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KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-20 – PDF DOWNLOAD
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KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-20 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-20 – PDF DOWNLOAD
Language : English
Pages : 1500
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-20 – PDF DOWNLOAD
Cover......................................................................................................................... 1 00 Index and foreword......................................................................................................... 3 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........................................................................................... 24 Explanation of terms for maintenance standard......................................................................... 26 Handling of electric equipment and hydraulic component................................................................ 28 Handling of connectors newly used for engines......................................................................... 37 How to read electric wire code........................................................................................ 40 Precautions when carrying out operation............................................................................... 43 Method of disassembling and connecting push-pull type coupler......................................................... 46 Standard tightening torque table...................................................................................... 49 Conversion table...................................................................................................... 53 01 Specification.............................................................................................................. 59 Specification and technical data.......................................................................................... 59 Specification drawings................................................................................................ 60 Specifications........................................................................................................ 61 Weight table.......................................................................................................... 64 Fuel, coolant and lubricants.......................................................................................... 65 10 Structure, function and maintenance standard............................................................................... 69 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....................................................................................................... 341 Standard service value table.............................................................................................. 341 Standard value table for engine....................................................................................... 342 Standard value table for chassis...................................................................................... 343 30 Testing and adjusting...................................................................................................... 349 Testing and adjusting, Part 1............................................................................................. 349 Precautions before work............................................................................................... 351 Tools for testing, adjusting, and troubleshooting..................................................................... 352 Sketches of special tools............................................................................................. 357 Measuring engine speed................................................................................................ 358 Testing intake air pressure (boost pressure).......................................................................... 359 Testing exhaust temperature........................................................................................... 360 Testing exhaust gas color............................................................................................. 361 Adjusting valve clearance............................................................................................. 362 Testing compression pressure.......................................................................................... 363 Testing blow-by pressure.............................................................................................. 365 Testing engine oil pressure........................................................................................... 366 Testing EGR valve and bypass valve drive oil pressure................................................................. 367 Handling of fuel system devices....................................................................................... 368 Releasing residual pressure from fuel system.......................................................................... 368 Testing fuel pressure................................................................................................. 369 Testing fuel return and leakage amount................................................................................ 370 Bleeding air from fuel circuit........................................................................................ 373 Testing the fuel circuit for leakage.................................................................................. 375 Testing and adjusting fan belt tension................................................................................ 376 Testing and adjusting alternator belt tension......................................................................... 377 Testing and adjusting air conditioner compressor belt tension......................................................... 378 Adjusting the shims in the body mount................................................................................. 379 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............................................................................................................ 505 General information on troubleshooting.................................................................................... 505 Precautions before work............................................................................................... 506 Points to remember when performing troubleshooting.................................................................... 507 How to proceed in troubleshooting..................................................................................... 509 Check before troubleshooting.......................................................................................... 511 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................................................ 607 Failure code [15SCL1] Hi clutch pressure control valve failure I...................................................... 608 Failure code [15SCMA] Hi clutch pressure control valve failure II..................................................... 611 Failure code [15SDL1] Lo clutch pressure control valve failure I...................................................... 612 Failure code [15SDMA] Lo clutch pressure control valve failure II..................................................... 615 Troubleshooting by failure code, Part 2................................................................................... 