special tool ............................................. 30-118
Removal.................................................. 30-118
Installation............................................... 30-120
CENTER DIFFERENTIAL ASSEMBLY ........ 30-122
Special tool ............................................. 30-122
Disassembly............................................ 30-122
Assembly ................................................ 30-127
REAR DIFFERENTIAL ASSEMBLY ............. 30-142
Removal.................................................. 30-142
Installation............................................... 30-143
30-1
(10)
2

REAR DIFFERENTIAL ASSEMBLY ............. 30-144
Special tool ............................................. 30-144
Disassembly............................................ 30-144
Assembly ................................................ 30-148
FRONT FINAL DRIVE AND
BRAKE ASSEMBLY ..................................... 30-159
Removal.................................................. 30-159
Installation............................................... 30-160
BRAKE ASSEMBLY ..................................... 30-161
Special tool ............................................. 30-161
Disassembly............................................ 30-161
Assembly ................................................ 30-165
CENTER FINAL DRIVE AND
BRAKE ASSEMBLY ..................................... 30-175
Removal.................................................. 30-175
Installation............................................... 30-176
BRAKE ASSEMBLY ..................................... 30-177
Special tool ............................................. 30-177
Disassembly............................................ 30-177
Assembly ................................................ 30-179
REAR FINAL DRIVE ASSEMBLY................. 30-188
Special tool ............................................. 30-188
Disassembly............................................ 30-188
Assembly ................................................ 30-190
CENTER AXLE ASSEMBLY......................... 30-196
Removal.................................................. 30-196
Installation............................................... 30-197
REAR AXLE ASSEMBLY ............................. 30-198
Removal.................................................. 30-198
Installation............................................... 30-200
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
(14)
2
Removal ................................................. 30-204

Installation .............................................. 30-205
HITCH FRAME ASSEMBLY......................... 30-206
Special tool............................................. 30-206
Removal ................................................. 30-206
Installation .............................................. 30-211
Sketches of special tools........................ 30-215
HITCH FRAME ASSEMBLY......................... 30-216
Special tool............................................. 30-216
Disassembly ........................................... 30-216
Assembly................................................ 30-217
Sketches of special tools........................ 30-222
DISASSEMBLY AND
ASSEMBLY OF
STEERING VALVE ASSEMBLY .................. 30-223
Disassembly ........................................... 30-225
Assembly................................................ 30-228
FLOW AMP VALVE...................................... 30-233
Removal ................................................. 30-233
Installation .............................................. 30-234
HOIST VALVE ASSEMBLY.......................... 30-235
Removal ................................................. 30-235
Installation ........................................... 30-235-1
STEERING CYLINDER ASSEMBLY............ 30-236
Special tool............................................. 30-236
Disassembly ........................................... 30-236
Assembly................................................ 30-237
HOIST CYLINDER ASSEMBLY ................... 30-239
Special tool............................................. 30-239
Disassembly ........................................... 30-239
Assembly................................................ 30-241
BODY ASSEMBLY ....................................... 30-243
Removal ................................................. 30-243
Installation .............................................. 30-244
HM300-1
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools
Special tools that are deemed necessary for removal or installation of parts are listed.
List of the special tools contains the following
kind of information.
1) Necessity
: Special tools which cannot be substituted, should always be used.
z Special tools which are very useful if
available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N:
Tools with new part numbers, newly
developed for this model.
R:
Tools with upgraded part numbers, remodeled from already available tools
for other models.
Blanks: Tools already available for other
models, used without any modification.
3) Circle mark (c) in sketch column:
A circle mark means that a sketch of the special 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.
Installation of parts
Except where otherwise instructed, install parts
is the reverse order of removal.
Instructions and precautions for installing parts
are shown with q 1 mark in the INSTALLATION
Section, identifying which step the instructions
are intended for.
Marks shown in the INSTALLATION Section
stand for the following.
This mark indicates safety-related precautions which must be followed when

doing the work.
This mark gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified
torque.
5
This mark indicates an amount of oil or

water to be added.
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
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.

doing the work.
This mark gives guidance or precautions

when doing the procedure.
q1
This mark shows that there are instructions or precautions for installing parts.
6
This mark shows oil or water to be
drained.
4 Mass of a part or component.
HM300-1
30-3
(9)c

ASSEMBLIES
Special tools
Special tools which are deemed ncessary for
disassembly and assembly are listed in this section.
List of the special tools contains the following
kind of information.
1) Neccessity
: Special tools which cannot be substituted, should always be used.
z Special tools which are very useful if
available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N:
Tools with new part numbers, newly
developed for this model.
R:
Tools with upgraded part numbers, remodeled from already available tools
for other models.
Blanks: Tools already available for other
models, used without any modification.
3) Circle mark (c) in sketch column:
A circle mark means that a sketch of the special 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.
Assembly
Section titled ASSEMBLY contain procedures,
precautions and the know-how for the work, as
well as the amount of oil or water to be added.
Various symbols used in the ASSEMBLY Section are explained and listed below.

doing the work.
This mark gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified
torque.
5
This mark indicates an amount of oil or

water to be added.
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
Disassembly
The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water
to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.

doing the work.
This mark gives guidance or precautions

when doing the procedure.
q1
This mark shows that there are instructions or precautions for installing parts.
6
This mark shows oil or water to be
drained.
4 Mass of a part or component.
30-4
(9)
HM300-1
c

OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions 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 disconnecting 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
number
Plug (nut end)
Nut (elbow end)
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
number
Flange (hose end)
Sleeve head (tube end)
Split flange
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
number
Part Number
06
07049-00608
Dimensions (mm)
D
08
07049-00811
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

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 securely.
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 hydraulic 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 cylinder 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 reassembling 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
(9)
HM300-1
c
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).
Component
Symbol
Part No.
795-471-1800
A1
Part Name
Remover
Necessity
Qty
New/
Sketch
remodel
1 795-471-1810
Plate
2 795-471-1820
Bolt
3 795-471-1830
Bracket
4 01435-01035
Bolt
5 01435-01025
Bolt
2 790-331-1110
Wrench
3 795T-471-1550
Wrench
Removal, Installation of
fuel supply pump
Engine assembly
01050-61225
Bolt
790-501-5000
Unit repair stand
Bracket
Plate
2 792-213-1110
Wrench
Remove of pump bearing

nut
1 790-102-1871
Nut wrench
Remove of PTO bearing

nut
2 796-465-1120
Push tool
Press-fitting of lower shaft

bearing (side of 3rd)
3 792T-423-1110
Push tool
792T-213-1210
Push tool
Clip
01010-81240
Bolt
752T-213-1230
Push tool
Clip
Bolt
6 790-201-2730
Spacer
7 792T-413-1120
Push tool
8 792T-215-1120
Push tool
9 799-301-1500
Oil leak tester
792T-213-1220
5 790-101-5421
01010-81240
HM300-1
Removal, Installation of
Nozzle tip
4 790-101-5421
Transmission
assembly
Centering tool
1 790-901-2110
C
Tightening of cylinder
head bolt
792-220-1110
4
Torque converter
assembly
Nature work remarks
Carrying out shaft of

engine assembly and
translation assembly
c
N
Disassembly, assembly of
torque converter assembly
Press-fitting of lower shaft

bearing (side of 2nd)
c
Press-fitting of dust seal of
input coupling
c
Press-fitting of dust seal of
input coupling
Press-fitting of PTO
bearing
Press-fitting of idoler gear

bearing
Press-fitingt of output
coupling cover
Test of clutch assembly
30-6-1
3
(6)
Component
Symbol
Front differential
assembly
Part No.
792T-423-1130
Push tool
Clip
Bolt
Spacer
Push tool
Clip
01010-51240
Bolt
790-101-5401
Push tool kit
790-101-5441
Plate
790-101-5421
Clip
01010-51240
Bolt
Spacer
Unit repair stand

(AC100V)
Unit repair stand

(AC110V,AC220V)
790-901-2110
Bracket
792T-222-1210
Plate
7 792-103-0901
Wrench
8 792T-223-1120
Push tool
792T-423-1140
Push tool
Clip
01010-51240
Bolt
10 792T-223-1110
Clip
Unit repair stand

(AC100V)
Unit repair stand

(AC110V,AC220V)
790-901-2110
Bracket
792T-222-1210
Plate
7 792-103-0901
Wrench
10 792T-223-1110
Clip
792T-227-1120
Fixture
792T-223-1140
Plate
01010-61240
Bolt
Washer
01580-01210
Nut
01010-61245
Bolt
01010-62440
Bolt
792T-423-1130
5 790-201-2770
790-501-5000
6 790-501-5200
9 790-101-5421
790-501-5000
6 790-501-5200
30-6-2
3
(9)
New/
Sketch
remodel
2 790-101-5421
Front final drive

brake assembly
Qty
3 790-201-2840
Rear differential
assembly
Necessity
Push tool
01010-51240
Part Name
1 792T-227-1110
2 790-101-5421
Center differential
assembly
SPECIAL TOOL LIST
1 01643-31232
Nature work remarks

Press-fit bearing of output
shaft
c
Press-fitting of side carrier
oil seal
Press-fitting of bevel pinion bearing
c
Press-fitting of oil seal of
transfer input shaft cage
Press-fitting oil seal of

bearing cage
Press-fitting side seal of

bearing cage
Disassembly and assembly of center differential

assembly
N
c
Adjustment of bearing
pre-load
Press-fitting of transfer
input shaft bearing
c
Press-fitting oil seal of
transfer input shaft cage
N
Press-fitting of bevel
pinion bearing
Disassembly , assembly of
rear differential
N
c
Adjustment of bearing
pre-load
Press-fitting of bevel
pinion bearing
Removal, installation of
brake assembly
HM300-1
Component
Symbol
792T-227-1130
Bolt
4 791-580-1520
Installer
5 791-580-1510
Installer
Push tool
Grip
Bolt
7 797T-622-1240
Push tool
2 792T-222-1220
Push tool
4 791-580-1520
Installer
5 791-580-1510
Installer
793T-622-1110
New/
Sketch
remodel
Press fitting of shaft

bearing
Installation of floating seal
Bolt
Push tool
792T-227-1130
Fixture
792T-223-1140
Plate
01010-61240
Bolt
Washer
Nut
Bolt
01010-62440
Bolt
2 792T-222-1220
Push tool
7 797T-622-1240
Push tool
1 792T-246-1130
Plate
2 792T-246-1140
Plate
3 792T-246-1110
Push tool
790-101-5201
Push tool kit
790-101-5314
Plate
790-101-5221
Grip
01010-51225
Bolt
792-201-3141
1 790-101-5221
01010-51225
Press fitting of outer gear

oil seal
Press fitting of inner hub
bearing
Removal , installation of
brake assembly
01580-01210
Press fitting of outer gear

oil seal
01010-61245
Press fitting of shaft oil

seal

bearing
8 01643-31232
Press fitting of shaft

bearing
Push tool
7 797T-622-1240
Nature work remarks
Installation of floating seal
Grip
01010-81240
HM300-1
6 790-101-5421
01010-81240
Disassembly
assembly of suspension
6 790-101-5421
Hitch frame
assembly
793T-622-1110
Rear final drive

assembly
Push tool
Push tool
01010-81225
Center final drive

brake assembly
Qty
Part Name
Grip
3 790-101-5221
Necessity
Part No.
2 792T-222-1220
Front final drive

brake assembly
SPECIAL TOOL LIST
Press fitting of wheel hub

bearing

bearing
Press-fitting of dust seal
Press-fitting of bearing
Push tool
Grip
Bolt
Press fitting of roll bushing
30-6-3
3
(14)
Component
Symbol
Part No.
Hydraulic pump
2 790-102-3802
Wrench assembly
cylinder head
3 790-102-1320
Socket(width
across flats:70mm)
Nut
Expander
Ring
07281-01159
Clamp
790-201-1702
Push tool KIT
790-101-5021
Grip
01010-50816
Bolt
790-202-1781
Push tool
790-201-1500
Push tool KIT

Grip
Bolt
790-201-1590
Plate
790-502-1003
Cylinder repair
stand
790-101-1102
Hydraulic pump
Wrench assembly
Expander
Ring
07281-01159
Clamp
790-201-1702
Push tool KIT
790-101-5021
Grip
4 796-720-1660
5 01010-50816
Bolt
790-201-1831
Push tool
790-201-1871
Push tool
790-201-1500
Push tool KIT
790-101-5021
30-6-4
(8)
3
(14)
Installation of piston ring
Press-fitting of bushing
cylinder assembly
cylinder head
Installation of piston ring
Press-fitting of bushing
Grip
Bolt
790-201-1640
Plate
790-201-1680
Plate
6 01010-50816
cylinder assembly
01010-50816
790-720-1000
790-101-5021
2 790-102-3802
Air conditioner
assembly
Nature work remarks
790-101-1102
New/
Sketch
remodel
Operator's cab
assembly
Qty
790-720-1000
Hoist cylinder
assembly
Necessity
Cylinder repair
stand
4 796-720-1660
Part Name
790-502-1003
Steering cylinder
assembly
SPECIAL TOOL LIST
790-102-4300
Wrench assembly
790-102-4310
Pin
792-454-1100
Pump assembly
799-703-1200
Service tool KIT
799-703-1100
Vacuum(100V)
799-703-1111
Vacuum(220V)
799-703-1121
Vacuum(240V)
799-703-1400
Gas leak tester
Tighten piston assembly

N
Tilting of operator's cab
Extraction and charging

the refrigerant gas
HM300-1

FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL SUPPLY PUMP
ASSEMBLY
SPECIAL TOOL
Mark
Part No.
795-471-1800
A1
Part Name
Remover
Necessity Q'ty
Distinction*
Sketch
1 795-471-1810
Plate
2 795-471-1820
Bolt
3 795-471-1830
Bracket
4 01435-01035
Bolt
5 01435-01025
Bolt
*Distinction of new part and improved part
REMOVAL
k
k
Disconnect the negative (-) terminal of battery

beforehand.
Turn the parking brake switch on and put
wooden blocks under the wheels.
5. Remove the clamp and cover, and disconnect

high pressure tubes (7) and (8) between the fuel
supply pump and common rail.
6. Remove the clamps at 4 points and disconnect
fuel filter tubes (9) and (10).
7. Remove the clamp and disconnect lubrication
tube (11).
1. Release the remaining pressure in the fuel system, 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.
3. Disconnect wiring connectors (PCV1) (2), (PCV

2) (3) and (G) (4).
4. Disconnect fuel supply hose (5) and fuel return
hose (6).
Before disconnecting the hoses, move the
fuel valve to the CLOSE side.
HM300-1
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 compression top dead center, the rocker
arms of the intake valve and exhaust
valve of the No. 1 cylinder can be
moved by the valve clearance with the
hand. If the rocker arms cannot be
moved, rotate the crankshaft one more
turn.
30-7
2
(9)
4) Remove gear mounting nut (14) and washer

(14a).
a Take great care not to drop the nut and
washer in the case.

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.
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 fingers.

a Set tap hole "e" of plate A1-1 down.
30-7-1
(6)
HM300-1

11) Tighten bolt A1-2 and remove the gear and

fuel supply pump assembly (17).
3 Removing torque of gear:

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

mounting nut (14) and washer (14a)
temporarily.
4) Remove bracket A1-3 and plate A1-1.
5) Tighten fuel supply pump drive gear
mounting nut (14).
Installation is carried out in the reverse order to

removal.
3
Fuel hose joint bolt:

14.8 - 19.6 Nm {1.51 - 2.0 kgm}
Mounting nut:
127 147 Nm {13 15 kgm}
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 distance of over 10 mm from the wiring harness.
Make a visual check of the taper seal portion 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.
Install the fuel supply pump and high pressure tubes (7) and (8) between the fuel supply pump and common rail in the following
manner.
1) Install fuel supply pump (17) and brackets

(16A) and (16B), and temporarily tighten
high pressure tubes (7) and (8) manually.
2) Tighten high pressure tubes (7) and (8).
3
3
Sleeve nut on common rail side:

39.2 - 58.8 Nm {4 - 6 kgm}
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).
30-8
2
(9)
Install the fuel supply pump according to the

following procedure.
1) Remove bolt A1-2 from plate A1-1.
2) Insert fuel supply pump (17) with key
(18) up and matched to the keyway of
the gear, and then secure it temporarily.
5) Temporarily install clamp brackets (18) and

(19) as well as high pressure clamp (20) by
tightening manually.
6) Tighten high pressure clamp (20).
3
Clamp bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
HM300-1

7) Tighten clamp bracket (18) first and clamp

bracket (19) thereafter.
3
Check for fuel leak

Check for fuel leak, referring to the section
of "CHECKING FOR LEAKAGE IN FUEL
CIRCUIT" in TESTING AND ADJUSTING.
Air bleeding
Bleed air from the fuel circuit, referring to
the section of "BLEEDING AIR FROM FUEL
CIRCUIT" in TESTING AND ADJUSTING.
Bracket mounting bolt:

11.8 - 14.7 Nm {1.2 - 1.5 kgm}
8) Install high pressure clamp (21) and clamp

bracket (22) temporarily.
9) Tighten clamp (21).
3
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.
HM300-1
Fuel filter tube joint bolt:

24.5 - 34.3 Nm {2.5 - 3.5 kgm}
Lubrication tube joint bolt:

9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Cover mounting bolt:

14.7 - 17.6 Nm {1.5 - 1.8 kgm}
30-9
2
(9)

FUEL INJECTOR ASSEMBLY
REMOVAL AND
INSTALLATION OF
REMOVAL
k
k

beforehand.

