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Komatsu HM350-2 Articulated Dump Truck Shop Manual CEBM007801 – PDF DOWNLOAD
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Komatsu HM350-2 Articulated Dump Truck Shop Manual
SERIAL NUMBERS HM350-2 A11001 and up
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Description
Komatsu HM350-2 Articulated Dump Truck Shop Manual CEBM007801
FILE DETAILS:
Komatsu HM350-2 Articulated Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Articulated Dump Truck
Manuals Type: Shop Manual
Machine Model: HM350-2
Serial Number: A11001 and up
Book Code: CEBM007801
Language: English
Pages: 1462
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM350-2 Articulated Dump Truck Shop Manual
How to read the shop manual:
1. 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 contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby 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.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu HM350-2 Articulated Dump Truck Shop Manual
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........................................................................................... 23
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.............................................................................................................. 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............................................................................... 71
ENGINE AND COOLING SYSTEM................................................................................................. 71
RADIATOR, OIL COOLER, AFTERCOOLER..................................................................................... 72
OUTPUT SHAFT.......................................................................................................... 73
POWER TRAIN, PART 1....................................................................................................... 77
POWER TRAIN SKELETON.................................................................................................. 78
MACHINE WITH LIMITED SLIP DIFFERENTIAL................................................................................ 80
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING.................................................................... 82
BRAKE COOLING OIL CONTROL VALVE (BCV)................................................................................. 84
POWER TRAIN PUMP...................................................................................................... 85
BRAKE COOLING, BRAKE SYSTEM PUMP.................................................................................. 86
TRANSMISSION PUMP (MACHINE WITH LIMITED SLIP DIFFERENTIAL)........................................................ 87
TORQUE CONVERTER...................................................................................................... 88
TRANSMISSION.......................................................................................................... 94
TRANSMISSION CONTROL VALVE............................................................................................ 122
ECMV.................................................................................................................. 123
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE............................................................................ 130
POWER TRAIN, PART 2....................................................................................................... 133
DRIVE SHAFT........................................................................................................... 134
AXLE.................................................................................................................. 138
DIFFERENTIAL.......................................................................................................... 142
MACHINE WITH LIMITED SLIP DIFFERENTIA;................................................................................ 148
LIMITED SLIP DIFFERENTIAL............................................................................................. 154
FINAL DRIVE........................................................................................................... 158
STEERING SYSTEM........................................................................................................... 167
STEERING COLUMN....................................................................................................... 168
BRAKE SYSTEM.............................................................................................................. 171
BRAKE PIPING.......................................................................................................... 172
BRAKE VALVE........................................................................................................... 174
ACCUMULATOR CHARGE VALVE.............................................................................................. 177
ACCUMULATOR........................................................................................................... 181
SLACK ADJUSTER........................................................................................................ 182
BRAKE................................................................................................................. 184
PROPORTIONAL REDUCING VALVE........................................................................................... 189
BRAKE SYSTEM TANK..................................................................................................... 190
PARKING BRAKE......................................................................................................... 192
PARKING BRAKE SOLENOID VALVE.......................................................................................... 196
UNDERCARRIAGE AND FRAME................................................................................................... 199
SUSPENSION............................................................................................................ 200
SUSPENSION CYLINDER................................................................................................... 205
OSCILLATION HITCH..................................................................................................... 207
HYDRAULIC SYSTEM.......................................................................................................... 211
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM........................................................................... 212
DUMP BODY CONTROL..................................................................................................... 213
HYDRAULIC TANK AND FILTER............................................................................................. 214
FLOW AMP VALVE........................................................................................................ 215
STEERING VALVE........................................................................................................ 218
STEERING CYLINDER..................................................................................................... 222
HOIST VALVE........................................................................................................... 224
DUMP CONTROL VALVE (EPC VALVE)........................................................................................ 230
PILOT CHECK VALVE..................................................................................................... 234
HOIST CYLINDER........................................................................................................ 235
HYDRAULIC PUMP........................................................................................................ 236
CAB AND ITS ATTACHMENTS................................................................................................... 241
ROPS CAB.............................................................................................................. 242
CAB TILT.............................................................................................................. 243
AIR CONDITIONER....................................................................................................... 244
REAR VIEW MONITOR .................................................................................................... 252
CONTROLLER RELATED.................................................................................................... 255
ELECTRICAL SYSTEM, PART 1................................................................................................. 257
MACHINE MONITOR SYSTEM................................................................................................ 258