617 Failure code [15SEL1] 1st clutch pressure control valve failure I..................................................... 620 Failure code [15SEMA] 1st clutch pressure control valve failure II.................................................... 623 Failure code [15SFL1] 2nd clutch pressure control valve failure I..................................................... 624 Failure code [15SFMA] 2nd clutch pressure control valve failure II.................................................... 627 Failure code [15SGL1] 3rd clutch pressure control valve failure I..................................................... 628 Failure code [15SGMA] 3rd clutch pressure control valve failure II.................................................... 631 Failure code [15SJMA] Lockup clutch pressure control valve failure II................................................. 632 Failure code [15SKMA] Interaxle differential lock clutch pressure control valve failure II............................ 634 Failure code [2A62L1] Front wheel differential lock pressure control valve failure II................................. 636 Failure code [2A62LH] Front wheel differential lock pressure control valve failure I.................................. 638 Failure code [2B62L1] Rear wheel differential lock pressure control valve failure II.................................. 640 Failure code [2B62LH] Rear wheel differential lock pressure control valve failure I................................... 642 Failure code [2C4MNX] Retarder cooling oil filter clogging............................................................ 644 Failure code [2F00KM] Dragging of parking brake....................................................................... 646 Failure code [2G42ZG] Lowering of accumulator oil pressure (front).................................................... 648 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)..................................................... 648 Failure code [989A00] Engine overrun prevention activated............................................................. 649 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope).................................... 649 Failure code [A570NX] Engine oil filter clogging...................................................................... 650 Failure code [AA10NX] Air cleaner clogging............................................................................ 652 Failure code [AB00MA] Battery charge circuit failure.................................................................. 654 Failure code [B@BAZG] Lowering of engine oil pressure................................................................. 655 Failure code [B@BAZK] Lowering of engine oil level.................................................................... 656 Failure code [B@BCNS] Engine overheat................................................................................. 657 Failure code [B@BCZK] Lowering of coolant level....................................................................... 658 Failure code [B@C6NS] Overheat of brake cooling oil temperature (front)............................................... 660 Failure code [B@C8NS] Overheat of brake cooling oil temperature (center).............................................. 660 Failure code [B@CENS] Overheat of torque converter oil temperature.................................................... 661 Failure code [B@JANS] Overheat of steering oil temperature............................................................ 661 Troubleshooting by failure code, Part 3................................................................................... 663 Failure code [CA111] Abnormality in engine controller................................................................. 666 Failure code [CA115] Engine Ne or Bkup speed sensor error............................................................. 668 Failure code [CA122] Charge (boost) pressure sensor high error........................................................ 670 Failure code [CA123] Charge (boost) pressure sensor low error......................................................... 672 Failure code [CA131] Throttle sensor high error....................................................................... 674 Failure code [CA132] Throttle sensor low error........................................................................ 677 Failure code [CA135] Engine oil pressure sensor high error............................................................ 680 Failure code [CA141] Engine oil pressure sensor low error............................................................. 682 Failure code [CA144] Coolant temperature sensor high error............................................................ 684 Failure code [CA145] Coolant temperature sensor low error............................................................. 686 Failure code [CA153] Charge (boost) temperature sensor high error..................................................... 688 Failure code [CA154] Charge (boost) temperature sensor low error...................................................... 690 Failure code [CA187] Sensor power supply 2 low error.................................................................. 692 Failure code [CA221] Atmospheric pressure sensor high error........................................................... 696 Failure code [CA222] Atmospheric pressure sensor low error............................................................ 698 Failure code [CA227] Sensor power supply 2 high error................................................................. 700 Failure code [CA234] Engine overspeed................................................................................. 701 Failure code [CA238] Ne speed sensor power supply error............................................................... 702 Failure code [CA263] Fuel Temperature Sensor High Error............................................................... 704 Failure code [CA265] Fuel Temperature Sensor Low Error................................................................ 706 Failure code [CA271] PCV1 Short circuit............................................................................... 708 Failure code [CA272] PCV1 Disconnection............................................................................... 709 Failure code [CA273] PCV2 Short circuit............................................................................... 710 Failure code [CA274] PCV2 Disconnection............................................................................... 711 Failure code [CA322] Injector #1 open/short error..................................................................... 712 Failure code [CA323] Injector #5 open/short error..................................................................... 714 Failure code [CA324] Injector #3 open/short error..................................................................... 716 Failure code [CA325] Injector #6 open/short error..................................................................... 718 Failure code [CA331] Injector #2 open/short error..................................................................... 720 Failure code [CA332] Injector #4 open/short error..................................................................... 722 Failure code [CA342] Calibration code inconsistency................................................................... 724 Failure code [CA351] Injectors drive circuit error.................................................................... 725 Failure code [CA352] Sensor power supply 1 low error.................................................................. 726 Failure code [CA386] Sensor power supply 1 high error................................................................. 728 Troubleshooting by failure code, Part 4................................................................................... 731 Failure code [CA431] Idle validation switch error..................................................................... 