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KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-17 – PDF DOWNLOAD
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KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-17 – PDF DOWNLOAD
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KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-17 – PDF DOWNLOAD
Language : English
Pages : 1520
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-17 – PDF DOWNLOAD
Cover......................................................................................................................... 1 00 Index and foreword......................................................................................................... 0 Index..................................................................................................................... 3 Composition of shop manual............................................................................................ 4 Table of contents..................................................................................................... 6 Foreword and general information.......................................................................................... 17 Safety notice......................................................................................................... 18 How to read the shop manual........................................................................................... 23 Explanation of terms for maintenance standard......................................................................... 25 Handling of electric equipment and hydraulic component................................................................ 27 Handling of connectors newly used for engines......................................................................... 36 How to read electric wire code........................................................................................ 39 Precautions when carrying out operation............................................................................... 42 Method of disassembling and connecting push-pull type coupler......................................................... 45 Standard tightening torque table...................................................................................... 48 Conversion table...................................................................................................... 52 01 Specification.............................................................................................................. 0 Specification and technical data.......................................................................................... 59 Specification drawings................................................................................................ 60 Specifications........................................................................................................ 61 Weight table.......................................................................................................... 64 Fuel, coolant and lubricants.......................................................................................... 65 10 Structure, function and maintenance standard............................................................................... 0 Engine and cooling system................................................................................................. 69 Radiator, oil cooler, aftercooler..................................................................................... 70 Output shaft.......................................................................................................... 71 Power train, Part 1....................................................................................................... 75 Power train skeleton.................................................................................................. 76 Torque converter and transmission hydraulic piping.................................................................... 80 Brake cooling oil control valve (BCV)................................................................................. 82 Power train pump...................................................................................................... 83 Torque converter...................................................................................................... 86 Transmission.......................................................................................................... 92 Transmission control valve............................................................................................ 120 ECMV.................................................................................................................. 121 Main relief, torque converter relief valve............................................................................ 128 Power train, Part 2....................................................................................................... 131 Drive shaft........................................................................................................... 132 Axle.................................................................................................................. 136 Differential.......................................................................................................... 140 Limited slip differential............................................................................................. 152 Final drive........................................................................................................... 156 Steering system........................................................................................................... 163 Steering column....................................................................................................... 164 Brake system.............................................................................................................. 167 Brake piping.......................................................................................................... 168 Brake valve........................................................................................................... 170 Accumulator charge valve.............................................................................................. 173 Accumulator........................................................................................................... 177 Slack adjuster........................................................................................................ 178 Brake................................................................................................................. 180 Proportional reducing valve........................................................................................... 185 Brake system tank..................................................................................................... 186 Parking brake......................................................................................................... 188 Parking brake solenoid valve.......................................................................................... 192 Undercarriage and frame................................................................................................... 195 Suspension............................................................................................................ 196 Suspension cylinder................................................................................................... 201 Oscillation hitch..................................................................................................... 203 Hydraulic system.......................................................................................................... 207 Steering, hoist oil pressure piping diagram........................................................................... 208 Dump body control..................................................................................................... 209 Hydraulic tank and filter............................................................................................. 210 Flow amp valve........................................................................................................ 211 Steering valve........................................................................................................ 214 Steering cylinder..................................................................................................... 218 Hoist valve........................................................................................................... 220 Dump control valve (EPC valve)........................................................................................ 