2. Remove the common rail cover cum high pressure tube clamp (1).
6. Loosen and remove sleeve nut (8) for high pressure 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 injector 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
2
(9)
HM300-1

INSTALLATION

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 distance of over 10 mm from the wiring harness.
Make a visual check of the taper seal portion 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

common rail and fuel injector in the following
manner.
1) Tighten 6 sleeve nuts (8) and (9) for high

pressure tube (7).
3
High pressure tube sleeve nut:

39.2 - 49 Nm {4 - 5 kgm}
2) Temporarily install clamps (5) and (6) for the

high pressure tube by tightening manually.
3) Tighten clamps (5) and (6) for the high pressure tube.
3
30-12
2

4) Tighten the mounting bolt for clamp bracket

(14).
5) Install common rail cover and high pressure
tube clamp (1) and portal frame (4) temporarily.
6) Tighten common rail cover and high pressure tube clamp (1) first and portal frame (4)
thereafter.
3
Clamp bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
Clamp bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
HM300-1

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.
Head cover mounting bolt:

8.33 - 10.8 Nm {0.9 - 1.1 kgm}
Check for fuel leak

Check for fuel leak, referring to the section of
"CHECKING FOR LEAKAGE IN FUEL CIRCUIT" in TESTING AND ADJUSTING.
Air bleeding
Bleed air from the fuel circuit, referring to the
section of "BLEEDING AIR FROM FUEL CIRCUIT" in TESTING AND ADJUSTING.
Wiring harness mounting nut:

2.0 - 2.4 Nm {0.2 - 0.24 kgm}
Install the fuel injector assembly in the following 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
HM300-1
Injector holder mounting bolt:

58.8 - 73.5 Nm {6.0 - 7.5 kgm}
30-13
2
(9)
REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND
INSTALLATION OF
NOZZLE TIP
3. Loosen retaining nut (4) with 19 mm deep

socket (3).
[EPA regulations]
For countries subject to EPA regulations, the
entire nozzle assembly of the common rail
engine shall be replaced if any of its components needs to be replaced. For other countries,
the following procedure may be applied for
replacing the nozzle tip.
SPECIAL TOOL
Mark
A3
Part No.
Part Name
795T-471-1550 Wrench
Necessity Q'ty
DisSketinc- tch
tion*
REMOVAL
1. Fix tool A3 in vice [1].
Do not pinch the injector directly in the vice.
4. Remove retaining nut (4) from injector assembly

(3).
5. Lift nozzle assembly (5) perpendicularly upward
to remove it.
Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
Be careful not to get the assembly dirty.
2. Set injector assembly (3) on tool A3.
30-14
2
HM300-1
INSTALLATION
5. Mount nozzle assembly (3) and manually

tighten retaining nut (2).
1. Fit tool A3 in vice (1).

Do not pinch the injector directly in the vice.
2. Set injector assembly (1) on tool A3.

3. Completely clean the lower body and screw
sections of retaining nut (2) with parts cleaner,
and apply air blow.
6. Set 19-mm deep socket [2] in the torque

wrench, then tighten the retaining nut by following the steps below.
Apply rust prevention oil on the nozzle body.
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 tightening).
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
2
HM300-1

CYLINDER HEAD ASSEMBLY
REMOVAL AND
INSTALLATION OF
SPECIAL TOOL
Mark
A2
Part No.
Part Name
790-331-1110 Wrench
Neces
Distin
Q'ty ction*
sity
Sketch
REMOVAL
k

beforehand.
1. Open up the engine hood, and tilt the operator's

cab with a crane or a built-in tilt-up cylinder.
k
6. Disconnect the following connectors and wiring

harnesses.
(6): PIM
(7): THL
(8): EG4
(9): EG5
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 converter (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
(11): Terminal (PHO)
(12): Terminal (HT)
(13): Terminal (OF)
(14) 2 locations: Grounding terminal
CN1 - CN-6 (15)

10. Remove exhaust pipe (22) between the turbocharger and the exhaust muffler.
11. Separate exhaust brake linkage (23) at the turbocharger side and remove bracket (24).
Before separating, measure the installed
dimensions.
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
(6)
2
HM300-1

13. Sling turbocharger and exhaust manifold assembly (27) to remove.

Be careful not to bend the turbocharger
lubrication tube.
4
Turbocharger and
assembly:70kg
exhaust
17. Disconnect oil feeding pipe (34).
manifold
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 manner.

21. Remove common rail cover and high pressure
tube clamp (38).
22. Remove 6 covers (39) from the fuel injector
side.
Likewise remove 6 covers from the common

rail side, too.
1) Disconnect wiring harness (43) from the fuel

injector.
2) Remove holder mounting bolt (44), and then
remove fuel injector assembly (45) with the
holder.
Do not pinch the portion of electromagnetic
valve on the upper part of the injector with
pliers.
23. Disconnect water tube (40) and spill tube (41).
24. Remove cylinder head cover (42) corresponding to the cylinder head to be removed and
installed.
30-20
2
HM300-1

26. Remove the rocker arm and rocker shaft

assembly in the following manner.
1) Loosen lock nut (46), and then loosen
adjustscrew (47) by 2 to 3 turns.
2) Remove the mounting bolt and remove
rocker arm and rocker shaft assembly (48).
If it is necessary to replace cross head
(49), loosen lock nut (50) and also
loosen adjustscrew (51) by 2 to 3 turns,
then remove the cross head.
(The cylinder head may be removed and
installed with the cross head installed.)
INSTALLATION

removal.
Two clamps are used. Install them in the

way that clamping position of one of the two
is shifted by 180f from that of the other and
both can still be tightened from the same
direction.
3
3
HM300-1
B terminal nut:
2.45 - 2.94 Nm {0.25 - 0.3 kgm}
HT terminal nut:
1.86 - 2.45 Nm {0.19 - 0.25 kgm}
Air hose clamp:

8.8 0.5 Nm {90 5 kgm}
Seal the mating part of the exhaust pipe

thermal insulation covers closely with an
accessory belt.
Install the exhaust brake linkage to the

dimensions measured before the separation.
27. Remove 6 mounting bolts (52), and then

remove rocker housing (53).
28. Remove 6 head bolts (54) and the supplemental
bolts, and then remove cylinder head assembly
(55).
After cooler hose clamp:

9.8 0.5 Nm {100 5 kgm}
30-21
2
(9)

Tighten the exhaust manifold mounting bolts

in the following order, and then tighten the
other bolts, starting from the center bolt.
Exhaust manifold mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
Install the oil tube and oil filter bracket in the

following manner.
1) Tighten oil filter bracket mounting bolt (a)

temporarily.
2) Tighten oil tube mounting bolts (b) and (c)
temporarily.
30-22
2
(9)
Corrosion resistor hose clamp:

3.3 0.49 Nm {0.34 0.05 kgm}
Oil supply hose clamp:
5.9 0.49 Nm {0.6 0.05 kgm}
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

tube between the common rail and fuel
injector tube, refer to the section of
"REMOVAL AND INSTALLATION OF FUEL
INJECTOR ASSEMBLY" .
3) Tighten the mounting bolts in the order of

(c), (b) and (a).
Corrosion resistor and bracket assembly mounting bolt:

44.1 - 58.8 Nm {4.5 - 6 kgm}
Water and spill tube joint bolt:

9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
Injector wiring harness mounting nut:

2.0 - 2.4 Nm {0.2 - 0.24 kgm}
Injector holder mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
Fuel filter tube joint bolt:

24.5 - 34.3 Nm {2.5 - 3.5 kgm}
HM300-1

Rocker shaft mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
For procedures of adjusting the valve clearance, refer to the section of "ADJUSTING
VALVE CLEARANCE" in TESTING AND
ADJUSTING.
0
Install cross head (49) in the following manner.
Screw the bolts in the cylinder block manually at least by 2 turns or more.
Before installing, measure the stem length
"a" of all the bolts and check before use that
each bolt has not exceeded the maximum
limit of length. If there is a bolt elongated
beyond the maximum limit, do not use it
again but replace with new one.
Max. tolerable length of bolt: Below
171.4 mm.
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 adjustscrew (47) until it comes into contact with
the valve stem.
5) Tighten the adjust-screw (47) to further 20
degrees after it contacts the valve stem.
Should any bolt be tightened beyond the

specified angle, remove the bolt once and
measure the stem length again.
6) Tighten lock nut (50), while holding adjustscrew (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, cylinder block upper surface and cylinder liners
thoroughly with dry cloth or cloth with cleaning agent.
Coat the bolt threads and bolt neck with LMP or EO30-CD.
HM300-1
30-23
2
(9)

Tighten the cylinder head bolts in the following manner and in the order shown in the
figure.
When tightening for the 3rd run, use tool A2

(angle tightening wrench).
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
2
HM300-1

ENGINE ASSEMBLY
REMOVAL AND
INSTALLATION OF
ENGINE ASSEMBLY
SPECIAL TOOL
Mark
A4
Part No.
Part name
792-220-1110
Centering tool
01050-61225
Bolt
Disti
Neces
SkeQ'ty nctio tch
sity
n*
t
t
2
8
REMOVAL
k
k
k
k
k
k
k
k
k
k
k
k
k
When tilting the cab, observe the following

precautions to prevent a serious injury or fatal
accident caused by fall of the cab.
level ground.
knob.
Turn the parking brake switch ON and chock
the wheels.
Set the lock bar to the frame and lock front
and rear frame.
When tilting the cab, check that the lock lever
is fixed securely.
When it is obliged to start the engine for testing etc., check that there is nobody under the
cab.
lever.
Disconnect the negative () terminal of battery
beforehand.
If the water temperature in the radiator is high,
you may get scalded. Accordingly, wait until
the water temperature lowers, then drain.

bar.
3. Remove the engine undercover.

4. Drain engine coolant from the engine as well as
steering and torque converter (brake) oil cooler.
6
Radiator, steering and torque converter (brake) oil cooler: 51l
5. Disconnect 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

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
HM300-1
Check that the lock lever closes and the

cab (6) is held securely in position by the
lock bar (2).
30-25
(10)
2
6. Remove thermal insulation covers (4) to (6)

from the turbocharger and exhaust manifold.

ENGINE ASSEMBLY
13. Disconnect radiator outlet hose (17) on the radiator side.
7. Remove thermal insulation cover (7) from the

exhaust pipe.
14. Remove 2 fan guards (18).

8. Remove exhaust pipe (8) between the turbocharger and exhaust muffler.
9. Separate exhaust brake linkage (9) on the turbocharger 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
2
(10)
HM300-1
16. Disconnect centralized connectors of engine

(EG4) (20) and (EG5) (21).

ENGINE ASSEMBLY
18. Disconnect fuel supply hose (30) and fuel return

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).
3) Loosen air conditioner compressor mounting bolt (25) as well as adjust-rod mounting
bolt and nut (26).
19. Disconnect the following tubes and wiring from

the right side of engine.
1) Separate E terminal (E1) (30), R terminal
(CN-80) (31) and B terminal (32) from the
alternator.
4) Loosen adjust-nut (27) and remove air conditioner 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 fasten 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

ENGINE ASSEMBLY
4) Disconnect water connector (36) and water

hose (37).
5) Disconnect heater hoses (38) and (39).
20. Remove the following parts from the rear of the

engine.
2) Remove wiring clamps (41) at three points.
22. Remove 4 engine mounting bolts (44).

a Mounting bolts are on the upper side of the
engine mount and a mounting nuts are on
the underside.
23. Sling engine assembly (45) to remove.

a Check that there is no wiring or tube that is
still connected, and sling the engine assembly 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
2
(10)
HM300-1
INSTALLATION

removal.
a When replacing an engine assembly or engine
controller assembly, refer to your Komatsu distributor for fuel injection amount adjustment
before starting the work.
a Seal the mating part of the exhaust pipe
thermal insulation covers closely with an
accessory belt.
a Install the exhaust brake linkage to the
dimensions measured before the separation.
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
the same direction.
3 After-cooler hose clamp:

9.8 0.5 Nm {100 5 kgm}

ENGINE ASSEMBLY
a When removing the engine assembly, transmission and torque converter assembly or
drive shafts, carry out centering the engine
and transmission in the left and right direction in the following manner, using tool A4.
1) Install tool A4 to the coupling on the engine
side and the coupling on the torque converter side.
2) Put scale [1] to the left and right sides of tool
A4.
3) Measure the clearance between scale [1]
and tool A4 on the left side (a) and on the
right side (b).
a Check that the max. clearance remains
below 3 mm both on the left and right
sides. (If both clearances are not in parallel, check that the clearance remains
less than 3 mm even at the widest point)
a If the clearance exceeds 3 mm, make
adjustment by shifting the position of
torque converter and transmission
assembly mount.
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
the same direction.
a For adjustment of the air conditioner compressor belt tension, refer to the section of
"TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION"
in the chapter of INSPECTION AND
ADJUSTMENT.
a When installing the drive shaft, check that

the keyway of spider cap fully engage with
that of the corresponding yoke, and then
tighten the mounting bolt.
2 Mounting bolt
: Liquid adhesive compound (LT-2)
3 Mounting bolt for drive shaft
between engine and transmission:
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

RADIATOR ASSEMBLY
a When measuring dimension "a" between

the flywheel housing and the coupling tip,
while drive shaft (43) between the engine
and transmission is in place, and if this
dimension "a" falls out of the value shown
below, make adjustment by shifting the position of engine assembly mount or transmission and front differential assembly mount
so that the dimension falls within the specified value.
Dimension "a" between flywheel housing
and coupling tip: 161.2 -30 mm
REMOVAL AND
INSTALLATION OF
RADIATOR ASSEMBLY
REMOVAL
k

beforehand.
k Turn the parking brake switch on and put
wooden blocks behind the wheels.
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
2
(10)
HM300-1
6. Disconnect radiator outlet hose (7) from the bottom of radiator.

RADIATOR ASSEMBLY
9. Remove 4 mounting bolts, and put air conditioner 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
(9)
2

RADIATOR ASSEMBLY
13. Sling radiator and after-cooler assembly (14) to

remove, using eyebolt [1].
4
Radiator and after-cooler assembly

: 165kg
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.
14. Separate radiator assembly (15) from aftercooler assembly (16).

4
After-cooler assembly: 30kg
INSTALLATION

removal.

direction.
3 After-cooler hose clamp:
9.8 0.5 Nm {100 5 kgm}

direction.
30-32
2
(9)
HM300-1

OUTPUT SHAFT ASSEMBLY
REMOVAL AND
INSTALLATION OF
Check that the lock lever (2-1) closes and

the operator cab assembly (3) is held
securely in position by the lock bar (2).
SPECIAL TOOL
Mark
A4
V
Part No.
Part name
792-220-1110
Centering tool
01050-61225
Bolt
792-454-1100
Pump assembly
Disti
Neces
SkeQ'ty nctio tch
sity
n*
t
t
q
2
8
1
REMOVAL
k
k
k
k
k
k
k
k
k
k
k
k
k

level ground.
knob.
the wheels.
and rear frame.
is fixed securely.
cab.

4. Disconnect the following 5 hoses from steering

and hoist pump (1).
(2), (3), (4) and (5): Discharging hoses
(6): Suction hose

lever.
Loosen the hydraulic oil filler cap to release
the remaining pressure in the hydraulic tank.
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 tiltup 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

remove.
4
Steering and hoist pump assembly

: 50kg
6. Sling drive shaft (7) between the engine and

transmission to remove.
7. Remove coupling (8).
30-34
2
(10)

a When replacing oil seal (10), remove oil seal

cage (9) first, using forcing screws [1], and
then take out the oil seal from the cage.
8. Remove cover plate assembly (10).
9. Remove plate (12) from cover (11).

a A seal is provided between cover (11) and
plate (12).
HM300-1
10. Sling output shaft assembly (13) to remove,

using guide bolts [2].
4
Output shaft assembly: 50kg
INSTALLATION

removal.
a Install the drive shaft between the engine
and transmission, referring to the section of
"REMOVAL AND INSTALLATION OF
ENGINE ASSEMBLY".

a When installing the oil seal, press-fit it until

"f" dimension from the edge of oil seal cage
is reached.
Oil seal press-fitting dimension f
: 1 0.5mm
a When installing the oil seal, fill "G" clearance 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:
Molylex No. 2 of Kyodo Yushi or
equivalent
Retinax AM of Showa Shell
Sekiyu or equivalent
Molynoc No. 2 of Nippon
Mitsubishi Oil or equivalent
a Install the coupling after filling "S" part with

20 cc of extreme-pressure grease containing lithium type molybdenum disulfide.
2 Extreme-pressure grease containing

lithium type molybdenum disulfide:
Molylex No.2 of Kyodo Yushi or
equivalent
Molynoc No. 2 of Nippon
a Coat the spline portion of coupling with drying type lubricant of molybdenum disulfide
and install after the lubricant dries up in a
few minutes.
2 Drying type lubricant of molybdenum

disulfide:
Rocol Dry Spray of Sumico Lubricant
or equivalent
HM300-1
3 Oil seal cage mounting bolt

: 58.8 - 73.5 Nm {6 - 7.5 kgm}
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
3 Output shaft assembly mounting bolt
: 58.8 - 73.5 Nm {6 - 7.5 kgm}
30-35-1
2(10)
HM300-1
ASSEMBLY AND
DISASSEMBLY OF
DISASSEMBLY

2. Outer body
1) Set outer body (5) on wooden blocks [2],
keeping it off the ground.
2) Separate outer body (5) from inner body (6),
hitting the inner body with push tool [3].
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
2
HM300-1
3) Push inner body (11) out of outer flange (12)

with a press, using push tool [4].