734 Failure code [CA432] Idle validation action error..................................................................... 737 Failure code [CA441] Battery voltage low error........................................................................ 740 Failure code [CA442] Battery voltage high error....................................................................... 741 Failure code [CA449] Common rail pressure high error 2................................................................ 742 Failure code [CA451] Common rail pressure sensor high error........................................................... 744 Failure code [CA452] Common rail pressure sensor low error............................................................ 746 Failure code [CA553] Common rail pressure high error 1................................................................ 748 Failure code [CA554] Common rail pressure sensor in range error....................................................... 749 Failure code [CA559] Supply pump pressure very low error 1............................................................ 750 Failure code [CA689] Engine Ne speed sensor error..................................................................... 754 Failure code [CA731] Engine Bkup speed sensor phase error............................................................. 756 Failure code [CA757] All continuous data lost error................................................................... 757 Failure code [CA778] Engine Bkup speed sensor error................................................................... 758 Failure code [CA1228] EGR valve servo error 1......................................................................... 760 Failure code [CA1625] EGR valve servo error 2......................................................................... 761 Failure code [CA1626] Bypass valve solenoid current high error........................................................ 762 Failure code [CA1627] Bypass valve solenoid current low error......................................................... 764 Failure code [CA1628] Bypass Valve Servo Error 1...................................................................... 766 Failure code [CA1629] Bypass Valve Servo Error 2...................................................................... 767 Failure code [CA1631] Bypass valve lift sensor high error............................................................. 768 Failure code [CA1632] Bypass valve lift sensor low error.............................................................. 770 Failure code [CA1633] KOMNET datalink timeout error................................................................... 772 Failure code [CA1642] EGR inlet pressure sensor low error............................................................. 774 Failure code [CA1653] EGR inlet pressure sensor high error............................................................ 776 Failure code [CA2185] Throttle sensor power supply voltage high error................................................. 778 Failure code [CA2186] Throttle sensor power supply voltage low error.................................................. 780 Failure code [CA2249] Supply pump pressure very low error 2........................................................... 782 Failure code [CA2271] EGR valve lift sensor high error................................................................ 784 Failure code [CA2272] EGR valve lift sensor low error................................................................. 786 Failure code [CA2351] EGR valve solenoid operation short circuit...................................................... 788 Failure code [CA2352] EGR valve solenoid operation disconnect......................................................... 790 Failure code [CA2555] Intake air heater relay open circuit error...................................................... 792 Failure code [CA2556] Intake air heater relay short circuit error..................................................... 794 Troubleshooting by failure code, Part 5................................................................................... 797 Failure code [DAF9KM] Wrong connection of connector................................................................... 800 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication............................ 801 Failure code [DAQ0KK] Lowering of source voltage...................................................................... 802 Failure code [DAQ0KT] Trouble in non-volatile memory.................................................................. 804 Failure code [DAQ2KK] Trouble in solenoid power supply system......................................................... 806 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)....................................... 808 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication............................... 810 Failure code [DAQRMA] Disagreement of option setting (Transmission controller)........................................ 815 Failure code [DB10KT] Trouble in non-volatile memory.................................................................. 815 Failure code [DB12KK] Trouble in solenoid power supply system......................................................... 816 Failure code [DB13KK] Lowering of battery direct voltage.............................................................. 818 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 820 Failure code [DB1QMA] Disagreement of option setting (Retarder controller)............................................ 821 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled................................. 822 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled................................... 826 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal....................................... 832 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve.......................................................... 834 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve.......................................................... 835 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve......................................................... 836 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve......................................................... 837 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve......................................................... 838 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve..................................................... 839 Failure code [DF10KA] Input of no lever signals....................................................................... 840 Failure code [DF10KB] Input of multiple lever signals................................................................. 844 Failure code [DGF1KX] Transmission oil temperature out of range....................................................... 848 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)........................................... 850 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 852 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................ 854 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................................... 856 Failure code [DGR6KX] Steering oil temperature out of range........................................................... 858 Troubleshooting by failure code, Part 6................................................................................... 861 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system................................. 864 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system.... 866 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor................................................. 868 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system....................................... 