Komatsu MX352,MX502 Hydraulic Excavator Shop Manual SEBM035400 PDF

Description

Komatsu MX352,MX502 Hydraulic Excavator Shop Manual SEBM035400  – PDF DOWNLOAD

FILE DETAILS:

Komatsu MX352,MX502 Hydraulic Excavator Shop Manual SEBM035400  – PDF DOWNLOAD

Language : English
Pages : 491
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu MX352,MX502 Hydraulic Excavator Shop Manual SEBM035400  – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• MX352                      6Y6089 and up
• MX502                      6Y7038 and up

MAIN MENU . 0
COVER . 1
CONTENTS 2
SAFETY 3
SAFETY NOTICE . 3
FOREWORD 5
GENERAL . 5
HOW TO READ THE SHOP MANUAL . 6
HOISTING INSTRUCTIONS . 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
COATING MATERIALS . 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
UNITS . 22
01 GENERAL 23
SPECIFICATION DIMENSION DRAWING . 24
WORKING RANGE DRAWING . 25
SPECIFICATIONS 26
WEIGHT TABLE 32
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS . 34
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . 37
PTO . 38
COOLING SYSTEM 40
POWER TRAIN . 42
SWING CIRCLE 43
SWING MACHINERY . 44
TRACK FRAME . 48
IDLER CUSHION . 49
IDLER . 50
TRACK ROLLER 52
CARRIER ROLLER 54
SPROCKET 55
TRACK SHOE 56
HYDRAULIC COMPONENTS LAYOUT DRAWING . 64
HYDRAULIC TANK 66
CENTER SWIVEL JOINT . 69
TRAVEL MOTOR 71
HYDRAULIC CYLINDER 79
SOLENOID VALVE 83
MULTI-CONTROL VALVE . 86
HYDRAULIC PUMP 87
CONTROL VALVE . 98
CLSS 112
OPERATION FOR EACH FUNCTION AND VALVE .116
SWING MOTOR .138
PPC VALVE .147
WORK EQUIPMENT 155
DIMENSIONS OF EACH PART OF WORK EQUIPMENT .158
FLOOR .164
AIR CONDITIONER .165
ENGINE CONTROL 166
ELECTRIC CONTROL SYSTEM .168
COMPONENT PARTS OF SYSTEM .173
MONITOR SYSTEM 174
MONITOR PANEL .175
SENSORS .177
20 TESTING AND ADJUSTING 179
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS .180
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 182
TESTING AND ADJUSTING .197
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS .198
MEASURING ENGINE SPEED 200
MEASUREMENT OF EXHAUST GAS COLOR 201
ADJUSTING VALVE CLEARANCE .202
MEASURING COMPRESSION PRESSURE 205
MEASURING ENGINE OIL PRESSURE .206
TESTING AND ADJUSTING FUEL INJECTION TIMING .207
TESTING AND ADJUSTING ALTERNATOR BELT TENSION .209
ADJUSTING FUEL CONTROL LEVER 210
TESTING WEAR OF SPROCKET 211
TESTING AND ADJUSTING TRACK SHOE TENSION 212
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING, AND BLADE CIRCUITS 213
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE 217
ADJUSTING PC VALVE 221
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE .222
MEASURING SOLENOID VALVE OUTPUT PRESSURE 224
MEASURING PPC VALVE OUTPUT PRESSURE .226
ADJUSTING PPC VALVE .229
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE 230
TESTING AND ADJUSTING TRAVEL DEVIATION 231
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER .233
BLEEDING AIR FROM EACH PART .235
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 238
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK .238
PRESSURIZING HYDRAULIC TANK .239
INSPECTION PROCEDURES FOR DIODE .240
TROUBLESHOOTING .241
POINTS TO REMEMBER WHEN TROUBLESHOOTING .242
SEQUENCE OF EVENTS IN TROUBLESHOOTING .243
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 244
CHECKS BEFORE TROUBLESHOOTING .252
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 253
TYPES AND LOCATIONS OF CONNECTORS .256
CONNECTOR ARRANGEMENT DIAGRAM .262
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 270
T-ADAPTER – BOXES AND T-ADAPTER TABLE .292
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) .295
BEFORE STARTING E-MODE TROUBLESHOOTING 296
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 297
E-1 ENGINE DOES NOT START .298
E-2 ENGINE DOES NOT STOP 306
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES 310
E-4 WINDSHIELD WIPER DOES NOT OPERATE .314
E-5 WINDSHIELD WASHER DOES NOT OPERATE 316
E-6 TRAVEL ALARM DOES NOT SOUND .320
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) .323
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 324
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW .325
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 329
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK 330
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP .333
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW .333
H-6 SPEED OR POWER OF BOOM IS LOW .334
H-7 SPEED OR POWER OF ARM IS LOW 335