ASSEMBLY
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
Molynoc No.2 of Nippon
Bearing outside contact face and

periphery
: Loctite 601 or equivalent
4) Remove bearing (13) from outside flange

(12).
HM300-1
30-37
(9)
2

2) Set outside flange (12) on inner body (11),

and then press-fit, using push tool [5].
2
Bearing inside contact face and

perimeter
: Loctite 601 or equivalent
3. Rubber
Install 4 large pieces of rubber (7) and 4 small
pieces of rubber (8).
Set the rubber pieces as shown in the photo
below.
2
When installing the rubber pieces, coat

all over the rubber, inner body periphery and outer body periphery with
grease (G2-LI).
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
30-38
2
Mating face
HM300-1
REMOVAL AND INSTALLATION OF TRANSMISSION AND

FRONT DIFFERENTIAL ASSEMBLY
REMOVAL AND
INSTALLATION OF
TRANSMISSION AND
FRONT DIFFERENTIAL
ASSEMBLY
6. Remove the operator's cab assembly in the following order.
SPECIAL TOOL
Mark
Neces Q'ty Distin Skesity

ction* tch
Part No.
Part Name
799-703-1200
Service Tool Kit
799-703-1100
Vacuum Pump
(100 V)
799-703-1110
Vacuum Pump
(200 V)
799-703-1120
Vacuum Pump
(240 V)
799-703-1400
Gas leak tester
REMOVAL
k

beforehand.
k Turn the parking brake switch on and put
1. Drain hydraulic oil.
6
Hydraulic tank: 120l
1) Disconnect 11 wiring connectors (1) to (11)

from "A" part.
(1) : J08
(2) : J09
(3) : J02
(4) : J04
(5) : J05
(6) : J06
(7) : J07
(8) : J10
(9) : J11
(10) : J01
(11) : (Spare)
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 converter (brake) oil cooler: 51l

cab with a crane or using a built-in tilt-up cylinder.
k

bar.
For procedures of removing and installing the
operator's cab, refer to the section of
"METHOD OF TILTING CAB UP" in TESTING AND ADJUSTING.
HM300-1
30-39
(9)
2

2) Disconnect 5 brake valve hoses (12) to (16)

from "B" part and remove clamp (17) at 2
points.
In order to make no mistake about the
installing position, either mark each
hose or attach an identification tag.
(12) : A port hose
(13) : B port hose
(14) : PB port hose
(15) : T port hose
(16) : PA port hose
3) Disconnect 5 hoses (18) to (22) from "C"

part.
The ports listed hereunder stands for a
port in the steering valve.
(18) : LS port hose
(19) : R port hose
(20) : L port hose
(21) : T port hose
(22) : P port hose
30-40
(9)
2
4) Disconnect air conditioner hoses (23) and

(24) as well as heater hoses (25) and (26)
from "D" part.
k In disconnecting the air conditioner
hoses, it is a dangerous practice to disconnect the hoses without first releasing pressure inside the cooling system.
For this reason, evacuate the air conditioner gas before the work, using tool
X.
When the heater hose is disconnected,
coolant leaks out, so prepare for a blind
plug.
5) Remove head pin (28) from cab lift cylinder

(27) in "E" part.
After removing the head pin, retract the
lift cylinder to its stroke end.
Shims are provided, so check their
thickness, number in use and installed
position beforehand.
HM300-1

6) Lower the tilted operator's cab assembly

with a crane.
Lower the operator's cab after checking
that no wiring or piping gets pinched.
7. Sling vertical member (31) to remove.

4
Vertical member: 35 kg
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 thickness, number in use and installed location beforehand.
8. Separate the following parts from the transmission upper front side.
1) Disconnect 5 hoses (33) to (37) from steering 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
HM300-1
Steering and hoist pump assembly

: 50 kg
30-41
(5)
2

3) Remove upper and lower drive shaft guards

(33), and then remove drive shaft (34)
between the engine and transmission.
8) Disconnect grounding wire (42) at the front

left side.
4) Remove coupling (35) on the output shaft

side.
9. Separate the following parts from the transmission 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
(9)
(5)
2
HM300-1

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 supply 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 coupling (52) between the sub-tank and oil supply piping.
4) Remove the mounting bolts of oil supply
connector (53).
5) Disconnect oil supply piping (54).
6) Disconnect transmission output shaft revolution 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 differential mount (58) from the machine's
underside.
Shims are installed, so check their thickness, number in use and installed location beforehand.
7) Remove drive shaft (56) between the transmission and hitch frame.
4 Drive shaft between transmission
and hitch frame: 30 kg
HM300-1
30-43
(9)
2

13. Sling the transmission and front differential

assembly to remove.
1) Sling the transmission and front differential
assembly until the transmission front mount
(59) gets clear of the floor, and remove left
and right mount brackets (61).
INSTALLATION

removal.
2) Sling transmission and front differential

assembly (62) slowly and remove it.
Make sure that no hose or wiring is left
still connected.
In particular, take good care to avoid
interference between the torque converter outlet tube on the front side and
the output shaft oil seal as well as interference between the rear left mount and
the hoist valve.
4 Transmission and front differential
assembly: 1,450 kg
30-44
(9)
2
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 connecting them, and then tighten with a double
spanner.
3 Hose spigot (M16 x 1.5)

: 12 - 15 Nm {1.2 - 1.5 kgm}
3 Hose spigot (M24 x 1.5)
: 30 - 35 Nm {3.0 - 3.5 kgm}
Adjust the clearance between operator's

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
HM300-1

3 Mounting bolt for front differential
mount
: 1,150 - 1,440 Nm {118 - 147 kgm}
Install the drive shaft between the engine

and transmission, referring to the section of
"REMOVAL AND INSTALLATION OF
ENGINE ASSEMBLY".
3 Mounting bolt for front transmission

mount
: 153 - 190 Nm {15.5 - 19.5 kgm}
3 Mounting bolt for rear transmission
mount
: 171.5 - 214.5 Nm {17.5 - 21.9 kgm}
Coat the coupling spline with dry type lubricant of molybdenum disulfide, and install
after it dries up in a few minutes.
2
Dry type lubricant of molybdenum

disulfide:
Rocol Dry Spray of Sumico Lubricant
or equivalent
When installing the drive shaft between the

transmission and hitch frame, turn it to face
in the same direction as the yoke of the
drive shaft between the hitch frame and
center differential.
When installing drive shafts, check that the
spider cap keyway fully engages with the
keyway of the counter yoke, and then
tighten the mounting bolts.
Install the drive shaft between the transmission and hitch frame only after confirming
that it faces in the same direction as the
yoke of the drive shaft between the hitch
frame and center differential does.
2
3 Mounting bolt for rear transmission

mount
: 171.5 - 214.5 Nm {17.5 - 21.9 kgm}
Oil supply (hydraulic tank)

Refill with oil through the oil filler port up to the
specified level, then start the engine to let oil circulate in the piping and check the oil level
again.
5 Hydraulic tank :120l (EO10-CD)
Oil supply (transmission case and brake oil

tank)
specified level, then start the engine and run at
low idle, and check the oil level again.
5 Transmission and brake oil tank
: 77.5l (EO10-CD)
Mounting bolt
3 Mounting bolt for drive shaft between

transmission and hitch frame and
mounting bolt for left and right drive
shaft
:98 - 123 Nm {10 - 12.5 kgm}
Install the transmission front mount, keeping

it clear of the floor.
Water supply
Refill with water through water filler port up to
the specified level, then start the engine to raise
the coolant temperature, and check the coolant
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 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
(9)
2
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL

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 differential assembly (9), and support front differential assembly (9) with hydraulic jack [1].
6. Remove the front differential assembly mounting 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 actuating pump (5).
4
Front differential assembly: 340 kg
Rear brake cooling and brake actuating pump: 30 kg
3. Remove the torque converter, transmission and

front brake cooling pump (6).
4
30-46
(9)
2
Torque converter, transmission and

front brake cooling pump: 25 kg
HM300-1
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL

ASSEMBLY AND TRANSMISSION ASSEMBLY
CONNECTION
Carry out connection in the reverse order to

disconnection.
2
Mount bracket mounting bolt

Mount bracket mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
Front differential mounting bolt

HM300-1
Front differential mounting bolt

: 245 - 309 Nm {25 - 31.5 kgm}
30-47
2

TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
TORQUE CONVERTER
ASSEMBLY
SPECIAL TOOL
Mark
Part No.
790-501-5000
1 790-901-2110
Part Name
Unit Repair Stand
Bracket
792T-213-1210 Plate
2 792-213-1110
Wrench
DisNeces- Q'ty tinc- Sketch

sity
tion*
1
1
1
2) Turbine
Reverse the drive case, then remove the
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
2
HM300-1
5) Plate and snap ring

Reverse the clutch housing, then remove
snap ring (11), and remove plate (12).
6) Shaft and piston

Remove shaft (13) from clutch housing
assembly (9), using push tool [4], and then
remove piston (14).

8) Bearing, seal ring and pin

i) Remove bearing (16) from the clutch
housing, using push tool [5].
ii) Remove seal ring (17).
3. Stator assembly
Pull up stator assembly (18) to remove.
4. Further disassembly of stator assembly

7) Seal ring
Remove seal rings (15) from piston (14).
HM300-1
1) Stator
Remove snap ring (40) and then remove
stator (41).
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 assembly from tool C1.
3) Stator shaft assembly and bearing inner
race
Remove stator shaft assembly (28) and
bearing inner race (29) from pump assembly (27) by pushing stator shaft assembly
(28).
30-50
2
HM300-1
5) Retainer
Remove mounting bolts (33) and then
remove retainer (35) from pump (34).

ASSEMBLY
1. Subassembly of pump and stator shaft
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

HM300-1

: 58.8 - 73.5 Nm {6 - 7.5 kgm}
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 manufacturing 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 (EO10CD 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

4) Stator shaft assembly and bearing inner

race
i) Press-fit stator shaft assembly (28) into
pump assembly (27).
Nut
: 441.3 - 490.3 Nm {45 - 50 kgm}
2. Subassembly of stator assembly

ii) Press-fit bearing inner race (29) into stator shaft (30), using push tool [7].
Bearing inner race (29) 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.
1) One-way clutch and race

Install one- way clutch (23) to race (19).
Install the one-way clutch so that an
arrow shown on the cage edge faces
the input side, and check the stator rotation direction as viewed from the input
side.
Clockwise: No load
Counter-clockwise: Lock
2
Sliding surface
: Engine oil (EO10-CD or EO30-CD)
30-52
2
HM300-1
2) Bushing
Expansion-fit bushings (20) and (21) with
ball (50) into race (19).
2
Sliding surface

4. Subassembly of turbine and clutch assembly

1) Bearing, seal ring and pin
i) Install bearing (16), using push tool [8]
ii) Install seal ring (17).
2
Seal ring periphery

: Grease (G2-LI)
Drip approx. 6 cc of engine oil (EO10CD 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 direction 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

assembly.
2
Seal ring periphery

: Grease (G2-LI)

4) Disc
Install disc (10) to clutch housing assembly
(9).
2
Sliding surface
5) Drive case
Install drive case (8) to clutch housing
assembly (9).
2
Mounting bolt
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

Install plate (12) to the shaft and then install
snap ring (11).
30-54
(9)
2
Mounting bolt
: 58.8 - 73.5 Nm {6.0 - 7.5 kgm}
HM300-1

7) Input shaft
i) Install bearing (6), using push tool [10].
Drip approx. 6 cc of engine oil (EO10CD 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
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
HM300-1
Mounting bolt
: 27 - 34 Nm {2.8 - 3.5 kgm}
30-55
2


C1 Plate
30-56
2
HM300-1

TRANSMISSION ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
SPECIAL TOOL
Mark
Part No.
Part Name
1 790-102-1871
Nut Wrench
2 796-465-1120
Push Tool
3 792T-423-1110 Push Tool

792T-213-1220 Push Tool
4 790-101-5421
01010-81240
D
Grip
Bolt
792T-213-1230 Push Tool

5 790-101-5421
01010-81240
6 790-201-2730
Grip
Bolt
Spacer
7 792T-413-1120 Push Tool

8 792T-215-1120 Push Tool
9 799-301-1500
Oil Leak Tester Kit
Dis- SkeNecesQ'ty tincsity

tch
tion*
1
1
N
c
c
c
c
1
1
1
1
1
1
1
1
1
1
1
DISASSEMBLY
1. Trunnion
1) Remove plate (300) and then remove trunnions (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), output 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 disconnect piping (14).
4. Strainer (left and right)

Remove cover (15) and then remove strainer
(16) and block (17).
5. Transmission control valve assembly

Seal the oil holes on the installing face with
tape or the like so that no foreign objects
enter them.
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 outlet oil temperature sensor (26).
Seal the oil holes on the installing face with
tape or the like so that no foreign objects
enter them.
1) Disconnect tubes (18), (19) and (20).

2) Remove transmission control valve assembly (21) and valve seat (302) together.
3) Remove each transmission control valve
and filter assembly (303) from the valve
seat.
30-58
2
HM300-1
7. Coupling
1) Remove input coupling (27) and output coupling (28).
2) Remove cover (304) from output coupling

(28).


3) Remove cage (30), using forcing screws [1].
Check the thickness of shims and their
number in use beforehand.
4) Remove outer race (31) from cage (30).
8. Cover and cage (R clutch and 2nd clutch

side)
9. Retainer and cage (differential lock clutch

rear output side)
1) Sling the transmission assembly and set it

on the block so that the transmission case
faces up.
1) Screw forcing screws in holes A and remove

retainer (32).
HM300-1
2) Screw forcing screws in holes B and remove

cage (33).
30-59
(9)
2

3) Remove dust seal (34) and oil seal (35)

from retainer (32).
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
be broken. Accordingly, be sure to disassemble the transmission with the torque
converter side down.
12. Seal ring

Remove seal rings (44), (45) and (46).
11. Further disassembly of rear transmission

case assembly
1) Remove holder (37) to remove bearing (39),
then remove gear (38), bearing (40) and collar (41).
2) Remove outer races (320) and (321) from
gear (38).
3) Remove bearings (42) and (43).
30-60
(5)
2
HM300-1
13. Clutch assembly

Sling [53] is shown just as an example.
1) Take out idler gear (138) of FH and 1st
clutch assembly (47) together with inner
race (137), using puller [18].

5) Sling FL and R clutch assembly (49) to

remove.
For details on the further disassembly of
the FL and R clutch assembly, refer to
the sections of 23 and 24.
2) Sling 2nd and 3rd clutch assembly (48) to

remove.
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 independently, when the differential lock
clutch assembly is still installed.
differential lock clutch assembly, refer to
the section of 18.
4) Sling FH and 1st clutch assembly (47) to
remove.
the FH and 1st clutch assembly, refer to
the sections of 21 and 22.
14. Further disassembly of front transmission

case assembly
1) Remove bearing (50) and outer races (51)
and (52).
2) Reverse the case and remove cage (53),

using forcing screws [3].
HM300-1
30-61
(9)
2

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) beforehand, 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 further 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
2
HM300-1
17. Torque converter assembly

Remove mounting bolts (67) connecting the
torque converter assembly with front transmission case, and then remove torque converter
assembly (68).
a For disassembly of the torque converter
assembly, refer to the section of "DISASSEMBLY AND ASSEMBLY OF TORQUE
CONVERTER".

2) Separate rear housing (70) from the output

gear, using forcing screws [6].
3) Sling rear housing (70) together with bearing (71) and rear output shaft (72), using
tool [54] and remove.
4) Disassemble the rear output shaft, rear

housing and ring gear further in the following 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.
HM300-1
ii) Screw bolt [7] into the tapped hole for

slinging and raise ring gear (74) to
remove.
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
2(10)
HM300-1
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

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).
14) Disassemble the front output shaft, front

housing and output gear further in the following steps.
i) Separate front output shaft and housing
assembly (92) from output gear (93),
using forcing screws [10], and sling to
remove.
ii) Remove seal rings (94).

iii) Remove snap ring (308).
30-66
(9)
2

iv) Reverse the front output shaft and housing assembly, and separate front output
shaft (95) from front housing (96), using
puller [11].
v) Remover seal rings (306) from front output shaft (95) and seal ring (307) from
front housing (96).
vi) Remove snap ring (97) and spacer (98),

and then remove bearing (99) from the
front output shaft.
HM300-1

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
the following steps.
i) Remove snap ring (102) and then bearing (103).
2) Remove 2nd gear (112) together with bearing (109), plate (110) and thrust washer
(111), using forcing screws [13].
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) during the work.
HM300-1
30-67
(9)
2
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 thickness in between the tool and end plate
(114), and compress the spring.
5) Remove end plate (114).
30-68
2
HM300-1

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 piston (120).

(128) with a C clamp, and remove snap ring
(129).
20. Further disassembly of 2nd and 3rd clutch

assembly (3rd clutch side)
7) Remove end plate (128), 10 plates (130), 9

discs (131) and 9 springs (132).
(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


(144).
21. Further disassembly of FH and 1st clutch

assembly (1st clutch side)
1) Set the clutch assembly to a cylinder-like
tool.
7) Remove 12 plates (145), 11 discs (146) and

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
2
HM300-1
22. Further disassembly of FH and 1st clutch

assembly (FH clutch side)
2) Remove FH gear (155) together with bearing (152), plate (153) and thrust washer
(154).

3) Remove bearing (156) from FH gear (155).

(157), using a C clamp, and remove snap
ring (158).
The spring can also be compressed by
fitting the tool to tapped holes A on the
FH and 1st cylinder and idler gear, and
then inserting a spacer of appropriate
thickness in between the tool and end
plate.
(162).
HM300-1
30-71
2

4) Remove bearing (169) from R gear (168).
23. Further disassembly of FL and R clutch

assembly (R clutch side)

(170) with a C clamp, and remove snap ring
(171).
1) Set the clutch assembly to a cylinder-like

tool.

2) Hook the claw of puller [22] to the underside

of plate (166), and remove inner race (165)
and plate (166).
7) Remove thrust washer (175) and thrust

bearing (176).
3) Remove thrust washer (167) and then R

gear (168).
30-72
2
HM300-1
24. Further disassembly of FL and R clutch

assembly (FL clutch side)

4) Remove bearings (184) from FL gear (183).

2) Remove idler gear (181) together with inner

(186).
3) Remove thrust washer (182) and then FL

gear (183).
HM300-1
7) Remove 11 plates (187), 10 discs (188) and

10 springs (189).
30-73
2

8) Remove thrust washers (190) and thrust

bearing (191).
ASSEMBLY
Clean each of the parts thoroughly and

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 (EO10CD) for more than 2 minutes before
assembling.
Assemble each seal ring (a) for pistons of
the clutch assembly with its pressurereceiving side (b side) facing housing (c) as
shown in the figure below.
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 pressurereceiving side facing the housing side.
30-74
2
HM300-1
2) Install piston (192).