870 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system........................................ 872 Failure code [DJF1KA] Disconnection in fuel level sensor system....................................................... 874 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................ 876 Failure code [DK52KX] Trouble in dump lever potentiometer 1........................................................... 878 Failure code [DK53L8] Trouble in dump lever potentiometer 2........................................................... 880 Failure code [DK54KX] Trouble in dump positioner sensor............................................................... 882 Failure code [DKH0KX] Pitch angle sensor signal out of range.......................................................... 884 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system................................... 886 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor................................................ 887 Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor......................................... 888 Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system............................ 889 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system.................................. 890 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system.................................. 891 Failure code [DV00KB] Short circuit in buzzer output circuit.......................................................... 892 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system...................... 894 Failure code [DW73KZ] Trouble in dump selector valve output system.................................................... 896 Failure code [DW78KZ] Trouble in rear wheel BCV command output system................................................. 898 Failure code [DW79KZ] Trouble in front wheel BCV command output system................................................ 900 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1........................... 902 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve..... 904 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve...... 906 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve......... 908 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2........................... 910 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1.......................... 912 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve.... 914 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve..... 916 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve........ 918 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2.......................... 920 Troubleshooting by failure code, Part 7................................................................................... 923 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve............................................... 926 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve................................................ 928 Failure code [DX13KY] Hot short in output circuit of dump EPC valve................................................... 930 Failure code [DX14KZ] Rear wheel differential lock command output system failure...................................... 932 Failure code [DX15KZ] Front wheel differential lock command output system failure..................................... 934 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid.................. 936 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid................... 938 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid...................... 940 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid....................................... 942 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid........................................ 944 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid........................................... 946 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch ECMV solenoid...................................... 948 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid....................................... 950 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid.......................................... 952 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch ECMV solenoid...................................... 954 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid....................................... 956 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid.......................................... 958 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch ECMV solenoid..................................... 960 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid...................................... 962 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid......................................... 964 Troubleshooting by failure code, Part 8................................................................................... 967 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid..................................... 968 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid...................................... 970 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid......................................... 972 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid..................................... 974 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid...................................... 976 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid......................................... 978 Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid................................. 980 Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid.................................. 982 Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid..................................... 984 Troubleshooting for electrical system (E-mode)............................................................................ 987 Before troubleshooting for electrical system.......................................................................... 989 Information in troubleshooting table.................................................................................. 995 E-1 Engine does not start (Starting motor does not turn).............................................................. 996 E-2 Auto preheater does not operate...................................................................................1000 E-3 When starting switch is turned ON, machine monitor displays nothing...............................................1004 E-4 When starting switch is turned OFF, machine monitor cannot be operated............................................1006 E-5 Alarm buzzer does not stop sounding...............................................................................1008 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section....................1009 E-7 Display of character display section cannot be changed............................................................1010 E-8 Power mode selection function does not operate normally...........................................................1014 E-9 AISS function does not operate normally...........................................................................1016 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification).........1018 E-11 Interaxle differential lock-up function does not operate normally................................................1022 E-12 Display of seat belt caution lamp is abnormal....................................................................1024 E-13 Turn signal lamps and pilot lamps do not operate normally........................................................1026 E-14 Night lighting is abnormal.......................................................................................1031 E-15 Backup