226 Pilot check valve..................................................................................................... 230 Hoist cylinder........................................................................................................ 231 Hydraulic pump........................................................................................................ 232 Cab and its attachments................................................................................................... 237 ROPS cab.............................................................................................................. 238 Cab tilt.............................................................................................................. 239 Air conditioner....................................................................................................... 240 Rear view monitor..................................................................................................... 248 Controller related.................................................................................................... 251 Electrical system, Part 1................................................................................................. 253 Machine monitor system................................................................................................ 254 Electrical system, Part 2................................................................................................. 275 Automatic shift control system........................................................................................ 276 Transmission controller............................................................................................... 279 Retarder control system............................................................................................... 308 Auto emergency steering system........................................................................................ 320 Battery disconnector switch........................................................................................... 322 Dump control lever.................................................................................................... 324 Electrical system, Part 3................................................................................................. 329 Sensors, switches..................................................................................................... 330 KOMTRAX terminal system (if equipped)................................................................................. 338 20 Standard value table....................................................................................................... 0 Standard service value table.............................................................................................. 341 Standard value table for engine....................................................................................... 342 Standard value table for chassis...................................................................................... 343 30 Testing and adjusting...................................................................................................... 0 Testing and adjusting, Part 1............................................................................................. 349 Tools for testing, adjusting, and troubleshooting..................................................................... 351 Measuring engine speed................................................................................................ 357 Testing intake air pressure (boost pressure).......................................................................... 358 Testing exhaust temperature........................................................................................... 359 Testing exhaust gas color............................................................................................. 360 Adjusting valve clearance............................................................................................. 361 Testing compression pressure.......................................................................................... 362 Testing fuel pressure................................................................................................. 368 Testing blow-by pressure.............................................................................................. 364 Testing engine oil pressure........................................................................................... 365 Testing EGR valve and bypass valve drive oil pressure................................................................. 366 Handling of fuel system devices....................................................................................... 367 Releasing residual pressure from fuel system.......................................................................... 367 Testing fuel return and leakage amount................................................................................ 369 Bleeding air from fuel circuit........................................................................................ 372 Sketches of special tools............................................................................................. 356 Testing the fuel circuit for leakage.................................................................................. 374 Testing and adjusting fan belt tension................................................................................ 375 Testing and adjusting alternator belt tension......................................................................... 376 Testing and adjusting air conditioner compressor belt tension......................................................... 377 Adjusting the shims in the body mount................................................................................. 378 Testing and adjusting, Part 2............................................................................................. 381 Testing torque converter stall speed.................................................................................. 383 Testing power train oil pressure...................................................................................... 384 Testing and adjusting of differential lock oil pressure (differential lock spec.)..................................... 392 Adjusting transmission speed sensor................................................................................... 397 Testing and adjusting brake oil pressure.............................................................................. 399 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas................. 403 Testing brake performance............................................................................................. 411 Releasing remaining pressure in brake circuit......................................................................... 412 Bleeding air from brake circuit....................................................................................... 413 Testing wear of wheel brake disc...................................................................................... 414 Testing the parking brake pad wear.................................................................................... 415 Emergency release of the parking brake................................................................................ 416 Testing and adjusting steering circuit oil pressure................................................................... 417 Testing and adjusting suspension cylinder............................................................................. 419 Method of tilting cab up.............................................................................................. 423 Testing and adjusting dump circuit oil pressure....................................................................... 425 Adjusting body positioner sensor...................................................................................... 427 Adjusting length of spring in body heating spherical joint............................................................ 428 Adjustment of tilt lock lever of steering wheel....................................................................... 429 Handling of voltage circuit of engine controller...................................................................... 430 Adjusting transmission controller..................................................................................... 430 Method for emergency escape at electrical system failure.............................................................. 431 Testing and adjusting, Part 3............................................................................................. 