2

6) Install bearings (184) to FL gear (183).
Seal ring periphery and sliding surface: Engine oil (EO-10CD)
3) Install thrust washer (190) and thrust bearing (191).
4) Install each of 11 plates (187), 10 discs

(188) and 10 springs (189) alternately from
the bottom to the top.
Immerse the discs in clean engine oil
(EO-10CD) for more than 2 minutes
before assembling.
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
disc mountains.
8) Remove FL gear (183) once.
(185), using tool [25], and install snap ring
(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

(182).
If it is found difficult to assemble the FL
gear in, start the work all again from the
step 7) above.
11) Install idler gear (181) and shrink-fit inner

race (180).
Shrink-fit temperature
: For 30 minutes at approx. 120fC
12) Apply a dial gauge to the edge surface of
idler gear (181), move the idler gear in the
thrust direction and check that clearance "a"
remains within the range of 0.28 and 1.10
mm.

2. Subassembly of FL and R clutch assembly

(R clutch side)
(177).
Install the seal ring with its pressurereceiving side facing the housing.

2
Seal ring periphery and sliding surface

: Engine oil (EO-10CD)
3) Install thrust washer (175) and thrust bearing (176).

before assembling.
30-76
2
HM300-1
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
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).
HM300-1
3. Actuation test of FL and R clutch assembly

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.
30-77
2
4. Subassembly of FH and 1st clutch assembly

(FH clutch side)

6) Install bearing (156) to FH gear (155).

(162).
Install the seal rings with their pressurereceiving side facing the housing.

2
3) Install thrust washer (210).

before assembling.
7) Install FH gear (155) to the clutch assembly,

and match disc grooves.
disc mountains.
8) Remove FH gear (155) once.
(157) with a C clamp, and install snap ring
(158).
30-78
2
HM300-1
10) Install FH gear (155).

If it is found difficult to assemble the FH
step 7) above.
11) Install thrust washer (154) and plate (153).


2
12) Shrink-fit bearing (152).

Shrink fit temperature
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.

before assembling.
5. Subassembly of FH and 1st clutch assembly

(1st clutch side)
(149).
Install seal rings with their pressurereceiving side facing the housing.
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.
8) Remove 1st gear (141) once.
(143), using tool [19], and install snap ring
(144).
12) Install idler gear (138) and shrink-fit inner

race (137).

1st gear (141), move the 1st gear in the
thrust direction and check that clearance "d"
mm.
30-80
2
HM300-1
6. Actuation test of FH and 1st clutch assembly

1) Blow air into the shaft oil hole, using tool D9,
If the gear on the air-blown side is fixed,
the clutch is in normal operation.


2

4) Install each of 10 plates (130), 9 discs (131)
and 9 springs (132) alternately from the bottom 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 assembly (3rd clutch side)
(134).
HM300-1
6) Install bearing (127) to 3rd gear (126).
30-81
2
7) Install 3rd gear (126) to the clutch assembly

disc mountains.


3rd gear (126), move the 3rd gear in the
thrust direction and check that clearance "e"
mm.
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 assembly (2nd clutch side)

(120).
12) Press-fit bearing (124), using tool D2. (Or

shrink-fit the bearing)

2
30-82
2
HM300-1
4) Install each of 10 plates (116), 9 discs (117)

and 9 springs (118) alternately from the bottom to the top.
before assembling.

6) Install bearing (113) to 2nd gear (112).
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).

If it is found difficult to assemble the 2nd
step 7) above.
12) Press-fit bearing (109), using tool D3. (Or

shrink-fit the bearing.)
30-84
2


2nd gear (112), move the 2nd gear in the
thrust direction and check that clearance "f"
mm.
9. Actuation test of 2nd and 3rd clutch assembly

Blow air into the shaft oil hole, using tool D9,
If the gear on the air-blown side is fixed, the
clutch is in normal operation.
HM300-1
10. Subassembly of differential lock clutch

assembly
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 carrier side.
Before hammering, make sure that the
alignment is correct so that the thrust
washers are not damaged.

iv) Install bearing (103) and then snap ring

(102).
2) Carry out subassembly of the front output

shaft, front housing and output gear in the
following steps.
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

shaft.
iv) Install spacer (98) and snap ring (97).

vii) Install snap ring (308), and then install

seal rings (94) to the front output shaft.
viii) Sling front output shaft and housing

assembly (92) and install output gear
(93).
v) Install seal rings (306) to front output

shaft (95) and seal ring (307) to front
housing (96).
Install seal ring (307) with its pressure-receiving side facing the bearing in the housing.
Housing mounting bolt

Housing mounting bolt

: 59 - 74 Nm {6 - 7.5 kgm}
Seal ring periphery

: 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
(9)
2
HM300-1
3) Set the front output shaft-housing-output

gear assembly with the rear output shaft
connecting side facing up.
4) Install seal ring (91) to piston (90).
Install the seal ring with its pressurereceiving side facing the housing.
2

7) Install each of 6 plates (87), 5 discs (88) and

5 springs (89) alternately from the bottom to
the top.
(EO-10CD or EO-30CD) for more than 2
minutes before assembling.
Seal ring periphery

: Grease (G2-LI)
8) Compress the spring by pushing plate (87),

using tool [27], and install snap ring (86).
9) Install sun gear (84), snap ring (82), inner

race (83) and snap ring (81).
6) Install clutch hub (85).
HM300-1
30-87
(9)
2

10) Install carrier assembly (80) to the front output shaft-housing-output gear assembly.
i)
Shrink-fit bearing (71) to rear housing

(70).
Shrink-fit temperature of bearing
(71)
: For 30 minutes at approx. 120C
11) Install plate (79).

2
3
Plate mounting bolt

Plate mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}
ii) Install snap ring (73), ring gear (74) and

spacer (76) to the rear shaft.
iii) Press fit the rear housing assembly to
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 following steps.
30-88
2(10)
HM300-1

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
3
Rear housing mounting bolt

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

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".

2) Install retainer (64) to the PTO case.
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)
Periphery of press-fitted face on

retainer side
: Gasket sealant (Three Bond 1110B)
After press-fitting, wipe out oozed gasket sealant completely.
30-90
2
HM300-1
ii) Press-fit bearing (60) into PTO gear

(61), using tool D6.
Check that a manufacturing No. and
a counter mark on inner ring (58)
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.)
iii) Install spacer (59) to the shaft of PTO

gear (61), and assemble in the PTO
case.
iv) Press-fit bearing (58) and install spacer
(57) and snap ring (56).

13. PTO case assembly

1) Install guide bolt [27] to the front transmission case, and install PTO case assembly
(54) to the front transmission case.
2) Tighten nut (55) of the PTO gear, using tool

D1.
Install the nut with its chamfered side
facing inward.
Install the input coupling and use it as a
lock.
2
Nut: Grease (G2-LI)

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
Tool [53] is shown just as an example.
Seal ring: Grease (G2-LI)
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
2) Install FH and 1st clutch assembly (47).

Install this assembly with idler gear
(138) and inner race (137) as removed.
1) Install collar (41).

Be careful of the installing direction.
(Refer to the figure below.)
2) Press-fit bearing (40), using tool D7.
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
2
HM300-1

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 manufacturing 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)
Holder mounting bolt
: 245 - 309 Nm {25 - 31.5 kgm}
6) Install bearings (42) and (43).
2) Install guide bolt [28] to rear transmission

case assembly (29) and install the assembly.
When installing, be careful of interference 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
(9)
2

19. Subassembly of retainer and cage (differential 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 completely after press-fitting.
2
Seal lip face and clearance

between dust seal and oil seal
: Silicone grease (Three Bond 1855)
Press-fitted surface of periphery on

cover side
30-94
2
HM300-1
21. Shim adjustment of taper roller bearing (2nd

clutch side and differential lock clutch side)
1) Install cages (30) and (33) without shims to
the rear transmission case.
3
Mounting bolts of cages (30) and

(33)
: 8.8 - 10.8 Nm {0.9 - 1.1 kgm}
2) Blow air into oil passage A through oil hole

B for the differential lock clutch to operate
this clutch, using tool D9, and rotate output
shaft (200) by 20 turns.
3) Check that there is no change in the tightening torque of cages (30) and (33) mounting
bolts. If any, repeat the steps 1) and 2).
4) Loosen cages (30) and (33) mounting bolts.
5) Measure rotation torque of output shaft
(200).
Rotation torque
: 11.8 - 17.6 Nm {1.2 - 1.8 kgm}
6) Measure clearance "a" between cage (30)
and the rear transmission case at three
points of periphery (120 degrees apart) and
calculate the average value.
If fluctuation of the values measured at
three points does not fall within 0.15
mm, check whether the bearing is correctly installed, or there is any other
cause. Take a corrective action as the
case may be, and measure again.

8) Tighten cage (30) mounting bolts.

3
Mounting bolt
: 98 - 122 Nm {10 - 12.5 kgm}
9) Activate the differential lock clutch to measure rotation torque of output shaft (200),
and check that increment from the value of
rotation torque obtained in the step 5
remains within the following range of values.
Rotation torque increment
: 4.9 - 12.8 Nm {0.5 - 1.3 kgm}
10) Measure clearance "b" between cage (33)
and the rear transmission case at three
points of periphery (120w apart) and calculate the average value.
If fluctuation of the values measured at
three points does not fall within 0.15
mm, check whether the bearing is correctly 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.
Thickness decrement: 0.20 - 0.25 mm
Shim thickness tolerance (for reference): 1.5 - 2.9 mm
12) Tighten cage (33) mounting bolts.
3
Mounting bolt
: 98 - 122 Nm {10 - 12.5 kgm}
13) Measure rotation torque of output shaft

(200), and check that increment from the
value of rotation torque obtained in the step
9) remains within the following range of values. (See a note below.)
Rotation torque increment
: 1.9 - 9.8 Nm {0.2 - 1.0 kgm}
Note: Only with the 2nd clutch, this measurement is to be taken at the time of shim
adjustment.
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 reference): 1.2 - 2.1 mm
HM300-1
30-95
(9)
2

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 coupling (27) together with the holder.
2
Output coupling mounting bolt

22. Install retainer (32).
Output coupling mounting bolt

: 662 - 829 Nm {67.5 - 84.5 kgm}
Input coupling mounting bolt

Input coupling mounting bolt

: 245 - 309 Nm {25 - 31.5 kgm}
23. Install cover (305).

2
Mounting bolt
30-96
2
Mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}
HM300-1
26. Main relief valve assembly, valve flow

assembly and each sensor
Install 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 outlet oil temperature sensor (26).
Degrease the grounding wire mounting part
on the main relief valve assembly thoroughly.
When installing the input shaft rotation sensor, refer to the section of "ADJUSTING
TRANSMISSION SPEED SENSOR" in
3
3
2
HM300-1
Main relief valve assembly mounting bolt

: 44.1 - 53.9 Nm {4.5 - 5.5 kgm}
Valve flow assembly mounting bolt
: 29.4 - 39.2 Nm {3 - 4 kgm}
Torque converter intermediate
pressure oil pressure sensor
thread: Gasket sealant (LG-5)

27. Transmission control valve assembly

1) Install filter assembly (303) to valve seat
(302).
When case (310) and plug (311) have
been removed from the filter assembly,
tighten each of them to the following
torque.
3
3
Case
: 34.3 - 44.1 Nm {3.5 - 4.5 kgm}
Plug
: 15.7 - 19.2 Nm {1.6 - 2.0 kgm}
2) Install each transmission control valve to

valve seat (302).
3
Mounting bolt
: 8 - 10 Nm {0.8 - 1.0 kgm}
3) Install transmission control valve assembly

(21) together with the valve seat in the rear
transmission case after installing O-rings to
the case.
4) Install tubes (18), (19) and (20).
Torque converter intermediate

pressure oil pressure sensor
: 9.8 - 19.6 Nm {0.15 - 0.20 kgm}
Torque converter output oil temperature sensor thread
Torque converter output oil temperature sensor
: 29.4 - 49 Nm {3 - 5 kgm}
30-97
(9)
2
28. Strainer (left and right)

Install block (17) and then strainer (16) and
cover (15).

30. Wiring harness, each sensor and piping

1) Install tubes (8), (9) and (10).
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 intermediate shaft rotation sensor (5).
a When installing them, refer to the section of "ADJUSTING TRANSMISSION
SPEED SENSOR" in INSPECTION
AND ADJUSTMENT.
4) Install hose (4) and wiring harness assembly (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 sensor (11).
2
3
30-98
2(10)
sensor thread
sensor: 29.4 - 49 Nm {3 - 5 kgm}
HM300-1

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 application adhesive compound of Loctite
Prism in cloth and clean the mating surface on the bushing side.
iii) Coat the trunnion mating surfaces with
411 instant adhesive compound of Loctite 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 coating the hard-to-stick application
adhesive compound of Loctite
Prism.
Do not mix the primer with the adhesive compound.
2) Install trunnions (1) and (2).
HM300-1
30-99
2


D3 Push Tool
D4 Push Tool
30-100
2
HM300-1

D5 Push Tool
D7 Push Tool
HM300-1
30-101
2

D8 Push Tool
30-102
2
HM300-1

DISASSEMBLY AND
ASSEMBLY OF
FRONT DIFFERENTIAL
ASSEMBLY
4. Coupling
Remove holder (4) and coupling (5).
SPECIAL TOOL
Mark
Part No.
Part Name
DisNeces- Q'ty tinc- Sketch

sity
tion*
1 792T-227-1110
Push Tool
792T-423-1130
Push Tool
H 2 790-101-5421
01010-51240
3 790-201-2840
Grip
Bolt
Spacer
c
c
1
1
1
DISASSEMBLY
1. Drive shaft cover
Remove drive shaft covers (1) at left and right.
5. Removal of bevel pinion and cage assembly

Remove bevel opinion and cage assembly (6),
Shims are provided, so check their thickness, number in use and installed locations
beforehand.
2. Upper cover
Remove upper cover (2).
6. Further disassembly of bevel pinion and

cage assembly
3. Bevel gear fall-proof bolt
Remove bevel gear fall-proof bolt (3).
HM300-1
1) Remove bevel pinion assembly (8) from

cage assembly (7), using push tool [2].
30-103
2
2) Remove spacer (10) and bearing (11) from

bevel pinion (9).

8. Side carrier and shaft assembly and differential gear assembly

1) Sling differential gear assembly (22), and
remove side carrier assemblies (23) and
(24), using forcing screws [3].
locations beforehand.
2) Remove differential gear assembly (22)
from differential housing (25).
3) Remove oil seals (13) and (14) from cage

(12).
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 locations beforehand.
30-104
2
HM300-1

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).

Put fingers into a hole on the case side
and lift.

8) Remove 4 pinion gears (46) and 4 bushings

(47) from shaft (45).
9) Remove differential side gear (48).


7) Remove pinion gear assembly (44) in one
piece.
30-106
2
HM300-1
11) Remove discs (50) and plates (51), 3 for

each.

2) Install bevel gear (53) to case (54).

Install according to the counter marks
which were left at the time of removing.
2
Mounting bolt
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.
15) Remove bearing (55).
3) Reverse the bevel gear and case assembly.

4) Put washers (52) in the case, and assemble
plates (51) and discs (50) 3 for each.
Immerse the discs and plates in the following 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.
30-108
2
Match a cutout portion on disc (50) (at 4

points) with a groove on differential side
gear (48) (at 4 points).
HM300-1

10) Install pressure ring (42).
13) Install washer (39).

11) Assemble discs (41) and plates (40) 3 for
each.
Immerse the discs and plates in the following 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 following 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 clearance "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 carrier (30).
30-110
2
HM300-1

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 coupling (19).
4. Differential gear assembly and side carrier

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
7) Press-fit oil seal (31) into carrier (30), using

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
2
HM300-1
Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
Oil seal periphery surface

: Seal End 242 or equivalent
Oil seal lip face and oil seal inside
(to be filled completely)
: Grease (G2-LI)
30-111
(9)
2
5. Adjustment of pre-load on side bearing

bearing thoroughly.
1) Measure start torque of bevel gear (53) at
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
specified in the step 2).

7. Subassembly of bevel pinion and cage

assembly
1) Install outer races (17) and (16) to cage
(12).
2) Press-fit bearing (11) into bevel pinion (9),

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
30-112
2
Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
HM300-1

4) Put cage assembly (7) and bearing (11) on

bevel pinion assembly (8), and press-fit
bearing (11) into the cage assembly, while
turning the cage assembly, using coupling
(5), holder (4) and push tool [6].
bearing (11).
Remove holder (4) and coupling (5)
after press- fitting.
6) Press-fit oil seal (13), using tool [8].

Keep press-fitting until the oil seal
periphery surface is flush with the cage
(12) end surface.

Keep press-fitting until distance "d"
between periphery surface of the oil seal
and end surface of cage (12) is 26 0.5
mm.
8. Installation of bevel pinion and cage assembly

Assemble the shims whose thickness, number
in use and location were confirmed at the time
disassembling, and then install bevel pinion
cage assembly (6).
Tighten with 3 mounting bolts.
Tighten all the mounting bolts after adjusting
tooth contact.
2
2

Oil seal lip face and between lips
: Grease (G2-LI)
2
2

Oil seal lip face and between lips
: 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
HM300-1
Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
30-113
(9)
2

10. Adjustment of tooth contact and backlash

Adjust backlash and adjust tooth contact at
the same time.
1) Adjustment of backlash
i) To shift the bevel gear for the adjustment, change shims (57) between differential case (25) and side carrier
assembly (23) or (24). In that case, do
not change the total thickness of left and
right shims (57) in order not to change
the pre-load given to the bearing.
iv) If the 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 a small backlash:
Decrease the shims on the right side of
chassis and add as many shims to the
left side (i.e. shifting the bevel gear in
direction A).
ii) Apply the probe of dial gauge [9] perpendicularly to the tip of bevel gear.
iii) Read out the dial when moving the
bevel gear back and forth (in the direction 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
2
When there is a big backlash:

Decrease the shims on the left side of
chassis and add as many shims to the
right side (i.e. shifting the bevel gear in
direction B).
HM300-1

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
Inspection
i)
Coat the bevel gear tooth surface thinly

with minium or red lead, then rotate the
bevel gear back and forth to check the
tooth contact pattern on the bevel gear.
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
addendum A, dedendum B, small end C
and big end D.
If the adjustment is made this way,
right tooth contact is ensured, when
load is applied.
HM300-1
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 carrier assemblies, do not change the total
thickness of left and right shims in order
not to change the pre-load given to the
bearing.
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.
Make adjustment in the following manner.
Shift the bevel pinion in direction A by
adjusting the shims on the bevel pinion
side.
In addition, shift the bevel gear in direction B and check the tooth contact pattern and backlash again.
30-115
(9)
2

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.
side.
12. Upper cover

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)
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}
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
(9)
2
HM300-1


H1 Push Tool
H2 Push Tool
HM300-1
30-117
2

CENTER DIFFERENTIAL ASSEMBLY
REMOVAL AND
INSTALLATION OF
CENTER DIFFERENTIAL
ASSEMBLY
2) Sling carrier assembly (1) to remove.