lamp and backup buzzer operate abnormally.................................................................1037 E-16 Emergency steering system does not operate.......................................................................1041 E-17 Air conditioner does not operate normally........................................................................1045 Troubleshooting of hydraulic and mechanical system (H-mode)...............................................................1051 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................1053 Information in troubleshooting table..............................................................................1053 H-1 Machine does not start........................................................................................1054 H-2 Travel is not smooth (Machine hunts)..........................................................................1056 H-3 Lockup is not reset...........................................................................................1056 H-4 Start shock and gear shift shock are abnormally large.........................................................1057 H-5 Gear is not shifted up........................................................................................1058 H-6 Travel speed or power is low..................................................................................1060 H-7 Start and gearshift time lag is large.........................................................................1064 H-8 Torque converter oil temperature is high......................................................................1066 H-9 Torque converter oil temperature is low.......................................................................1067 H-10 Front brake does not work fully..............................................................................1068 H-11 Center brake does not work fully.............................................................................1069 H-12 Rear brake does not work fully...............................................................................1070 H-13 Steering wheel is heavy......................................................................................1071 H-14 Steering wheel does not move.................................................................................1072 H-15 Steering wheel waggle........................................................................................1073 H-16 Dump body raising speed is low...............................................................................1074 H-17 Dump body does not move......................................................................................1075 H-18 Hydraulic drift of dump body is large........................................................................1076 Troubleshooting of engine (S-mode)........................................................................................1079 Method of using troubleshooting chart.................................................................................1082 S-1 Starting performance of engine is poor...........................................................................1086 S-2 Engine does not start............................................................................................1088 S-3 Engine does not pick up smoothly.................................................................................1092 S-4 Engine stops during operation....................................................................................1093 S-5 Engine does not rotate smoothly..................................................................................1094 S-6 Engine lack output (or lacks power)..............................................................................1095 S-7 Exhaust gas is black (incomplete combustion).....................................................................1096 S-8 Oil consumption is excessive (or exhaust gas is blue)............................................................1098 S-9 Oil becomes dirty quickly........................................................................................1099 S-10 Fuel consumption is excessive...................................................................................1100 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................1101 S-12 Oil pressure drops..............................................................................................1102 S-13 Oil level rises (Entry of coolant or fuel)......................................................................1104 S-14 Coolant temperature becomes too high (Overheating)..............................................................1106 S-15 Abnormal noise is made..........................................................................................1107 S-16 Vibration is excessive..........................................................................................1108 50 Disassembly and assembly...................................................................................................1111 General information on disassembly and assembly...........................................................................1111 Precautions before work...............................................................................................1112 How to read this manual...............................................................................................1113 Coating materials list................................................................................................1115 Special tool list.....................................................................................................1118 Sketches of special tools.............................................................................................1123 Engine and cooling system.................................................................................................1139 Removal and installation of fuel supply pump..........................................................................1140 Removal and installation of engine assembly...........................................................................1143 Removal and installation of cylinder head assembly....................................................................1151 Removal and installation of fuel injector assembly....................................................................1164 Removal and installation of radiator assembly.........................................................................1169 Removal and installation of cooling assembly..........................................................................1173 Removal and installation of aftercooler...............................................................................1177 Removal and installation of engine front seal.........................................................................1180 Removal and installation of engine rear seal..........................................................................1182 Replacement procedure of exhaust pipe fire prevention cover1..........................................................1186 Power train, Part 1.......................................................................................................1195 Removal and installation of output shaft assembly.....................................................................1196 Disassembly and assembly of output shaft assembly.....................................................................1200 Removal and installation of transmission and front differential assembly..............................................1203 Disconnection and coupling of front differential and transmission.....................................................1211 Disassembly and assembly of torque converter assembly.................................................................1212 