437 Setting and adjusting various equipments.............................................................................. 438 Special function of machine monitor................................................................................... 447 How to start operation of KOMTRAX terminal............................................................................ 492 Lamp display of KOMTRAX terminal...................................................................................... 497 Pm Clinic check sheet................................................................................................. 500 40 Troubleshooting............................................................................................................ 0 General information on troubleshooting.................................................................................... 505 Points to remember when performing troubleshooting.................................................................... 506 How to proceed in troubleshooting..................................................................................... 508 Check before troubleshooting.......................................................................................... 510 Classification and procedures of troubleshooting...................................................................... 512 Information in troubleshooting table.................................................................................. 516 Troubleshooting method for disconnecting wiring harness of pressure sensor system..................................... 518 Phenomena looking like troubles and troubleshooting Nos............................................................... 520 Connection table for connector pin numbers............................................................................ 522 T- branch box and T- branch adapter table............................................................................. 558 Troubleshooting by failure code, General.................................................................................. 563 Failure codes table................................................................................................... 564 Before troubleshooting by failure code................................................................................ 572 Information in troubleshooting table.................................................................................. 580 Troubleshooting by failure code, Part 1................................................................................... 583 Failure code [1500L0] Detecting dual engagement....................................................................... 585 Failure code [15B0NX] Transmission oil filter: Clogging............................................................... 586 Failure code [15F0KM] R → F gear shift abuse 1........................................................................ 588 Failure code [15F0MB] R → F gear shift abuse 2........................................................................ 588 Failure code [15F7KM] Transmission forward clutch abuse............................................................... 589 Failure code [15G0MW] Reverse clutch system failure (Slip is detected)................................................ 590 Failure code [15G7KM] Transmission reverse clutch abuse............................................................... 592 Failure code [15H0MW] Hi clutch system failure (Slip is detected)..................................................... 594 Failure code [15J0MW] Lo clutch system failure (Slip is detected)..................................................... 596 Failure code [15K0MW] 1st clutch system failure (Slip is detected).................................................... 598 Failure code [15L0MW] 2nd clutch system failure (Slip is detected).................................................... 600 Failure code [15M0MW] 3rd clutch system failure (Slip is detected).................................................... 602 Failure code [15SBL1] Reverse clutch pressure control valve failure I................................................. 604 Failure code [15SBMA] Reverse clutch pressure control valve failure II................................................ 608 Failure code [15SCL1] Hi clutch pressure control valve failure I...................................................... 610 Failure code [15SCMA] Hi clutch pressure control valve failure II..................................................... 614 Failure code [15SDL1] Lo clutch pressure control valve failure I...................................................... 616 Failure code [15SDMA] Lo clutch pressure control valve failure II..................................................... 618 Troubleshooting by failure code, Part 2................................................................................... 623 Failure code [15SEL1] Trouble in 1st clutch pressure control valve I.................................................. 625 Failure code [15SEMA] Trouble in 1st clutch pressure control valve II................................................. 628 Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I.................................................. 630 Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II................................................. 634 Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I.................................................. 636 Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II................................................. 640 Failure code [15SJMA] Trouble in lockup clutch pressure control valve II.............................................. 642 Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II......................... 644 Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2............................... 646 Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............................... 648 Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2................................ 650 Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1................................ 652 Failure code [2C4MNX] Clogging of retarder cooling oil filter......................................................... 654 Failure code [2F00KM] Dragging of parking brake....................................................................... 656 Failure code [2G42ZG] Lowering of accumulator oil pressure (front).................................................... 658 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)..................................................... 658 Failure code [989A00] Operation of engine overrun prevention system................................................... 659 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope).................................... 659 Failure code [A570NX] Clogging of engine oil filter................................................................... 660 Failure code [AA10NX] Clogging of air cleaner......................................................................... 662 Failure code [AB00MA] Trouble in battery charge circuit............................................................... 664 Failure code [B@BAZG] Lowering of engine oil pressure................................................................. 665 Failure code [B@BAZK] Lowering of engine oil level.................................................................... 666 Failure code [B@BCNS] Overheating of engine........................................................................... 667 Failure code [B@BCZK] Lowering of coolant level....................................................................... 668 Failure code [B@BFZK] Lowering of fuel level.......................................................................... 670 Failure code [B@C6NS] Overheating of brake cooling oil (front)........................................................ 671 Failure code [B@C8NS] Overheating of brake cooling oil (center)....................................................... 671 Failure code [B@CENS] Overheating of torque converter oil............................................................. 672 Failure code [B@JANS] Overheating of steering oil..................................................................... 672 Troubleshooting by failure code, Part 3................................................................................... 675 Failure code [CA111] Abnormality in engine controller................................................................. 678 Failure code [CA115] Engine Ne or Bkup speed sensor error............................................................. 680 Failure code [CA122] Charge (boost) pressure sensor high error........................................................ 