4 Carrier assembly: 40kg (one side)
SPECIAL TOOL
Mark
Part No.
Part Name
Neces
sity
Q'ty
790-101-5401
Push Tool Kit
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
5 790-201-2770
Spacer
Disti
nctio Sketch
n*
1
1
1
1
REMOVAL
k

Raise the body assembly fully and insert a
safety pin.
3) Sling sun gear and drive shaft assembly (3)

to remove.
4 Sun gear and drive shaft assembly
: 25kg (one side)
1. Drain oil from the center differential case and

center final drive case.
6
Center differential case: 25l

Center final drive case: 4l (one side)
2. Remove the left and right drive shafts in the following steps.
1) Remove the mounting bolts of carrier
assembly (1), and pull out of the final drive
assembly, using forcing screws [1] and
guide bolts [2].
3. Remove drive shaft guard (4).

4. Sling drive shaft (5) between the hitch frame
and center differential temporarily, and disconnect it at the center differential side.
30-118
(9)
2
HM300-1

5. Sling drive shaft (6) between the center differential 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 coupling.
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
HM300-1
Center differential assembly: 300kg
30-119
(9)
2

INSTALLATION

removal.
Install the carrier assembly in the following

steps.
1) Insert the carrier assembly into the center axle assembly up to the intermediate
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).
3) In that condition, match the carrier
assembly with guide bolt [3], then match
the ring gear of the final drive assembly
with the planetary gear of the carrier
assembly, and push them in.
When installing the drive shaft between

hitch frame and center differential, let it face
in the same direction as that of the yoke of
drive shaft between the transmission and
hitch frame.
When installing, the yoke of drive shaft
between the hitch frame and center differential and the yoke of drive shaft between center differential and rear differential must be
shifted from each other by 45f 6f.
When installing the drive shafts, check that
the keyway of spider cap completely
engages with that of counter yoke, and then
2
Mounting bolt
3 Mounting bolts for drive shaft between

transmission and hitch frame and
drive shaft between center differential
and rear differential
: 98 - 123 Nm {10 - 12.5 kgm}
3 Carrier assembly mounting bolt

: 157 - 196 Nm {16 - 20 kgm}
[Target value: 177 Nm {18 kgm}]
Install as shifted from the coupling on the

input side of center differential by 45f 6f.
Mating faces between coupling and

bearing
: Lubricant containing molybdenum
disulfide (LM-P)
Coupling mounting bolt
3 Coupling mounting bolt

: 455 - 565 Nm {46.5 - 57.5 kgm}
30-120
(9)
2
HM300-1

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.
end surface.
2
2
3 Center differential mounting bolt

: 157 - 196 Nm {16 - 20 kgm}
Oil seal periphery

: Seal end 242 or equivalent
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
end face.
2
2
HM300-1
Side seal periphery

: Seal end 242
Side seal lip face: Grease (G2-LI)
30-121
(9)
2

DISASSEMBLY AND
ASSEMBLY OF
CENTER DIFFERENTIAL
ASSEMBLY
3. Cover
Remove cover (3).
SPECIAL TOOL
Mar
k
Part No.
Part Name
Distinc- Ske
NecesQ'ty
tion -tch
sity
*
01010-51240
Bolt
790-501-5000
Unit Repair Stand

(AC100V)
6 790-501-5200
Unit Repair Stand

(AC110V, AC220V)
790-901-2110
Bracket
792T-222-1210
Plate
792T-423-1130
2 790-101-5421
7 792-103-0901
Push Tool
Grip
Wrench
8 792T-223-1120
Push Tool
792T-423-1140
Push Tool
9 790-101-5421
Grip
01010-51240
Bolt
10 792T-223-1110
Grip
1
1
4. Input shaft cage
1
1
1) Remove input shaft cage assembly (4),

1
1
1
1
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
2
HM300-1

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).

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
(9)
2
8. Spacer and input gear

1) Remove spacer (22).
2) Remover spacer cover (23) and then
remove input gear (24).

10. Bevel pinion and bearing assembly

1) Remove bevel pinion and bearing assembly
(28).
2) Remove bearing (30) from bevel pinion (29).

9. Cage assembly
1) Remove cage assembly (25), using forcing
screws [3].
30-124
2
HM300-1
11. Removal of differential gear assembly

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.

assembly
HM300-1
30-125
(9)
2

Lift the ring with a finger inserted into the
case side hole.

8) Remove pinion gears (49) and bushings

(50) 4 for each from shaft (48).


piece.
30-126
2
HM300-1
11) Remove discs (53) and plates (54) 3 for

each.


Install the gear, matching the counter
marks which were put when removing.
2
Mounting bolt
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.
Immerse the discs and plates in the following 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
(9)
2


for each to shaft (48).

piece.
30-128
2
Match the cutout portion on disc (53) (at

4 points) with grooves on differential
side gear (51) (at 4 points).
HM300-1


each.
2
Disc and plate


Bearing shrink- fit temperature
plate (43).
to plate (43).
ii) Measure thickness "b" of case (40).
iii) Calculate difference "d" between dimensions "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 clearance 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

2
16) Adjust clearance between washer (42) and

case (40) and clearance between washer
(55) and case (57) in the following manner.
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
Mounting bolt
Mounting bolt
: 824 - 1,030 Nm {84 - 105kgm}
2. Installation of differential gear assembly

1) Sling differential gear assembly (38) and
keep it above the installing position of differential 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
2
HM300-1
3. Adjustment of bearing pre-load

1) Tighten adjusting nuts (34) and (35), using
tool H7.
bearing thoroughly.
Rap the bevel gear with a copper hammer, while rotating the bearing, so that
the bearing sits well with other parts in
contact.
2) Measure start torque in the tangential direction at the peripheral addendums of bevel
gear (56), using push-pull scale [4].
: 7.1 - 19.6 N (0.73 - 2.0 kg)
If the start torque is lower than the standard value, tighten the adjusting nuts,
and if it is higher, loosen the nuts.
When the adjusting nut is loosened on
one side, tighten the nut on the other as
much.
HM300-1

4. Subassembly of transfer input shaft

1) Install gear (13) and 2 spacers (12) to transfer input shaft (9).
2
Spline portion of inserted gear

2) Press-fit bearing (11), using tool H8.

Press-fit bearing (10) in the same manner, too.
5. Subassembly of transfer input shaft cage

2) Press-fit oil seal (7), using tool H9.
Keep press-fitting until distance "f "
between the oil seal periphery surface
and end surface of cage (12) is 10 0.5
mm.
2
2

Oil seal lip face and inside of oil
seal (to be filled completely)
: Grease (G2-LI)
30-131
2
3) Press-fit side seal (6), using tool H2.

Keep press-fitting until the side seal
periphery surface is flush with cage (12)
end surface.
2
2
Side seal periphery surface

Side seal lip face and inside of side
: Grease (G2-LI)

2) Measure the endplay with dial gauge [5]

while lifting and lowering input shaft and
gear assembly (8) with a crane.
3) Adjust thickness of shims (61) so that the
endplay may reach the standard value.
Standard value for endplay: 0 - 0.05 mm
Shim adjustment allowance
: 0.8 - 1.7 mm
: 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 disassembling) and install the input shaft
cage assembly.
Keep tightening the mounting bolts,
while rotating the bearing, until the bearing is steadied.
3
30-132
(9)
2
Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
HM300-1

Table 1
MD Shim
Thickness
Range
Letter
Spacer Part No. Notched on
Spacer
Dimension of
Spacer Width
1.07 - 1.16
56D-23-16900
24.765 0.025
1.17 - 1.26
56D-23-16910
24.665 0.025
1.27 - 1.36
56D-23-16920
24.565 0.025
1.37 - 1.46
56D-23-16930
24.465 0.025
1.47 - 1.56
56D-23-16940
24.365 0.025
1.57 - 1.66
56D-23-16950
24.265 0.025
1.67 - 1.76
56D-23-16960
24.165 0.025
1.77 - 1.86
56D-23-16970
24.065 0.025
1.87 - 1.96
56D-23-16980
23.965 0.025
1.97 - 2.06
56D-23-16990
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).

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 subsequent section of 12, change the spacers, 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 disassembling, in cage assembly (25), and install
the cage assembly.
Determine thickness and number in use
of shims after carrying out "Tooth contact and backlash adjustment" in the
subsequent section of 12.
3
HM300-1
Mounting bolt
: 157 - 196 mm {16 - 20 kgm}
30-133
2
4) Sling transfer case assembly (17) to install.

2
Case mating face

: Gasket sealant (LT-515 or equivalent)
Mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}

4) Measure start torque of the input shaft at the

holder mounting bolt, using torque wrench
[6].
Start torque: 4.1 - 9.0 N {0.42 - 0.92 kg}
If the measured start torque falls out of
the standard value, either increase or
decrease the shim thickness and measure again.
11. Bearing
2) Press-fit bearing (19) using push tool [5].
12. Tooth contact and backlash adjustment

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 loosening the adjusting nut on one side,
tighten the adjusting nut on the other as
much, in order not to change the preload 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 disassembling.
: 0.15 mm, 0.18 mm, 0.2 mm and 0.5 mm
Shim adjustment allowance
: 0.36 - 1.74 mm
2
Mounting bolt
30-134
2
Mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
HM300-1

ii) Apply the probe of dial gauge [7] perpendicularly to the addendums of bevel
gear.
iii) Fix the bevel pinion and shift the bevel
gear back and forth (in the direction of
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.
When there is big backlash:

Loosen the adjusting nut on the left side
of chassis and tighten the adjusting nut
on the right side as much (shift the bevel
gear in direction B).

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) Coat the tooth surface of bevel gear with
minium or red lead thinly, and check a
tooth contact pattern on the bevel gear
after moving the bevel gear back and
forth.
and big end D.
load is applied.
i)
When the bevel pinion is too far away

face curved inward.
side.

inward.
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 loosening the adjusting nut on one side,
tighten the adjusting nut on the other as
much, in order not to change the preload given to the bearing.
30-136
2
HM300-1

3) After adjusting the tooth contact, tighten the

bevel pinion cage mounting bolts.
3
Mounting bolt
: 157 - 196 Nm {16 - 20kgm}
13. Lock and cover

Install locks (32) and (33) for the left and right
adjusting nuts and cover (31).
3
Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
15. Cover
Install cover (3).
2
Cover mating part

: Gasket sealant (LT-515)
Mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}
16. Transfer input coupling and holder

Install an O-ring and coupling (2), then install
holder (1).
2
2
3
Mating part g of bearing and coupling

disulfide (LM-P)
Mounting bolt
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 foregoing step 7, then install an O-ring and install
input shaft cage assembly (4).
3
HM300-1
Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
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
30-138
2
Mounting bolt: Gasket sealant (LG-5)

Mounting bolt
: 196 - 245 Nm {20 - 25 kgm}
HM300-1


H2 Push Tool
H6 Plate
HM300-1
30-139
2

H8 Push Tool
H9 Push Tool
30-140
2
HM300-1

H10 Push Tool
HM300-1
30-141
2
REMOVAL AND
INSTALLATION OF
REAR DIFFERENTIAL
ASSEMBLY

REAR DIFFERENTIAL ASSEMBLY

4 Carrier assembly: 40 kg (one side)
REMOVAL
k

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

Rear final drive case: 5l (one side)
3. Remove the left and right drive shafts in the following manner.
3) Sling sun gear and drive shaft assembly (3)

to remove.
4 Sun gear and drive shaft assembly
: 25 kg (one side)
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 differential and rear differential and disconnect at the
rear differential side.
30-142
(9)
HM300-1

5. Remove the rear differential assembly.
3) Push the carrier assembly in along

guide bolts [3], matching the ring gear of
the final drive assembly with the planetary gear of the carrier assembly.
1) Remove the mounting bolts of rear differential assembly (7) and separate it from the
axle case, using forcing screw bolts [3].
2) Sling rear differential assembly (7) to

remove, using eyebolts [5] and guide bolts
[4].
4 Rear differential assembly: 200 kg
3 Carrier assembly mounting bolt

: 157 - 196 Nm {16 - 20 kgm}
Install after confirming that the yoke of drive

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 center 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
(9)
2

Rear differential mounting bolt

: 157 - 196 Nm {16 - 20 kgm}
Refilling with oil (rear differential case and
rear final drive case)
Refill with oil through the oil filler port of rear differential case and through oil filler ports of the
left and right rear final drives up to the specified
level.
5
5
DISASSEMBLY AND
ASSEMBLY OF
REAR DIFFERENTIAL
ASSEMBLY
SPECIAL TOOL
Mark
790-501-5000
Center differential case

: 25l (SHELL DONAX TD)
Center final drive case
: 5l (one side) (SHELL DONAX TD)
Part No.
6 790-501-5200
H
790-901-2110
Part Name
Unit Repair
Stand (AC100V)
Unit Repair
Stand (AC110V
and AC220V)
Bracket
792T-222-1210 Plate
7 792-103-0901
DisNeces- Q'ty tinc- Skesity

tch
tion*
Wrench
10 792T-223-1110 Grip
1
1
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
2
HM300-1
3. Pinion and cage assembly

1) Remove pinion and cage assembly (3),
location beforehand.
2) Remove side seal (5) and oil seal (6) from

the pinion and cage assembly.

4) Further disassembly of pinion assembly

Remove spacer (10) and bearing (11) from
pinion (9).
5) Further disassembly of cage assembly

Remove bearing (13) and bearing outer
races (14) and (15) from cage (12).
Bearing (13) has already been removed
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

1) Reverse tool H6.
2) Remove locks (16) and (17) together with
the cover.


assembly
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).
5) Sling differential gear assembly (22) to

remove.
Be careful not to let fall the bearing outer
race.
30-146
(9)
2
HM300-1


piece.

Put your fingers in the side hole and
raise the ring.
8) Remove pinion gears (33) and bushings

(34) 4 for each from shaft (32).
HM300-1
30-147
2

ASSEMBLY
Clean each of the parts and check that it is free

of any dust and damage. Coat the sliding surfaces with axle oil before assembling.

After installing, drip axle oil (SHELL
DONAX TD) on the bearing.
11) Remove discs (37) and plates (38) 3 for

each.

Install matching the counter marks
which were put at the time of disassembling.
2
Mounting bolt
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
2
HM300-1

3) Reverse the case and bevel gear case

assembly.
4) Put washer (39) in the case and assemble
plates (38) and discs (37) 3 for each.
2
Match the cutout portions on disc (37)

(at 4 points) with the groove portions of
differential side gear (35) (at 4 points).
Disc and plate

: SHELL DONAX TD

for each to shaft (32).

piece.
HM300-1
30-149
(9)
2
9) Install differential gear (30).

each.
2
30-150
(9)
2


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
Disc and plate

: SHELL DONAX TD
HM300-1


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}
16) Adjust the clearance between washer (26)

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
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
other side, too.
30-151
2

3) Install bearing caps (21) and (20), and

Install the caps in the same manner on
the other side, too.
2
Mounting bolt
If the measured start torque is lower

than the standard value, tighten the
adjusting nut. If it is higher than the standard value, loosen the adjusting nut.
When tightening the adjusting nut on
one side, loosen the adjusting nut on the
other as much.
Mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
4. Subassembly of bevel pinion and cage

assembly
1) Tighten adjusting nuts (19) and (18), using
tool H7.
Drip an ample amount of axle oil
(SHELL DONAX TD) on the bearing.
Rap the bevel gear with a copper hammer, while rotating the bearing, so that
the bearing can have a good contact
with other parts.
1) Subassembly of cage assembly

Install outer races (15) and (14) to cage
(12).
2) Measure start torque in the tangential direction 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
2
HM300-1
2) Subassembly of bevel pinion assembly

Install bearing (11) to bevel pinion (9).
When installing the bearing, either
shrink-fit or press-fit it using push tool
H10.

4) Mount cage assembly (8) on bevel pinion

assembly (7).
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.

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
3) Install spacer (10) to bevel pinion (9).
HM300-1
Oil seal peripheral surface

: Grease (G2-LI)
30-153
2

8) Press-fit side seal (5), using tool [6].

Press-fit so that the peripheral surface
of the side seal is flush with the end surface of cage (12).
2
2
Side seal peripheral surface

Side seal lip face and inside of side
seal (to be filled completely):
Grease (G2-LI)
6. Input coupling and holder

Remove coupling (2) and holder (1) with the Oring.
Mounting bolt
3 Mounting bolt
: 455 - 565 Nm {46.5 - 58 kgm}
7. Adjustment of tooth contact and backlash

5. Installation of bevel pinion and cage
assembly
Assemble shims (4) whose thickness, number
in use and installed location were confirmed at
the time of disassembling, then sling bevel pinion and cage assembly (3) to install.
: 0.15 mm, 0.2 mm, 0.3 mm and 1.0 mm
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
Determine the thickness and number of
shims to be used after carrying out the following "Adjustment of tooth contact and
backlash".
30-154
(9)
Adjust the backlash and also the tooth contact at the same time.
i) When shifting the bevel gear, do so with
adjusting nuts (18) and (19). In that case,
tighten the adjusting-nut on one side,
while loosening the adjusting-nut on the
other that much in order not to change
the preload given on the bearing.
HM300-1

ii) Apply the probe of dial gauge [7] perpendicularly to the addendums of bevel
gear.
iii) Read out the dial when moving the
bevel gear back and forth (in the direction 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 backlash values less than 0.1 mm.
When there are big backlash:

Loosen the adjusting nut on the left side
of chassis and tighten the adjusting nut
on the right side as much (i.e. shifting
the bevel gear in direction B).