H-8 SPEED OR POWER OF BUCKET IS LOW .336
H-9 SPEED OR POWER OF BOOM SWING IS LOW .337
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY 338
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE 339
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE 340
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW 340
H-14 MACHINE DEVIATES DURING TRAVEL .341
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL) .343
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .344
H-17 TRAVEL SPEED DOES NOT CHANGE .345
H-18 TRAVEL MOTOR DOES NOT WORK .346
H-19 SPEED OR POWER OF SWING IS LOW .348
H-20 MACHINE DOES NOT SWING .350
H-21 SWING ACCELERATION PERFORMANCE IS LOW 352
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING 354
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 355
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND 355
H-25 HYDRAULIC DRIFT OF SWING IS LARGE 356
H-26 SPEED OR POWER OF BLADE IS LOW .357
H-27 BLADE DOES NOT MOVE 358
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE 358
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE) 359
BEFORE STARTING M-MODE TROUBLESHOOTING 360
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 361
SYSTEM DIAGRAM RELATED TO MONITOR PANEL .362
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE 364
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE 366
M-3 ALARM BUZZER IS ABNORMAL 367
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON 369
M-5 CHARGE LEVEL CAUTION IS TURNED ON .370
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT .374
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL .376
M-8 FUEL LEVEL GAUGE IS ABNORMAL 381
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING 385
M-10 2ND TRAVEL SPEED IS NOT SELECTED .387
M-11 WORKING LAMP DOES NOT LIGHT UP .392
TROUBLESHOOTING OF ENGINE (S MODE) 395
METHOD OF USING TROUBLESHOOTING CHARTS 396
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) .400
S-2 ENGINE DOES NOT START .402
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 405
S-4 ENGINE STOPS DURING OPERATIONS 406
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) .407
S-6 ENGINE LACKS OUTPUT OR LACKS POWER 408
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 409
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE .410
S-9 OIL BECOMES CONTAMINATED QUICKLY 411
S-10 FUEL CONSUMPTION IS EXCESSIVE 412
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 413
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) .414
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) .415
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) .416
S-15 ABNORMAL NOISE IS MADE .417
S-16 VIBRATION IS EXCESSIVE .418
30 DISASSEMBLY AND ASSEMBLY .419
HOW TO READ THIS MANUAL .420
PRECAUTIONS WHEN PERFORMING OPERATION .422
SPECIAL TOOL LIST .424
SKETCHES OF SPECIAL TOOLS .428
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER .429
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP .438
REMOVAL AND INSTALLATION OF TRACK SHOE 445
DISASSEMBLY AND ASSEMBLY OF IDLER .446
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING .448
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER 451
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER .453
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT .454
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT .457
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 459
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY .463
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY .464
REMOVAL AND INSTALLATION OF WORK EQUIPMENT 470
REMOVAL AND INSTALLATION OF REVOLVING FRAME .472
REMOVAL AND INSTALLATION OF SWING CIRCLE 474
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE .475
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY .476
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 480
90 OTHERS .483
HYDRAULIC CIRCUIT DIAGRAM MX352 .484
HYDRAULIC CIRCUIT DIAGRAM MX502 .485
HYDRAULIC CIRCUIT DIAGRAM (Additional attachment circuit) MX502 .486
ELECTRICAL CIRCUIT DIAGRAM MX352 (1/2) 487
ELECTRICAL CIRCUIT DIAGRAM MX352 (2/2) 488
ELECTRICAL CIRCUIT DIAGRAM MX502 (1/2) 489

DESCRIPTION:

Komatsu MX352,MX502 Hydraulic Excavator Shop Manual SEBM035400  – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• MX352                      6Y6089 and up
• MX502                      6Y7038 and up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

G.B 30/12/24