682 Failure code [CA123] Charge (boost) pressure sensor low error......................................................... 684 Failure code [CA131] Throttle sensor high error....................................................................... 686 Failure code [CA132] Throttle sensor low error........................................................................ 689 Failure code [CA135] Engine oil pressure sensor high error............................................................ 692 Failure code [CA141] Engine oil pressure sensor low error............................................................. 694 Failure code [CA144] Coolant temperature sensor high error............................................................ 696 Failure code [CA145] Coolant temperature sensor low error............................................................. 698 Failure code [CA153] Charge (boost) temperature sensor high error..................................................... 700 Failure code [CA154] Charge (boost) temperature sensor low error...................................................... 702 Failure code [CA187] Sensor power supply 2 low error.................................................................. 704 Failure code [CA221] Atmospheric pressure sensor high error........................................................... 708 Failure code [CA222] Atmospheric pressure sensor low error............................................................ 710 Failure code [CA227] Sensor power supply 2 high error................................................................. 712 Failure code [CA234] Engine overspeed................................................................................. 713 Failure code [CA238] Ne speed sensor power supply error............................................................... 714 Failure code [CA263] Fuel Temperature Sensor High Error............................................................... 716 Failure code [CA265] Fuel Temperature Sensor Low Error................................................................ 718 Failure code [CA271] PCV1 Short circuit............................................................................... 720 Failure code [CA272] PCV1 Disconnection............................................................................... 721 Failure code [CA273] PCV2 Short circuit............................................................................... 722 Failure code [CA274] PCV2 Disconnection............................................................................... 723 Failure code [CA322] Injector #1 open/short error..................................................................... 724 Failure code [CA323] Injector #5 open/short error..................................................................... 726 Failure code [CA324] Injector #3 open/short error..................................................................... 728 Failure code [CA325] Injector #6 open/short error..................................................................... 730 Failure code [CA331] Injector #2 open/short error..................................................................... 732 Failure code [CA332] Injector #4 open/short error..................................................................... 734 Failure code [CA342] Calibration code inconsistency................................................................... 736 Failure code [CA351] Injectors drive circuit error.................................................................... 737 Failure code [CA352] Sensor power supply 1 low error.................................................................. 738 Failure code [CA386] Sensor power supply 1 high error................................................................. 740 Troubleshooting by failure code, Part 4................................................................................... 743 Failure code [CA431] Idle validation switch error..................................................................... 746 Failure code [CA432] Idle validation action error..................................................................... 749 Failure code [CA441] Battery voltage low error........................................................................ 752 Failure code [CA442] Battery voltage high error....................................................................... 753 Failure code [CA449] Common rail pressure high error 2................................................................ 754 Failure code [CA451] Common rail pressure sensor high error........................................................... 756 Failure code [CA452] Common rail pressure sensor low error............................................................ 758 Failure code [CA553] Common rail pressure high error 1................................................................ 760 Failure code [CA554] Common rail pressure sensor in range error....................................................... 761 Failure code [CA559] Supply pump pressure very low error 1............................................................ 762 Failure code [CA689] Engine Ne speed sensor error..................................................................... 766 Failure code [CA731] Engine Bkup speed sensor phase error............................................................. 768 Failure code [CA757] All continuous data lost error................................................................... 769 Failure code [CA778] Engine Bkup speed sensor error................................................................... 770 Failure code [CA1228] EGR valve servo error 1......................................................................... 772 Failure code [CA1625] EGR valve servo error 2......................................................................... 773 Failure code [CA1626] Bypass valve solenoid current high error........................................................ 774 Failure code [CA1627] Bypass valve solenoid current low error......................................................... 776 Failure code [CA1628] Bypass Valve Servo Error 1...................................................................... 778 Failure code [CA1629] Bypass Valve Servo Error 2...................................................................... 779 Failure code [CA1631] Bypass valve lift sensor high error............................................................. 780 Failure code [CA1632] Bypass valve lift sensor low error.............................................................. 782 Failure code [CA1633] KOMNET datalink timeout error................................................................... 784 Failure code [CA1642] EGR inlet pressure sensor low error............................................................. 786 Failure code [CA1653] EGR inlet pressure sensor high error............................................................ 788 Failure code [CA2185] Throttle sensor power supply voltage high error................................................. 790 Failure code [CA2186] Throttle sensor power supply voltage low error.................................................. 792 Failure code [CA2249] Supply pump pressure very low error 2........................................................... 794 Failure code [CA2271] EGR valve lift sensor high error................................................................ 796 Failure code [CA2272] EGR valve lift sensor low error................................................................. 798 Failure code [CA2351] EGR valve solenoid operation short circuit...................................................... 800 Failure code [CA2352] EGR valve solenoid operation disconnect......................................................... 802 Failure code [CA2555] Intake air heater relay open circuit error...................................................... 804 Failure code [CA2556] Intake air heater relay short circuit error..................................................... 806 Troubleshooting by failure code, Part 5................................................................................... 809 Failure code [DAF9KM] Wrong connection of connector................................................................... 812 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication............................ 813 Failure code [DAQ0KK] Lowering of source voltage...................................................................... 814 Failure code [DAQ0KT] Trouble in non-volatile memory.................................................................. 816 Failure code [DAQ2KK] Trouble in solenoid power supply system......................................................... 