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
i) Coat the tooth surface of bevel gear with
minium or red lead thinly, and check a
tooth contact pattern on the bevel gear
after moving the bevel gear back and
forth.
and big end D.
load is applied.

side.

inward.
side.
ADJUSTMENT
obtained as a result of the inspection, make
i) When the bevel pinion is too far away
face curved inward.
30-156
2
HM300-1

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
HM300-1
Mounting bolt: Gasket sealant (LG-5)

Mounting bolt
: 196 - 245 Nm {20 - 25 kgm}
30-157
2


H6 Plate
H10 Push Tool
30-158
2
HM300-1
REMOVAL AND
INSTALLATION OF FRONT
FINAL DRIVE AND BRAKE
ASSEMBLY
REMOVAL AND INSTALLATION OF FRONT FINAL

DRIVE AND BRAKE ASSEMBLY
4) Sling front wheel (2) and remove the mounting bolts.

4
Front wheel: 550 kg (one side)
REMOVAL
k

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 hydraulic jacks [1].
3. Disconnect drive shaft (3) at the front differential

side.
2) Support the front axle underside with a pedestal (frame) [2].
4. Remove cover (4).

3) Sling left fender (1) to remove.
4 Left fender: 80 kg
HM300-1
5. Disconnect left and right brake actuating tubes

(5).
6. Disconnect brake cooling tubes (6) and (7).
30-159
(9)
2
7. Disconnect wiring connectors (If equipped) (8).

Right final drive: B28
Left final drive: B01
REMOVAL AND INSTALLATION OF FRONT FINAL

DRIVE AND BRAKE ASSEMBLY
INSTALLATION

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

9. Sling final drive and brake assembly (10), and

remove the 14 mounting bolts and 8 mounting
nuts.
4
Front final drive and brake assembly

(including drive shaft)
: 420 kg (one side)

: 98 - 123 Nm {10 - 12.5 kgm}

mounting bolt
30-160
2

mounting bolt
: 490 - 680 Nm {50 - 62 kgm}
mounting nut
: 422 - 520 Nm {43 - 53 kgm}
HM300-1

FRONT FINAL DRIVE AND BRAKE ASSEMBLY
Refilling with oil (front final drive case)

Refill with oil through the oil filler port of front
final drive up to the specified level.
5 Front final drive case

: 4.5l (one side) (SHELL DONAX TD)
Air bleeding (brake)

After installing, bleed air from the brake circuit,
referring to the section of "BLEEDING AIR
FROM BRAKE CIRCUIT". in INSPECTION
AND ADJUSTMENT.
DISASSEMBLY AND
ASSEMBLY OF
BRAKE ASSEMBLY
SPECIAL TOOL
Mark
Part No.
792T-227-1120
Fixture
792T-223-1140
Plate
01010-61240
Bolt
1 01643-31232
Part Name
Washer
01580-01210
Nut
01010-61245
Bolt
01010-62440
Bolt
2 792T-222-1220
Push Tool
792T-227-1130
Push Tool
3 790-101-5221
01010-81225
Grip
Bolt
4 791-580-1520
Installer
5 791-580-1510
Installer
793T-622-1110
6 790-101-5421
01010-81240
7 797T-622-1240
Push Tool
Grip
Bolt
Push Tool
Distin SkeNeces
sity Q'ty ction* tch
3
3
3
3
3
1
1
1
1
1
1
1
1
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
(9)
2

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).

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).
30-162
(9)
2
3) Remove shaft (10).

Drain oil remaining in the case.
HM300-1

5. Plate
1) Remove plate (11), using forcing screws [3].
9. Floating seal retainer and floating seal

6. Retainer and shim
1) Fix tools J1 at three points between the
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.
1) Remove the assembly of floating seal

retainer (19) and floating seal (20), using
forcing screws [4].
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

3) Remove seal rings (26) and (27) from cylinder (24) and piston (25).
30-164
(9)
2
1) Remove dampers (30a) and (30b), 6 plates

(31), 7 discs (32) and plate (33) from outer
gear (29).
HM300-1

2) Remove plate (34) from outer gear (29) and

then remove oil seal (35).
2) Remove oil seal (45) and bushing (46).
3) Remove floating seal (36).
ASSEMBLY
13. Further disassembly of inner gear assembly
1) Remove floating seals (38) and (39) from
hub (inner gear) (37).
2) Remove outer races (40) and (41).
Before installing, clean each of the parts thoroughly; also check that it is free of dust and
damage and coat the sliding surface with axle
oil.
Precautions when installing floating seal
When installing a brand-new oil seal, completely 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 bushing (46) to shaft (42).

Install so that dimension "b" between
the shaft end surface and bushing end
surface is 5 0.2 mm.
3) Install floating seal (39) to hub (inner gear)

(37), using tool J4.
Refer to the section of "PRECAUTIONS
WHEN INSTALLING FLOATING SEAL".
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.
2
2

: Grease (G2-LI)

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
2
HM300-1

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.
2
2
HM300-1

: Loctite #648 or equivalent
: Grease (G2-LI)
4. Brake assembly
1) Install outer gear (29) to hub (inner gear)
(37).
When installing, take care so that the
floating seal will not be damaged or
turned up.
30-167
2
2) Install plate (33), 7 discs (32), 6 plates (31)

and dampers (30a) and (30b) to outer gear
(29).
surfaces of discs and plates are not
damaged.

4) Install piston (25) to cylinder (24).
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 disassembling.
30-168
(9)
2
HM300-1


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), holding forcing screw [4].
7. Installation of ring gear assembly

Install ring gear assembly (14).
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
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

of lift truck [5], and tighten every other hub
bolt (4 bolts in total) to the specified torque
of 49 4.9 Nm {5 0.5 kgm}., while rotating
the hub (inner gear) (37) by 20 to 30 turns.
If the bolts are tightened without hub
(inner gear) (37) being rotated, the bearing 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 configuration.)
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.
5) Remove retainer (12) 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
30-170
2

6) Assemble retainer (12) shims (13) whose

thickness was determined in the foregoing
step, and install the retainer.
Tighten the mounting bolts evenly, rotating hub (inner gear) (37), until an even
tightening torque is obtained for all the
bolts.
2
Mounting bolt
Mounting bolt
: 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).
9. Plate
Install plate (11).
HM300-1

10. Shaft
Install shaft (10).
13. Installation of carrier assembly

Sling carrier assembly (2) to install.
11. Collar and sun gear
1) Install collar (9) and sun gear (8).
12. Subassembly of carrier assembly

1) Set bearing (5) to gear (6) and install them
to the carrier.
2) Install shaft (4).
When installing, pay attention to the
spring pinholes.
3) Install spring pin (3).
HM300-1
Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
14. Drive shaft

Install drive shaft (1).
2
Mounting bolt
Mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}
30-171
(9)
2


J1 Fixture
J1 Plate
30-172
2
HM300-1

J2 Push Tool
J3 Push Tool
HM300-1
30-173
2

J6 Push Tool
J7 Push Tool
30-174
2
HM300-1

CENTER FINAL DRIVE AND BRAKE ASSEMBLY
REMOVAL AND
INSTALLATION OF
BRAKE ASSEMBLY
REMOVAL
k
k
k

beforehand.
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
6
Center differential case: 25l

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 hydraulic 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
HM300-1
Center wheel: 550kg (one side)
30-175
2
8. Remove carrier assembly (8) and the sun gear

and drive shaft assembly from the final drive
assembly, referring to the section of "REMOVAL
AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY".

9. Sling final drive and brake assembly (9) and

remove the 23 mounting bolts.
4
Refilling with oil (center differential case and

center final drive case)
Refill with oil through the oil filler ports of center
differential case and left and right center final
drive up to the specified level.
Center final drive and brake assembly

: 350kg (one side)
Center differential case

Center final drive case
Air bleeding
Bleed air from the brake circuit after finishing
installation, referring to the section of "BLEEDING AIR FROM BRAKE CIRCUIT" in INSPECTION ANDADJUSTMENT.
INSTALLATION

removal.
3
Center wheel mounting bolt

: 824 - 1,030 Nm {84 - 105 kgm}
Install the sun gear and drive shaft assembly and the carrier assembly, referring to the
section of "REMOVAL AND INSTALLATION
OF CENTER
DIFFERENTIAL
ASSEMBLY".

mounting bolt
30-176
2

mounting bolt
: 490 - 680 Nm {50 - 62 kgm}
HM300-1

DISASSEMBLY AND
ASSEMBLY OF
BRAKE ASSEMBLY
SPECIAL TOOL
Mark
Part No.
2 792T-222-1220
Push Tool
4 791-580-1520
Installer
5 791-580-1510
793T-622-1110
6 790-101-5421
01010-81240
J
Part Name
7 797T-622-1240
Installer
Push Tool
Grip
Bolt
Push Tool
792T-223-1130
Fixture
792T-223-1140
Plate
01010-61240
Bolt
8 01643-31232
Washer
01580-01210
Nut
01010-61245
Bolt
01010-62440
Bolt
Neces- Q'ty
sity
Distinction*
Sketch
1
1
c
3. Further disassembly of ring gear assembly

1
1

c
1
3
3
3
3
3
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
retainer (1) in order to protect the floating seal from damage.
Fix tools J8 at an equal interval.

1) Remove the assembly of floating seal
retainer (8) and floating seal assembly (9)
by fitting forcing screws [1].
2) Remove retainer (1) and shim (2).

heck the thickness, number in use and
installed location of the shims beforehand.
2. Removal of ring gear assembly
1) Remove ring gear assembly (3).
HM300-1
30-177
2
5. Removal of brake assembly

1) Remove brake assembly (11) from shaft
(tube) (10).
Before removing, put a counter mark on
both of them.

3) Remover seal rings (15) and (16) from cylinder (13) and piston (14) respectively.
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
(9)
2
HM300-1
7. Further disassembly of outer gear assembly

1) Remove dampers (19a) and (19b), 8 plates
(20), 9 discs (21) and plate (22) from outer
gear (18).
2) Remove plate (23) from outer gear (18) and

then remove oil seal (24).
3) Remove floating seal (25).
8. Further disassembly of inner gear assembly

1) Remove floating seals (27) and (28) from
hub (inner gear) (26).

9. Further disassembly of shaft assembly

Remove bearing (32) and retainer (33) from
shaft (31).
ASSEMBLY
Before assembling, clean each of the parts thoroughly; check that it is free of dust and damage,
and coat the sliding surface with axle oil.
Precautions when installing floating seal
When installing a brand-new O-ring, completely 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
against the carrier and hub as well as
retainer.
2) Remove outer races (29) and (30).
HM300-1
30-179
(9)
2

1. Subassembly of shaft assembly

1) Install retainer (33) to shaft (31).
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
2
HM300-1
2) Install oil seal (24) to outer gear (18), 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.
2
2


3
Mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}

: 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
(9)
2
3) Install seal rings (15) and (16) to cylinder

(13) and piston (14) respectively.

5) Install cylinder and piston assembly (12).

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
2
HM300-1
2) Install the assembly of floating seal cage (8)

and floating seal assembly (9), holding forcing screw [1].

7. Installation of ring gear assembly

Install ring gear assembly (3).
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
Mounting bolt
: 27.5 - 34.5 Nm {2.8 - 3.5 kgm}
3) Press-fit bearing (7) to inner hub (6), using

tool J7.
HM300-1
3) Fasten the ring gear assembly to the forks

of lift truck [3], and tighten every other hub
bolt (4 bolts in total) to the specified torque
of 49 4.9 Nm {5 0.5 kgm}, while rotating
hub (inner gear) (26) by 20 to 30 turns.
If the bolts are tightened without hub
(inner gear) (26) being rotated, the bearing 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 configuration.)
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
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
2
HM300-1


J2 Push Tool
J6 Push Tool
HM300-1
30-185
2

J7 Push Tool
J8 Fixture
30-186
2
HM300-1

J8 Plate
HM300-1
30-187
2

REAR FINAL DRIVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
REAR FINAL DRIVE
ASSEMBLY
SPECIAL TOOL
Mark
J
Part No.
Part Name
2 792T-222-1220 Push Tool

7 797T-622-1240 Push Tool
Neces
sity
Q'ty
1
Distin Skection* tch

N
c
c
4. Removal of carrier assembly
DISASSEMBLY
k

1. Body assembly
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
1) Remove the mounting bolts, and pull carrier

assembly (2) out of the final drive assembly,
using forcing screws [2] and guide bolt [3].
(Remove the carrier assembly without a
wheel unlike the photo below)
Rear differential case: 25l

Rear final drive case: 5l (one side)
3. Rear wheel
1) Raise the underside of rear axle with
hydraulic jack [1].

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
(9)
2
HM300-1
5. Further disassembly of carrier assembly

1) Drive spring pin (3) into shaft (4), using
round bar [4].


3) Remove sun gear (11) and spacer (12) from
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) beforehand.
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).
HM300-1
3) Remove ring gear (16).
30-189
2

8. Further disassembly of ring gear assembly
10. Retainer assembly
2) Remove protector (28) from retainer (27).
9. Wheel hub assembly

1) Sling flywheel hub assembly (21) to remove.
ASSEMBLY
Before assembling, clean each of the parts thoroughly, 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
(9)
2
HM300-1
2. Wheel hub assembly

1) Install outer races (25) and (26) to wheel
hub (22).

4) Sling wheel hub assembly (21) and install it

to the axle housing.

bearing.
3) Press-fit oil seal (23), using push tool [6].
comes into close contact with the wheel
hub.
2

: 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
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 calculate the average value.
3) Install ring gear assembly (16).
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
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 without rotating the ring gear assembly (16),
the bearing will not sit in well and no
right preload is given to the bearing.
30-192
2
HM300-1
5) Assemble shims (15) having thickness

selected in the step 4) above in retainer (14)
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) Install sun gear and drive shaft assembly

(8).
Mounting bolt
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 differential case and left and right rear final drives up
to the specified level.
5
5
30-194
2
Rear differential case

Rear final drive case
HM300-1


J2 Push Tool
J7 Push Tool
HM300-1
30-195
2
REMOVAL AND
INSTALLATION OF
CENTER AXLE ASSEMBLY
REMOVAL
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3. Separate drive shaft (2) between the hitch

frame and center differential and drive shaft (3)
between the center differential and rear differential at the center differential side.
After slinging, separate by removing the
drive shaft mounting bolts.
Disconnect the negative (-) terminal of battery.

Evacuate nitrogen gas from the rear suspension 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
[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
(9)
2
HM300-1

6. Disconnect wiring connector (T14) (6).
11. Sling center axle and arm assembly (12).
7. Disconnect brake actuator hose (7) and disconnect 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
9. Remove the mounting bolts for center lateral

rod (10) and sling the rod to remove.
4 Center lateral rod: 40 kg
Center axle and arm assembly

: 1,600 kg
INSTALLATION
10. Remove the mounting bolts for equalizer bar
spring (11) and separate the spring.

removal.
3 Center wheel mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
HM300-1
Install the center axle assembly after confirming that the yoke of drive shaft between
the hitch frame and center differential and
the yoke of drive shaft between center differential and rear differential are shifted
from each other at 45f 6f.
30-197
(9)
2

REAR AXLE ASSEMBLY

the spider cap keyway engages completely
with that of the counter yoke, and then
2

3 Drive shaft mounting bolt

: 98 - 123 Nm {10 - 12.5 kgm}
When installing bearing (B) to center lateral rod

(A), align tapped hole "c" with centerline "d" of
bearing (B).
REMOVAL AND
INSTALLATION OF
REAR AXLE ASSEMBLY
REMOVAL
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wooden blocks behind wheels.
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.
Refilling with oil (transmission case and
brake oil tank)
specified level, then start the engine and run at
low idle, and check the oil level again.
3. Sling rear wheel (1) to remove the mounting

bolts and then remove the left and right rear
wheels.
4 Rear wheel: 550 kg (one side)
Air Bleeding (brake)

After finishing the installation, bleed air from the
brake circuit , referring to the section of
"BLEEDING AIR FROM BRAKE CIRCUIT" in
30-198
(9)
2
HM300-1

REAR AXLE ASSEMBLY
4. Separate drive shaft (2) between the center differential and rear differential at the rear differential side.
After slinging, remove the drive shaft mounting bolts and separate the shaft.
5. Remove the mounting bolts of rear lateral rod

(3) and sling the rod to remove.
4
Rear lateral rod: 50 kg
7. Remove left bracket (5).

8. Remove rear suspension pins (6) of both left
and right sides at their head side.
9. Remove left and right caps (7) at a pin of the

arm mounting base, and take down rear axle
arm (4) to remove.
4
Rear axle and arm assembly: 1,100kg
6. Sling rear axle and arm assembly (4).
HM300-1
30-199
(9)
2

REAR AXLE ASSEMBLY
INSTALLATION

removal.
3
Rear wheel mounting bolt

: 824 - 1,030 Nm {84 - 105 kgm}

the spider cap keyway engages completely
2


: 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).
Bracket mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
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
(9)
2
HM300-1
REMOVAL AND
INSTALLATION OF
FRONT SUSPENSION
CYLINDER ASSEMBLY

FRONT SUSPENSION CYLINDER ASSEMBLY
4) Sling front wheel (2), and remove the

mounting bolts to remove the wheel.
4 Front wheel: 550 kg (one side)
REMOVAL
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Evacuate nitrogen gas from the front suspension cylinder, referring to the section of
AND ADJUSTMENT.
1. Remove the front wheel.

1) Raise the underside of front axle on the side
of wheel to be removed with hydraulic jack
[1].
2. Remove 3 covers (3).