Disassembly and assembly of transmission assembly.....................................................................1220 Power train, Part 2.......................................................................................................1265 Disassembly and assembly of front differential assembly...............................................................1266 Removal and installation of center differential assembly..............................................................1285 Disassembly and assembly of center differential assembly..............................................................1289 Removal and installation of rear differential assembly................................................................1305 Disassembly and assembly of rear differential assembly................................................................1307 Power train, Part 3.......................................................................................................1321 Removal and installation of front final drive and brake assembly......................................................1322 Disassembly and assembly of front final drive and brake assembly......................................................1325 Removal and installation of center final drive and brake assembly.....................................................1341 Disassembly and assembly of center final drive and plate assembly.....................................................1343 Removal and installation of rear final drive assembly.................................................................1355 Disassembly and assembly of rear final drive assembly.................................................................1357 Removal and installation of center axle assembly......................................................................1364 Removal and installation of rear axle assembly........................................................................1367 Undercarriage and frame...................................................................................................1371 Removal and installation of front suspension cylinder assembly........................................................1372 Removal and installation of rear suspension cylinder assembly.........................................................1374 Disassembly and assembly of front and rear suspension cylinder assembly...............................................1375 Removal and installation of equalizer bar assembly....................................................................1377 Removal and installation of front wheel assembly......................................................................1379 Removal and installation of rear front wheel assembly.................................................................1380 Removal and installation of rear rear wheel assembly..................................................................1380 Removal and installation of hitch frame assembly......................................................................1381 Disassembly and assembly of hitch frame...............................................................................1389 Removal and installation of body assembly.............................................................................1394 Hydraulic system..........................................................................................................1397 Disassembly and assembly of steering valve............................................................................1398 Removal and installation of flow amplifier valve assembly.............................................................1408 Removal and installation of hoist valve assembly......................................................................1410 Disassembly and assembly of hoist valve assembly......................................................................1412 Disassembly and assembly of steering cylinder assembly................................................................1414 Disassembly and assembly of hoist cylinder assembly...................................................................1420 Cab and its attachments...................................................................................................1429 Removal and installation of operator's cab............................................................................1430 Removal and installation of operator's cab glass (Stuck glass)........................................................1435 Disassembly and assembly of operator’s seat assembly..................................................................1442 Removal and installation of air conditioner unit assembly.............................................................1452 Electrical system.........................................................................................................1459 Removal and installation of retarder controller assembly..............................................................1460 Removal and installation of transmission controller assembly..........................................................1462 Removal and installation of engine controller assembly................................................................1464 90 Diagrams and drawings......................................................................................................1467 Hydraulic diagrams and drawings...........................................................................................1467 Power train hydraulic circuit diagram.................................................................................1469 Steering and hoist hydraulic circuit diagram..........................................................................1471 Brake hydraulic circuit diagram.......................................................................................1473 Brake cooling hydraulic circuit diagram...............................................................................1474 Differential lock hydraulic circuit diagram...........................................................................1475 Electrical diagrams and drawings..........................................................................................1477 Electrical circuit diagram for inside cab (1/4).......................................................................1479 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2092...............................................1481 Electrical circuit diagram for inside cab (2/4) Serial No.: 2093 and up...............................................1483 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2092...............................................1485 Electrical circuit diagram for inside cab (3/4) Serial No.: 2093 and up...............................................1487 Electrical circuit diagram for inside cab (4/4).......................................................................1489 Electrical circuit diagram for outside cab (1/3)......................................................................1491 Electrical circuit diagram for outside cab (2/3)......................................................................1493 Electrical circuit diagram for outside cab (3/3)......................................................................1495 Connectors table and arrangement drawing..............................................................................1497
DESCRIPTION:
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL SEN00238-20 – PDF DOWNLOAD
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
A. Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
B. Engine volume
This section explains the method of reproducing, repairing, and replacing parts
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