818 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)....................................... 820 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication............................... 822 Failure code [DAQRMA] Disagreement of option setting (Transmission controller)........................................ 827 Failure code [DB10KT] Trouble in non-volatile memory.................................................................. 827 Failure code [DB12KK] Trouble in solenoid power supply system......................................................... 828 Failure code [DB13KK] Lowering of battery direct voltage.............................................................. 830 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 832 Failure code [DB1QMA] Disagreement of option setting (Retarder controller)............................................ 833 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled................................. 834 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled................................... 838 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal....................................... 844 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve.......................................................... 846 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve.......................................................... 847 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve......................................................... 848 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve......................................................... 849 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve......................................................... 850 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve..................................................... 851 Failure code [DF10KA] Input of no lever signals....................................................................... 852 Failure code [DF10KB] Input of multiple lever signals................................................................. 856 Failure code [DGF1KX] Transmission oil temperature out of range....................................................... 860 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)........................................... 862 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 864 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................ 866 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................................... 868 Failure code [DGR6KX] Steering oil temperature out of range........................................................... 870 Troubleshooting by failure code, Part 6................................................................................... 873 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system................................. 876 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system.... 878 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor................................................. 880 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system....................................... 882 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system........................................ 884 Failure code [DJF1KA] Disconnection in fuel level sensor system....................................................... 886 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................ 888 Failure code [DK52KX] Trouble in dump lever potentiometer 1........................................................... 890 Failure code [DK53L8] Trouble in dump lever potentiometer 2........................................................... 892 Failure code [DK54KX] Trouble in dump positioner sensor............................................................... 894 Failure code [DKH0KX] Pitch angle sensor signal out of range.......................................................... 896 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system................................... 898 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor................................................ 899 Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor......................................... 900 Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system............................ 901 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system.................................. 902 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system.................................. 903 Failure code [DV00KB] Short circuit in buzzer output circuit.......................................................... 904 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system...................... 906 Failure code [DW73KZ] Trouble in dump selector valve output system.................................................... 908 Failure code [DW78KZ] Trouble in rear wheel BCV command output system................................................. 910 Failure code [DW79KZ] Trouble in front wheel BCV command output system................................................ 912 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1........................... 914 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve..... 916 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve...... 918 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve......... 920 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2........................... 922 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1.......................... 924 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve.... 926 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve..... 928 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve........ 930 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2.......................... 932 Troubleshooting by failure code, Part 7................................................................................... 935 Troubleshooting by failure code, Part 7............................................................................... 938 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve........................................... 938 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve............................................ 940 Failure code [DX13KY] Hot short in output circuit of dump EPC valve............................................... 942 Failure code [DX14KZ] Trouble in rear wheel differential lock command output system............................... 944 Failure code [DX15KZ] Trouble in front wheel differential lock command output system.............................. 946 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid.............. 948 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid............... 950 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.................. 952 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................................... 953 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid.................................... 954 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid....................................... 956 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid....................................... 958 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve............................. 960 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve................................ 962 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid....................................... 966 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve............................. 968 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve................................ 970 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid...................................... 974 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve............................ 976 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve............................... 978 Troubleshooting by failure code, Part 8................................................................................... 