2) Support the front frame underside with pedestal (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
(9)
2

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.
4
3 Bracket mounting bolt

: 69 - 74 Nm {6 - 7.5 kgm}
Front cylinder suspension assembly

: 75 kg
3 Pin mounting bolt

: 98 - 123 Nm {10 - 12.5 kgm}
30-202
(9)
2
Refilling with nitrogen gas and adjusting cylinder 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 ADJUSTMENT.
HM300-1
INSTALLATION AND REMOVAL OF

INSTALLATION AND
REMOVAL OF
REAR SUSPENSION
CYLINDER ASSEMBLY
INSTALLATION

removal.
Install bearing (B) to rear lateral rod (A) and

align tapped hole "c" with centerline "d" of bearing (B).
REMOVAL
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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
3 Bracket mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
Rear lateral rod: 50 kg
3. Remove left bracket (2).
Refilling with nitrogen gas and adjusting cylinder 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 ADJUSTMENT.
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 cylinder assembly (4) to remove.
HM300-1
30-203
(9)
2

DISASSEMBLY AND
ASSEMBLY OF FRONT AND
REAR SUSPENSION
CYLINDER ASSEMBLY
Q 1
792-201-3141
Push tool
t 1
790-101-5221
Grip
t 1
01010-51225
Bolt
t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
4.
Flange
1) Remove retainer (8) and flange (9) from
rod assembly (7).
2) Remove U-packing (11), backup ring, and
buffer ring (12), and O-ring (13) from
flange (9).
3) Remove the bushing (17) from flange (9).
4) Remove seal (14) and bushing from
retainer (8).
5.
Wear ring
Remove wear ring (15) from rod (16).
Disassembly
1.
Cover
Hanging the cylinder assembly, loosen band (1)
and remove the button, then remove cover (2).
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.
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
2(14)
HM300-1
Assembly
1.
Wear ring
Install wear ring (15) to rode (16).
2.
Flange
1) Install the bushing (17) to flange (9) with
tool Q1.
2) Install U-packing (11) to flange (9).
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)
together with mounting bolts (5).
3 Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
HM300-1

5.
Intake valve and oil level valve

Adjust the oil level. For details, see Testing and
adjusting, "Testing and adjusting suspension
cylinder".
6.
Cover
1) Install cover (2) and tighten band (1).
2) Install the protector of the intake valve and
oil level valve.
30-205
30-203-2
(14)
2
REMOVAL AND
INSTALLATION OF
EQUALIZER BAR

EQUALIZER BAR
3. Remove bottom pin (3) of rear suspension cylinder assembly (2).

Tilt back the rear suspension cylinder
toward the rear and secure it.
REMOVAL
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Evacuate nitrogen gas in the rear suspension
cylinder, referring to the section of "TESTING
AND ADJUSTING SUSPENSION CYLINDER" in the chapter of INSPECTION AND
ADJUSTMENT.
1. Raise the center axle, rear axle and rear frame

on the side of equalizer bar to be removed,
using 3 hydraulic jacks [1].
2. Sling center wheel (1), and remove its mounting

bolts to remove.
4 Center wheel: 550 kg (one side)
30-204
(9)
2
4. Separate equalizer spring (4) after removing its

mounting bolts.
5. Sling the equalizer bar.

6. Remove plate (5) in the center of equalizer bar.
HM300-1

EQUALIZER BAR
7. Remove bushing (6), using 3 forcing screws [2]

and tool [3].
INSTALLATION

removal.
: 824 - 1,030 Nm {84 - 105 kgm}
8. Sling equalizer bar (7) to remove.

4
Equalizer bar: 200kg
Tighten 3 cover bolts (M24) after confirming

the following installing dimensions.
Check that when dimension "x" between
upper and lower pins of rear suspension
cylinder is 518 mm (x = 518 mm),
dimension "a" between the bottom pin
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
(9)
2

HITCH FRAME ASSEMBLY
REMOVAL AND
INSTALLATION OF
4. Remove drive shaft (3) between the transmission and hitch frame.
4
Drive shaft between transmission and

hitch frame: 30 kg
SPECIAL TOOL
Mark
K
Part No.
Part Necess
Name
ity
1 792T-246-1130
Plate
2 792T-246-1140
Plate
Q'ty
Distinc Sketion*
tch
REMOVAL
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beforehand.
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1. Unscrew the cap on the hydraulic tank.

2. Remove drive shaft guard (1).
5. Sling exhaust box (4) to remove.

4
Exhaust box: 35 kg
6. Remove guard (5).

7. Remove hose covers (6) and (7).
3. Sling drive shaft (2) between the hitch frame

and center differential to remove.
4
30-206
(9)
2
Drive shaft between hitch frame and

center differential: 45 kg
HM300-1
8. Gradually loosen hoist cylinder hoses (8) and

(9) between the front frame and rear frame as
well as brake cooling hoses (10) and (11) and
evacuate oil.
6
6
Hydraulic oil [hose (8) and (9)]

: Approx. 50l

11. Disconnect the following wiring connectors and

terminal from the rear frame front side.
(15): J15
(16): J13
(17): Grounding terminal (ER)
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)
Parking brake hose (12)
Brake hose (13)
12. Disconnect the following wiring connectors and

terminal from the front frame rear side.
(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.

4
Exhaust duct assembly: 40 kg

2) Support the body underside at the machine

rear with block [2].
14. Remove brackets (22) and (23).
15. Remove left and right steering cylinder head

pins (29).
3) Support the front frame underside at the

rear and the rear frame underside at the
front with block [3] and pedestal [4] to
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 following 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.
30-208
(9)
2
HM300-1

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.
3) Hook puller [10] to a step inside the bushing, and take out bushing (32) upward by
pushing up the claw of puller [10], using
push tool [11] and puller [12].
18. Remove the lower hinge pin in the following

manner.
1) Remove the mounting bolts for the lower
hinge pin.
2) Remove the mounting bolts and nuts, and
then remove 2 O-rings (33).
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
(37).
21. While keeping the front portion of frame assembly lifted with a crane, move the assembly a bit
forward, using a lift truck, and separate front
frame assembly (38) from hitch frame assembly
(39).
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Before separating, carefully check levelness of the front frame and hitch frame and
also check that there is clearance between
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


23. Turn parking brake releasing bolt (41) counterclockwise to release the parking brake.
24. Sling parking brake caliper assembly (42) and

remove brackets (43) for expanding the pads
and bracket (44).
26. Sling parking brake disc (43) to remove.

4
Parking brake disc: 30 kg
27. Sling bracket (44) to remove, using eyebolts

[14].
4
Bracket: 30 kg
25. Sling parking brake caliper assembly (42) to

remove.
4
Parking brake caliper assembly: 45 kg
30-210
(9)
2
HM300-1

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 thickness, number in use and installed locations
beforehand.
INSTALLATION
31. Sling hitch frame assembly (48) to remove.

removal.
Before installing, check that the yoke of drive

shaft between the hitch frame and center differential and the yoke of drive shaft between
center differential and rear differential are
shifted from each other by 45f 6f.

the spider cap keyway completely engages
Bearing (49) may fall off from the rear frame,

so secure it to prevent fall-off.
HM300-1

: 98 - 123 Nm {10 - 12.5 kgm}
30-211
(9)
2

When aligning the pinholes, never put a

finger into the hole.
10) Install a combination of the selected shims

to retainer (30) and tighten retainer mounting bolts (52) and (53).
2

Install the hinge pin in the following steps.
1) Set bushing (35) to the hitch frame and

match the articulation center (position of
center pin) by moving the front frame
assembly to the rear.

: 225 - 309 Nm {25.0 - 31.5 kgm}
2) Insert lower hinge pin (34) from above.

2
Dust seal lip face

: Grease (G2-LI)
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
2
Dust seal lip

: Grease (G2-LI)
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).
3

: 225 - 309 Nm {25.0 - 31.5 kgm}
After confirming thorough running-in of
each contact surface, tighten mounting
bolt (52) again to the specified torque.
8) Measure dimension "g" of clearance
between retainer (30) and the front frame at
3 points.
9) Select appropriate shims and assemble
them in so that the clearance has measured
dimension "g" less 0.08 to 0.18 mm.
: 0.1 mm and 0.5 mm
Standard shim thickness: 2 mm
30-212
2
Check the parking brake pad wear amount

and adjust the pad clearance, referring to
the section of "TESTING WEAR OF PARKING BRAKE PAD" in INSPECTION AND
ADJUSTMENT.
3
Pad expanding bracket mounting

bolt (43)
: 98 - 123 Nm {10 - 12.5 kgm}
Bracket mounting bolt (44)

Bracket mounting bolt (44)

: 824 - 1,030 Nm {84 - 105 kgm}
HM300-1

Parking brake disc mounting bolt

2
3
2
3
Press-fit dust seal (55), using tool K2.
After installing the hitch frame assembly and

retainer (47), fill the space H - Q listed below
completely with hub grease.
Parking brake disc mounting bolt

: 490 - 608 Nm {50.0 - 62.0 kgm}

: 157 - 196 Nm {16.0 - 20.0 kgm}

: 455 - 565 Nm {46.5 - 58.0 kgm}
When removing dust seal (54) from retainer

(46), press-fit dust seal (54), using tool K1.
2
2
2
2
2
2
2
HM300-1
H space: 350 g (inside of dust seal

and dust seal lip)
J space: 620 g
K space: 1,030 g (inside of bearing)
L space: 2,400 g
M space: 2,085 g
N space: 680 g (inside of bearing)
P space: 530 g
Q space: 295 g (inside of dust seal
and dust seal lip)

*Select grease to be filled from among those
listed below.
No.
Manufacturer
Nihon Ryuyu
Grease Brand
Hilex HD-2
SHELL OIL
Super Duty Grease2
ESSO OIL
RONEX MP
BP
Energrease LS-EP2
30-213
2
Method for adjusting bearing at oscillating

portion
1) Measure thickness "s" of retainer (47) at 2

points. (Calculate the average value of the 2
points.)
2) Tighten retainer (47) without shims with 3
mounting bolts (54).
3
Mounting bolt: 49 Nm {5 kgm}
3) In that condition, measure dimension "t"

with a micrometer.
4) Rotate the hitch by 5 to 6 turns and repeat
the steps 2) and 3) above.
Repeat the steps 2) to 4) until
dimension "t" is constant.
30-214
2

5) Select appropriate shims so that the total

shim thickness is "u", i.e. the difference
between dimensions "t" and "s" (u = t - s)
minus 0 to 0.15 mm.
Standard thickness of shim: 3.0 mm
: 0.2 mm, 0.3 mm and 1.0 mm
6) Install a combination of selected shims (55)
to retainer (47) and install the retainer with
12 mounting bolts (54).
2
Mounting bolt
Mounting bolt
: 245 - 309 Nm {25.0 - 31.5 kgm}
HM300-1


K1 Plate
K2 Plate
HM300-1
30-215
2

DISASSEMBLY AND
ASSEMBLY OF
2) Remove ring (3), dust seal (4), grease fitting

(31), and nipple (32) from rear retainer (5).
a Grease fitting (31) and nipple (32) are
installed to serial No. 1054 and up.
SPECIAL TOOL
Mark
Part No.
Part Name
3 792T-246-1110 Plate
790-101-5201
K
Push Tool Kit
790-101-5314 Plate
NecesQ'ty
sity
Sketch
1
1
790-101-5221 Grip
01010-51225
Bolt
Distinction*
DISASSEMBLY
1. Coupling
Remove the mounting bolts and remove coupling (1).
2. Rear retainer
1) Remove rear retainer assembly (2), using
forcing screws [1].
30-216
2
(7)
3. Center shaft
1) Remove center shaft and bearing assembly
(6) from hitch frame assembly (7).
2) Remove bearing (8) and bearing inner race

(9) from center shaft (10).
HM300-1

4. Further disassembly of hitch frame

1) Remove front cage assembly (11) from hitch
frame (12).
2) Remove ring (13), bearing (14) and rings
(15), (16).
3) Remove dust seal (17) from front cage (18).
ASSEMBLY
Clean each of the parts thoroughly and check

that it is free of dust and damage.
When installing the seals, use a push tool of the
size which corresponds with the seal diameter.
Select grease to be filled from among those
listed below.
No.
Manufacturer
Nihon Ryuyu
Grease Brand
Hilex HD-2
SHELL OIL
Super Duty Grease2
ESSO OIL
RONEX MP
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).
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.
3

: 58.8 Nm {6 kgm} 10%
iii) Install retainer (22) to the hitch frame
underside with 4 mounting bolts.
3

: 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 difference between "e" and "b" dimensions (g
= e - d) minus 0.02 to 0.12 mm.
: 0.1 mm and 0.5 mm
Retainer (21) portion
: Standard shim thickness: 2 mm
Retainer (22) portion
: Standard shim thickness: 1 mm
vi) Install a combination of the shims to
retainers (21) and (22), and tighten all
the mounting bolts.
2. Subassembly of hitch frame

1) Install spacer (20) to hitch frame (12).
2) Press-fit bearing (19), using tool K3.

30-218
2

: 98 - 123 Nm {10.0 - 12.5 kgm}
HM300-1

Fill space A inside the bearing with grease

completely.
2
Space A: 1,030 g
3. Center shaft
1) Press-fit bearing inner race (9) and bearing
(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
2
Space B: 29 g
Space C: 80 g
4) Install bearing (14) and spacer (13).

Fill space D inside the bearing with
grease 40% as completely.
2
HM300-1
Space D: 14 g
Be careful not to make a mistake about
2) Insert center shaft and bearing assembly (6)

into hitch frame assembly (7).
Press-fit the portion of bearing outer
race of the center shaft and bearing
assembly.
30-219
2
4. Front cage assembly

1) Install ring (13) to the hitch frame front side.
2) Install dust seal (17) to the front cage.
a Coat the dust seal lip with grease and
also fill space F inside with grease completely.
2 Space F: 25 g
a Be careful not to make a mistake about
3) Fill space G with grease 60% completely.
2 Space G: 60 g
a Be careful not to make a mistake about
4) Install front cage assembly (11) to hitch

frame (12).

6. Rear retainer
1) Using tool K4, press fit dust seal (4) to rear
retainer (5).
a Supply grease of 25 g to the dust seal
lip and space H.
2
Dust seal lip and space H:

Grease (G2-L1)
a If the quantity of the grease is improper,
the bearing will overheat. Accordingly,
take care extremely.
2) Install ring (3) to rear retainer (5).

a Fill space J of the ring with grease of
65 g.
2 Space J of ring: Grease (G2-L1)
a If the quantity of the grease is improper,
the bearing will overheat. Accordingly,
take care extremely.
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
2
3
30-220
2
(7)
Coupling spline portion

: Lubricant containing
molybdenum disulfide (LM-G)
Mounting bolt
Mounting bolt
: 455 - 565 Nm {46.5 - 58 kgm}
HM300-1

4) Install rear retainer assembly (2).

2
Mounting bolt
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
HM300-1
Inside of retainer: Grease (G2-L1)
30-221
2
(7)


K3 Plate
30-222
2
HM300-1

STEERING VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
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.
Qty
Remarks
Screw
Retainer screw assembly
End cap
Gerotor
Spacer
Spacer
(1)
Spacer plate
Drive
Housing
10
Sleeve
11
Spool
12
Pin
Centering spring
For standard input torque specification
For low input torque specification
13
Centering spring
14
Flat spring
(2)
15
Race bearing
16
Thrust needle
17
O-ring
18
Oil seal
Only for low input torque specification
X-ring or Teflon seal
19
Dust seal
20
Retaining ring
21
Seal gland bushing
22
O-ring
Part No.: 5776
23
O-ring
Part No.: BA0098A
24
Inlet check valve sub assembly
(Cannot be disassembled)
25
Valve seat
26
Poppet
27
Spring
28
Plug
29
O-ring
30
Retainer plug
31
Spring
32
Ball
33
Valve seat
34
Ball
35
Ball holder
36
Spring
37
Plug
38
O-ring
39
Adapter screw
40
Ball
41
Name plate
42
Rivet
30-224
2
Part name
Seal kit (X-ring)
Part No.: BA0271A
Seal kit (Teflon seal)
Part No.: BA0273A
HM300-1

DISASSEMBLY
When disassenbling the valve, cleanliness is

extremely important. Cary out the work in a
clean place.
In the following explanation diagrams, it is not
absolutely necessary to hold the unit in a vice,
but it is recommended to use a vice as far as
possible.
Before removing the piping, remove all dirt and
dust from around the ports and joints on the outside circumferences of the motor.
k Be extremely careful not to injure yourself on
the edges of sleeves, spools, housing, and
other machined ports.
2. Gerotor
1) Remove spacer (5) inside spline on inside of
star of Gerotor (4).
2) Remove Gerotor (4).
Be careful not to drop star from ring of
outer cicumference of Gerotor.
3) Remove O-ring (22) from Gerotor.
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
adapter screw (39).
screwdriver,
remove
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.
5. Anti-cavitation check valve

Set housing updise down, remove 2 springs
(31), 2 retainer lugs (30), and 2 balls (32).
Be careful not to drop or lose the parts.
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 housing.
5) Remove oil seal and dust seal from gland
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 finished surface.
7. Race bearing and thrust needle

Remove 2 race bearings (15) and thrust needle
(16).
2) Use flat-headed screwdriver to raise tip of

retaining ring (20), then remove from housing.
k The retaining ring may fly out from the
housing, so always wear protective
glasses.
30-226
2
HM300-1
8. Spool and sleeve

1) Push spline portion inside spool with thumb
and remove spool and sleeve assembly
from opposite side of housing flange.