983 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid..................................... 984 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid...................................... 986 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid......................................... 988 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid..................................... 992 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid...................................... 994 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid......................................... 996 Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid.................................1000 Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid..................................1002 Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid.....................................1004 Troubleshooting for electrical system (E-mode)............................................................................1009 Before troubleshooting for electrical system..........................................................................1011 Information in troubleshooting table..................................................................................1017 E-1 Engine does not start (Starting motor does not turn)..............................................................1018 E-2 Auto preheater does not operate...................................................................................1022 E-3 When starting switch is turned ON, machine monitor displays nothing...............................................1026 E-4 When starting switch is turned OFF, machine monitor cannot be operated............................................1028 E-5 Alarm buzzer does not stop sounding...............................................................................1030 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section....................1031 E-7 Display of character display section cannot be changed............................................................1032 E-8 Power mode selection function does not operate normally...........................................................1036 E-9 AISS function does not operate normally...........................................................................1038 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification).........1040 E-11 Interaxle differential lock-up function does not operate normally................................................1044 E-12 Display of seat belt caution lamp is abnormal....................................................................1046 E-13 Turn signal lamps and pilot lamps do not operate normally........................................................1048 E-14 Night lighting is abnormal.......................................................................................1053 E-15 Backup lamp and backup buzzer operate abnormally.................................................................1059 E-16 Emergency steering system does not operate.......................................................................1063 E-17 Air conditioner does not operate normally........................................................................1067 Troubleshooting of hydraulic and mechanical system (H-mode)...............................................................1073 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................1075 Information in troubleshooting table..............................................................................1075 H-1 Machine does not start........................................................................................1076 H-2 Travel is not smooth (Machine hunts)..........................................................................1078 H-3 Lockup is not reset...........................................................................................1078 H-4 Start shock and gear shift shock are abnormally large.........................................................1079 H-5 Gear is not shifted up........................................................................................1080 H-6 Travel speed or power is low..................................................................................1082 H-7 Start and gearshift time lag is large.........................................................................1086 H-8 Torque converter oil temperature is high......................................................................1088 H-9 Torque converter oil temperature is low.......................................................................1089 H-10 Front brake does not work fully..............................................................................1090 H-11 Center brake does not work fully.............................................................................1091 H-12 Rear brake does not work fully...............................................................................1092 H-13 Steering wheel is heavy......................................................................................1093 H-14 Steering wheel does not move.................................................................................1094 H-15 Steering wheel waggle........................................................................................1095 H-16 Dump body raising speed is low...............................................................................1096 H-17 Dump body does not move......................................................................................1097 H-18 Hydraulic drift of dump body is large........................................................................1098 Troubleshooting of engine (S-mode)........................................................................................1101 Method of using troubleshooting chart.................................................................................1104 S-1 Starting performance of engine is poor...........................................................................1108 S-2 Engine does not start............................................................................................1110 S-3 Engine does not pick up smoothly.................................................................................1114 S-4 Engine stops during operation....................................................................................1115 S-5 Engine does not rotate smoothly..................................................................................1116 S-6 Engine lack output (or lacks power)..............................................................................1117 S-7 Exhaust gas is black (incomplete combustion).....................................................................1118 S-8 Oil consumption is excessive (or exhaust gas is blue)............................................................1120 S-9 Oil becomes dirty quickly........................................................................................1121 S-10 Fuel consumption is excessive...................................................................................1122 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................1123 S-12 Oil pressure drops..............................................................................................1124 S-13 Oil level rises (Entry of coolant or fuel)......................................................................1126 S-14 Coolant temperature becomes too high (Overheating)..............................................................1128 S-15 Abnormal noise is made..........................................................................................1129 S-16 Vibration is excessive..........................................................................................1130 50 Disassembly and assembly................................................................................................... 0 General information on disassembly and assembly...........................................................................1133 How to read this manual...............................................................................................1134 Coating materials list................................................................................................1136 Special tool list.....................................................................................................1139 Sketches of special tools.............................................................................................1144 Engine and cooling system.................................................................................................1159 Removal and installation of fuel supply pump..........................................................................1160 Removal and installation of engine assembly...........................................................................1163 Removal and installation of cylinder head assembly....................................................................1171 Removal and installation of fuel injector assembly....................................................................1184 Removal and installation of radiator assembly.........................................................................1189 Removal and installation of cooling assembly..........................................................................1193 Removal and installation of aftercooler...............................................................................1197 