4) Rotate spool slowly and pull out spool (11)

from sleeve (10).
5) Remove O-ring from housing.
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
(9)
2

10. Disassembly of overlord relief valve

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.
ASSEMBLY
k
Be extremely careful not to injure yourself on

the edges of sleeves, spools, housing, and
other machined parts.
Check all the joining parts.
Parts with gouges or burrs will cause leakage of
oil, so replace them with new parts.
Wash all metal parts with clean solvent and
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
will cause the hydraulic system to become dirty,
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 assembling.
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.
4) Hold centering spring at opposite end with a

finger and compress it to push it into spool
sleeve groove.
When doing this, slide insertion tool at
same speed as pushing in spring.
After inserting, align end of spring with
outside diameter of sleeve.
Insert sleeve pin into hole in sleeve, and
align both ends of pin with outside diameter of sleeve.
glasses.
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
2
HM300-1

5) Set housing on clean cloth with axial line of

valve horizontal. Insert spool and sleeve
assembly opposite end of housing to flange
end.
In this condition, check that spool and
sleeve assembly rotates smoothly inside
housing.
When inseting spool and sleeve assembly, be careful not to insert it at an angle
and get it caught.
Keep the pin at near the horizontal postion, and rotate slightly to left and right to
insert.
Insert so that the end face of the spool
and sleeve assembly is level with the
end face of the housing. If it is inserted
further, the pin will fall inside the housing, so stop inserting when the end face
is level.
3. Seal gland bushing

There are two types of seal: Teflon seal and
standard seal.
1) Assemble dust seal (19) to seal gland bushing (21).
Assemble dust seal so that flat surface
is at seal gland bushing end.
2) Assemble oil seal (18) to seal gland bushing.
Assemble the oil seal carefully so that
there is no twisting or deformation.
The diagram below is the Teflon seal
specification drawing; (44) is the distinguishing groove.
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

bushing (21) and insert to spool.
Tap with plastic hammer to insert to
specified position.
4) Assemble retaining ring to housing (20).
Push open with a flat-headed screwdriver so that the whole circumference
of the retaining ring fits securely in the
groove in the housing.

4. Assembly of steering relif valve

1) Assemble O-ring (29) to plug (28).
2) Using tweezers, assemble spring (27) and
popet (26) to housing.
3) Using hexagonal wrench (wrench (width
across flats: 3/16 inch), assemble plug (28)
to housing.

glasses.
5. Assembly of overload relief valve

1) Assemble O-ring (38) to plug (37).
Seal assembly drawing

Screwdriver 9, dust seal (19), retaining ring
(20), seal gland bushing (21), oil seal (18),
O-ring (17) .
30-230
2
2) Fit grease to ball holder (35) and install ball

(34).
3) Using tweezers, assemble ball holder (35)
and spring (36) to housing.
3/16 inch), assemble plug (37) to housing.
The size of the overload valve ball and
the anti-cavitation check valve ball is different, so be careful not to mix them.
HM300-1
6. Assembly of anti-cavitation check valve

1) Grip the port surface and side surface of the
housing lightly in a vice. Fit copper sheets in
the vice, and be careful not to tighten the
vice too strongly.

2) Of the 7 bolt holes in the end face of the

housing, insert ball (40) in the holes shown
in the drawing. Assemble adapter screw
(39) in holes in same drawing.
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 position 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) parallel to pin.
HM300-1
30-231
2

7) Assemble O-ring (22) to Gerotor (4).
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
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.
8. Spacer and end cap

1) Assemble spacer (5) to spline Gerotor star.
Do not assemble spacers to 51 cc/rev
and 69 cc/rev discharge capacity Orbitrolls.
Assemble 2 spacers to 184cc/rev discharge capacity orbit-roll.
(315 cc/rev. with HM300-1 model)
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.
Order for tightening end cap mounting

screws is as shown in diagram below.
After tightening to torque given below, install

handle to spool and check that spool
rotates.
Screw tightening torque

Discharge capacity cc/rev
Tightening torque (N.m{kgm}
51 - 230
22.6 {2.3}
277
23.5 {2.4}
369 - 737
28.4 {2.9}
(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
2
HM300-1
REMOVAL AND INSTALLATION OF FLOW AMP

VALVE
REMOVAL AND
INSTALLATION OF
FLOW AMP VALVE

6
SPECIAL TOOL
Mark
V
Part No.
792-454-1100
Part name
Pump assembly
Disti
Neces
SkeQ'ty nctio tch
sity
n*

cab with a crane or with a tilt cylinder and pump
assembly V.
a Use 2 shackles so that hook of the sling will
not hit glass of the cab assembly.
k Check that the lock lever (2-1) closes and

REMOVAL
k
k
k
k
k
k
k
k
k
k
k
k
k
Hydraulic tank: 120 l

level ground.
knob.
the wheels.
and rear frame.
is fixed securely.
cab.
lever.
For further details on removal and installation of the operator's cab, refer to the section of "METHOD OF TILTING CAB UP" in

the internal pressure of the hydraulic tank.
HM300-1
30-233
(10)
2
REMOVAL AND INSTALLATION OF FLOW AMP

VALVE
4. Disconnect the following hoses, and disconnect

tube (1) (for HP port) of the flow amp valve.
(2) and (3): Discharging hose for steering
and hoist pump
(4): Discharging hose for emergency steering motor
(5): Hose for centralized pressure check
6. Remove the mounting bolts for flow amp valve

assembly (15) and then remove the assembly.
4
Flow amp valve assembly: 35kg
5. Disconnect hoses (5) to (13) from the flow amp

valve assembly.
(6): LS port hose
(7): EF port hose
INSTALLATION
30-234
2(10)
(8): P port hose

(9): CL port hose
(10): T port hose
(11): L port hose
(12): HT port tube
(13): CL port tube
(14): CR port tube

removal.
Refilling with oil (hydraulic tank)

specified level, then start the engine to let the oil
circulate in the piping and check the oil level
again.
5 Hydraulic tank: 120l
l (EO10-CD)
HM300-1

HOIST VALVE ASSEMBLY
REMOVAL AND
INSTALLATION OF

6
Hydraulic tank: 120l

l
2. Remove inner cover (1) of the left fender.
SPECIAL TOOL
Mark
V
Part No.
792-454-1100
Part name
Pump assembly
Disti
Neces
SkeQ'ty nctio tch
sity
n*
REMOVAL
k
k
k
k
k

level ground.
knob.
the wheels.
and rear frame.
3. Open up the engine hood, and tilt operator's cab

with a crane or with a tilt cylinder and pump
assembly V.
a Use 2 shackles so that hook of the sling will
not hit glass of the cab assembly.
k Check that the lock lever (2-1) closes and
k
k
k
k
k
k
k
k

is fixed securely.
cab.
lever.

For further details on removal and installation of the operator's cab, refer to the section of "METHOD OF TILTING CAB UP" in
5. Remove the bracket mounting bolts of EPC

valve (2).
6. Disconnect the following piping from the hoist
valve.
(3): T port hose
(4): T port tube
a Disconnect the tube coupling.

the internal pressure of the hydraulic tank.
HM300-1
30-235
(10)
2

(5): T2 port tube

(6): A1 port hose
(7): A1 port tube
(8): B1 port tube
(9): P port tube
(10): PA port hose
Remove a U clamp and coupling from each
tube.
INSTALLATION

removal.
Refilling with oil (hydraulic tank)

specified level, then start the engine to have the
oil circulate in the piping, and check the oil level
again.
5 Hydraulic tank: 120l
l (EO10-CD)
a
a
(11): PB port hose

(12): A1 port hose
(13): B1 port hose
Start the work from the hitch frame side.
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
30-235-1
2(10)
Hoist valve assembly: 35kg
HM300-1

STEERING CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
STEERING CYLINDER
ASSEMBLY
3) Pull out cylinder head and piston rod

assembly (3) from cylinder (4) and remove.
When the piston rod assembly is pulled
out from the cylinder, oil will come out,
so catch it in a container.
4) Remove cylinder (4) from tool U1.
SPECIAL TOOL
Mar
k
Part No.
Part Name
DisNecesSkeQ'ty tincsity
tion* tch
790-502-1003 Cylinder Repair

Stand
790-101-1102 Hydraulic Pump
2 790-102-3802 Wrench Ass'y

3 790-102-1320 Socket (width
across flats: 70 mm)
790-720-1000 Expander
4 796-720-1660 Ring
07281-01159
Clamp
790-201-1702 Push Tool Kit

5
1
1
1
790-101-5021 Grip
01010-50816
Bolt
790-202-1781 Push Tool

790-101-5021 Grip
01010-50816
Bolt
790-201-1590 Plate
2. Disassembly of piston rod assembly

1) Set piston rod assembly (3) in tool U1.
2) Using tool U3, remove nut (5).
1
1
1
DISASSEMBLY
Be careful not to give damage to the rod packing, 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
tool U2, remove cylinder head assembly (2).
30-236
2
3) Remove piston assembly (6) and cylinder

head assembly (7) from rod (8).
HM300-1

3. Disassembly of piston assembly

1) Remove wear ring (9) from piston (10).
2) Remove wear ring (11) from piston (10).
ASSEMBLY
Clean all parts, and check for dirt or damage.

Coat the sliding surfaces all parts with engine oil
before installing.
1. Assembly of cylinder head assembly

1) Using tool U5, press fit bushing (15) to cylinder 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).
4) Remove O-ring (17) and backup ring (18).
2) Install rod packing (14).

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 cylinder head (16).

3) Using tool U4, shrink the piston ring.
4) Install wear ring (9).

3. Assembly of piston rod assembly

2. Assembly piston assembly
1) Using tool U4, expand piston ring (11).
Set piston ring (11) to the tool and rotate
the handle by 8 - 10 turns to expand the
ring.
1) Assemble cylinder head assembly (7) and

piston assembly (6) to piston rod (8).
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)

Nut
: 3.97 0.4kNm {405 40.5kgm}
3) Remove piston rod assembly (3) from tool

U1.
30-238
2
HM300-1

HOIST CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
SPECIAL TOOL
Mark
1
Part No.
Part Name
790-502-1003 Cylinder Repair Stand

790-101-1102 Hydraulic Pump
2 790-102-3802 Wrench Ass'y

790-720-1000 Expander
4 796-720-1660 Ring
4. Piston rod assembly
07281-01159 Clamp
1) Set cylinder (4) in tool U1.

2) Assemble cylinder head and piston rod
assembly (3) in cylinder (4).
DisNeces- Q'ty tinc- Skesity

tion* tch
1
1
1
1
1
1
1
790-101-5021 Grip
5 01010-50816 Bolt
790-201-1831 Push Tool
790-201-1871 Push Tool

790-101-5021 Grip
6 01010-50816 Bolt
790-201-1640 Plate
790-201-1680 Plate
7
790-102-4300 Wrench Ass'y

790-102-4310 Pin
1
1
1
1
DISASSEMBLY
3) Using tool U2, tighten cylinder head assembly (2).

3
HM300-1
Cylinder head nut

: 931 93.1Nm {95 9.5kgm}
Be careful not to damage the rod packing, dust

seal, piston ring, and wear ring.
1. Rod assembly
1) Set cylinder assembly to tool U1.
2) Using tool U2, remove cylinder head
assembly (1) from cylinder Y (2).
30-239
2

3) Remove cylinder U and rod assembly (3)
from cylinder Y (2).
4) Remove snap ring (12) and screw (12a).

5) Remove piston assembly (13), using tool
U7, and then sling rod (5) to detach from
cylinder U (4).
6) Remove wear ring (7) from cylinder U (4).

3. Further disassembling piston assembly

Remove piston ring (14), wear ring (15), O-ring
and backup ring (15a) from piston assembly
(13).
4. Cylinder U
Remove snap ring (16) from cylinder U (4),
then remove dust seal (17), rod packing (18)
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
2
HM300-1
ASSEMBLY

2. Assembly of piston assembly
Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.
1) Using tool U4, expand piston ring (14), and

assemble to piston (13).
Set the piston ring on tool, and turn the
handle 8 - 10 times to expand the ring.
1) Using tool U5, press fit bushing (19) to cylinder U (4).
2) Set tools U4 in position, and compress piston ring (14).
1. Cylinder U
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
(6).
Check the direction of assembly for the
rod packing when installing.
1) Fit wear ring (7) to cylinder U (4).

2) Tighten piston assembly (13), using tool U7.
3
Piston assembly
: 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 sufficiently.
5) Fit snap ring (12).
3) Using tool U6 install dust seal (9).
30-242
2
HM300-1

BODY ASSEMBLY

6) Assemble the rod assembly of cylinder U in
cylinder Y (2).
REMOVAL AND
INSTALLATION OF
BODY ASSEMBLY
REMOVAL
k

1. Sling the bottom side of hoist cylinder.

2. Remove bottom pins (1) of the left and right
hoist cylinders.
k
7) Install cylinder head assembly (1) to cylinder Y (2), using tool U2.
3
When the bottom pin is removed, the hoist

cylinder will swing outward, so fasten the
hoist cylinder with lever lock [1] inwardly.
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

BODY ASSEMBLY
4. Separate body potentio linkage (2) at the body

side.
5. Sling the body assembly at 4 points.
6. Remove 2 body hinge pins (3) on the left and
right sides.
a Shims are provided, so check their thickness, number in use and installed locations
beforehand.
INSTALLATION

removal.
k When matching the pinholes, never put a
finger into the hole.
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 POSITIONER SENSOR" in MAINTENANCE
AND ADJUSTMENT.
k When matching the pinholes, never put a
finger into the pinhole.
7. Sling body assembly (4) to remove.
4
3 Hinge pin mounting bolt

: 16 - 20 Nm {157 - 196 kgm}
Body assembly: 3,500kg

a Adjust the shims in the body mount, referring to the section of "ADJUSTING THE
SHIMS IN THE BODY MOUNT" in TESTING AND ADJUSTING.
30-244
2(15)
HM300-1

BODY ASSEMBLY
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 calculated in the step 3) above in bottom mount
(5).
Standard shim thickness: 4mm
: 1 mm and 3.2 mm
3 Shim mounting bolt:
235 285 Nm {23.5 29.5 kgm}
5) Remove spacer [1] and check that the bottom mount is in contact with the upper surface of the rear frame at all 4 points of A and
B.
HM300-1
30-245
2
(15)

OPERATORS SEAT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF OPERATORS SEAT

ASSEMBLY
a The procedure for disassembling and assembling the operators seat assembly {Air suspension (product
made from ISRING HAUSEN)} is shown below.
A:
B:
C:
D:
Headrest
Seatback
Seat cushion
Right-hand armrest
E : Left-hand armrest
F : Suspension cover
G : Sliderails
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
(5)
HM300-1
2) Apply force b to part a of each clip (2) in the

direction of the arrow to turn the clip. Release headrest stay (1) from part d of the clip
and pull out up headrest (3).

2. Seatback
1) Disconnect 3 air hoses (5) from the rear left
of seatback (4).
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)

in the direction of the arrow.
5) Applying the force to seatback (4), pull its
right side up.
6) Slide seatback (4) sideway and remove it.
3. Seat cushion
1) Push cushion adjuster lever (7) inward and
slide seat cushion (8) to the front end.
30-248
(5)

2) Push cushion stopper wire (9) down with

screwdriver [1], etc.
3) Pull out seat cushion (8) forward and remove
it.
4. Armrest
The procedure for disassembling right-hand
armrest (10) is shown below.
(Disassemble left-hand armrest (11) similarly.)
HM300-1

1) Remove plastic cap (12) from the armrest

hinge.
a Use a flat-head screwdriver, etc. to remove the cap.
2) Loosen armrest hinge mounting bolt (13).
6) Remove right-hand armrest (10).

a There are 2 position adjustment washers
(16) installed to each bolt between the
armrest and seatback. Take care not
lose them.
3) Remove plastic cap (14), and then remove

lower mounting bolt (15A) (M8 bolt) of righthand armrest (10).
5. Suspension cover
1) Remove right-hand hinge cover (17).
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 degrees.

a If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mounting bolt (15B).
HM300-1
30-249
(5)
3) Remove 4 suspension cover fixing rings

(19).

6) Remove 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
7) Remove suspension cover (27).
a If you remove the suspension cover without 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
(5)
HM300-1
2) Slide rails (28) to the rear end.

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of
q6
each rail.
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
q7
each rail, and then remove rails (28).

ASSEMBLY
1. Rails
1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
2) Set rails (28) to the front end and install 1

lock washer (30) and 1 hexagon socket head
bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
a Take care not to lose height adjustment

washers (31) between the rails and suspension.
HM300-1
30-251
(5)
3) Set rails (28) to the rear end and install 1 lock

washer (30) and 1 hexagon socket head bolt
(29) to each rail.

2) Install 3 metallic suspension cover clips (24).
3 Hexagon socket head bolt:
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),
and 4 mounting bolts (20).
3 Cushion rail mounting bolt:
2. Suspension cover
1) Set suspension cover (27) in position and install 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
21.4 27.6 Nm {2.18 2.82 kgm}
4) Install 4 suspension cover fixing rings (19).
30-252
(5)
HM300-1
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).

2) Tighten lower mounting bolt (15A) lightly and

turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
mounting bolt (15A) permanently.
3 Upper and lower armrest mounting

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
1) Slide in the seat cushion from the front of the
fitting position.
a If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).

5. Seatback
1) Insert the left side of seatback (4), and then
lower and set the right side.
2) Install seatback hinge mounting bolt (6) (M8

bolt).
3 Seatback hinge mounting bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
30-254
(5)
HM300-1

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 (30C 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
HM300-1
90-5-2
(12)
OTHERS

(30C 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
(12)
HM300-1

HM 300

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HM 300

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SEBM024815

HM300-1 mount the SAA6D125E-3 engine.

GENERAL ......................................................................................... 01-1

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

TESTING AND ADJUSTING ............................................................. 20-1

DISASSEMBLY AND ASSEMBLY ................................................... 30-1

OTHERS ............................................................................................ 90-1

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

When a manual is revised, an edition mark

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

3) Do not sling a heavy load with one rope alone,

k Slinging with one rope may cause turning

4) Do not sling a heavy load with ropes forming a

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Even if the residual pressure is released from

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

2) Hold in the condition in Step 1), and push

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, features

Used to prevent rubber gaskets, rubber

400 g 10 Bellows type

Main applications, features

Used for normal temperature, light load

Used for heavy load portion

Seizure resistance and heat resistance

Used as primer for cab side

Used as primer for glass side

Adhesive for cab glass

Used as primer for painted surface on

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Width across flat

STANDARD TIGHTENING TORQUE