Removal and installation of engine front seal.........................................................................1200 Removal and installation of engine rear seal..........................................................................1202 Replacement procedure of exhaust pipe fire prevention cover1..........................................................1206 Power train, Part 1.......................................................................................................1215 Removal and installation of output shaft assembly.....................................................................1216 Disassembly and assembly of output shaft assembly.....................................................................1220 Removal and installation of transmission and front differential assembly..............................................1223 Disconnection and coupling of front differential and transmission.....................................................1231 Disassembly and assembly of torque converter assembly.................................................................1232 Disassembly and assembly of transmission assembly.....................................................................1240 Power train, Part 2.......................................................................................................1285 Disassembly and assembly of front differential assembly...............................................................1286 Removal and installation of center differential assembly..............................................................1305 Disassembly and assembly of center differential assembly..............................................................1309 Removal and installation of rear differential assembly................................................................1325 Disassembly and assembly of rear differential assembly................................................................1327 Power train, Part 3.......................................................................................................1341 Removal and installation of front final drive and brake assembly......................................................1342 Disassembly and assembly of front final drive and brake assembly......................................................1345 Removal and installation of center final drive and brake assembly.....................................................1361 Disassembly and assembly of center final drive and plate assembly.....................................................1363 Removal and installation of rear final drive assembly.................................................................1375 Disassembly and assembly of rear final drive assembly.................................................................1377 Removal and installation of center axle assembly......................................................................1384 Removal and installation of rear axle assembly........................................................................1387 Undercarriage and frame...................................................................................................1391 Removal and installation of front suspension cylinder assembly........................................................1392 Removal and installation of rear suspension cylinder assembly.........................................................1394 Disassembly and assembly of front and rear suspension cylinder assembly...............................................1395 Removal and installation of equalizer bar assembly....................................................................1397 Removal and installation of front wheel assembly......................................................................1399 Removal and installation of rear front wheel assembly.................................................................1400 Removal and installation of rear rear wheel assembly..................................................................1400 Removal and installation of hitch frame assembly......................................................................1401 Disassembly and assembly of hitch frame...............................................................................1409 Removal and installation of body assembly.............................................................................1414 Hydraulic system..........................................................................................................1417 Disassembly and assembly of steering valve............................................................................1418 Removal and installation of flow amplifier valve assembly.............................................................1428 Removal and installation of hoist valve assembly......................................................................1430 Disassembly and assembly of hoist valve assembly......................................................................1432 Disassembly and assembly of steering cylinder assembly................................................................1434 Disassembly and assembly of hoist cylinder assembly...................................................................1440 Cab and its attachments...................................................................................................1449 Removal and installation of operator's cab............................................................................1450 Removal and installation of operator's cab glass (Stuck glass)........................................................1455 Disassembly and assembly of operator’s seat assembly..................................................................1462 Removal and installation of air conditioner unit assembly.............................................................1472 Electrical system.........................................................................................................1479 Removal and installation of retarder controller assembly..............................................................1480 Removal and installation of transmission controller assembly..........................................................1482 Removal and installation of engine controller assembly................................................................1484 90 Diagrams and drawings...................................................................................................... 0 Hydraulic diagrams and drawings...........................................................................................1487 Power train hydraulic circuit diagram.................................................................................1489 Steering and hoist hydraulic circuit diagram..........................................................................1491 Brake hydraulic circuit diagram.......................................................................................1493 Brake cooling hydraulic circuit diagram...............................................................................1494 Differential lock hydraulic circuit diagram...........................................................................1495 Electrical diagrams and drawings..........................................................................................1497 Electrical circuit diagram for inside cab (1/4).......................................................................1499 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2092...............................................1501 Electrical circuit diagram for inside cab (2/4) Serial No.: 2093 and up...............................................1503 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2092...............................................1505 Electrical circuit diagram for inside cab (3/4) Serial No.: 2093 and up...............................................1507 Electrical circuit diagram for inside cab (4/4).......................................................................1509 Electrical circuit diagram for outside cab (1/3)......................................................................1511 Electrical circuit diagram for outside cab (2/3)......................................................................1513 Electrical circuit diagram for outside cab (3/3)......................................................................1515 Connectors table and arrangement drawing..............................................................................1517
DESCRIPTION:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-17 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 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 warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 29/12/24