ELECTRICAL SYSTEM, PART 2................................................................................................. 279
AUTOMATIC SHIFT CONTROL SYSTEM........................................................................................ 280
TRANSMISSION CONTROLLER............................................................................................... 283
HOIST CONTROL FUNCTION................................................................................................ 310
RETARDER CONTROL SYSTEM............................................................................................... 312
AUTO EMERGENCY STEERING SYSTEM........................................................................................ 324
BATTERY DISCONNECT SWITCH............................................................................................. 326
DUMP CONTROL LEVER.................................................................................................... 328
ELECTRICAL SYSTEM, PART 3................................................................................................. 333
SENSORS, SWITCHES..................................................................................................... 334
KOMTRAX TERMINAL SYSTEM (IF EQUIPPED(................................................................................. 342
20 STANDARD VALUE TABLE....................................................................................................... 345
STANDARD SERVICE VALUE TABLE.............................................................................................. 345
STANDARD VALUE TABLE FOR ENGINE....................................................................................... 346
STANDARD VALUE TABLE FOR CHASSIS...................................................................................... 347
30 TESTING AND ADJUSTING...................................................................................................... 353
TESTING AND ADJUSTING, PART 1............................................................................................. 353
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................................... 355
MEASURING ENGINE SPEED................................................................................................ 359
TESTING INTAKE AIR PRESSURE (BOOST PRESSURE).......................................................................... 360
TESTING EXHAUST TEMPERATURE........................................................................................... 361
TESTING EXHAUST GAS COLOR............................................................................................. 362
ADJUSTING VALVE CLEARANCE............................................................................................. 363
TESTING COMPRESSION PRESSURE.......................................................................................... 364
TESTING BLOW-BY PRESSURE.............................................................................................. 366
TESTING ENGINE OIL PRESSURE........................................................................................... 367
TESTING EGR VALVE AND BYPASS VALVE DRIVE OIL PRESSURE................................................................. 368
HANDLING OF FUEL SYSTEM DEVICES....................................................................................... 369
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM.......................................................................... 369
TESTING FUEL PRESSURE................................................................................................. 370
TESTING FUEL RETURN AND LEAKAGE AMOUNT................................................................................ 371
BLEEDING AIR FROM FUEL CIRCUIT........................................................................................ 374
TESTING THE FUEL CIRCUIT FOR LEAKAGE.................................................................................. 376
TESTING AND ADJUSTING FAN BELT TENSION................................................................................ 377
TESTING AND ADJUSTING ALTERNATOR BELT TENSION......................................................................... 378
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION......................................................... 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............................................................................................. 407
BLEEDING AIR FROM BRAKE CIRCUIT....................................................................................... 408
TESTING WEAR OF WHEEL BRAKE DISC...................................................................................... 409
TESTING THE PARKING BRAKE PAD WEAR.................................................................................... 410
EMERGENCY RELEASE OF THE PARKING BRAKE................................................................................ 411
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE................................................................... 412
TESTING AND ADJUSTING SUSPENSION CYLINDER............................................................................. 414
METHOD OF TILTING CAB UP.............................................................................................. 418
TESTING AND ADJUSTING DUMP CIRCUIT OIL PRESSURE....................................................................... 420
ADJUSTING BODY POSITIONER SENSOR...................................................................................... 422
ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT............................................................ 423
HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLER...................................................................... 423
ADJUSTING TRANSMISSION CONTROLLER..................................................................................... 423
METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILURE.............................................................. 424
TESTING AND ADJUSTING, PART 3............................................................................................. 429
SETTING AND ADJUSTING VARIOUS EQUIPMENT............................................................................... 430
SPECIAL FUNCTION OF MACHINE MONITOR................................................................................... 439
HOW TO START OPERATION OF KOMTRAX TERMINAL............................................................................ 484
LAMP DISPLAY OF KOMTRAX TERMINAL...................................................................................... 489
PM CLINIC CHECK SHEET................................................................................................. 492
40 TROUBLESHOOTING............................................................................................................ 497
GENERAL INFORMATION ON TROUBLESHOOTING.................................................................................... 497
POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................... 498
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 499
CHECK BEFORE TROUBLESHOOTING.......................................................................................... 500
CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING..................................................................... 501
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................ 504
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................................................... 540
TROUBLE SHOOTING BY FAILURE CODE, GENERAL................................................................................. 545
FAILURE CODES TABLE................................................................................................... 546
BEFORE TROUBLESHOOTING BY FAILURE CODE................................................................................ 554
INFORMATION IN TROUBLESHOOTING TABLE.................................................................................. 562
TROUBLESHOOTING BY FAILURE CODE, PART 1................................................................................... 565
FAILURE CODE [1500L0] DOUBLE ENGAGEMENT............................................................................... 567
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: CLOGGED............................................................... 568
FAILURE CODE [15F0KM] R-F SHIFTING ABIUSE 1........................................................................... 570
FAILURE CODE [15F0MB] R-F SHIFTING ABIUSE 2........................................................................... 570
FAILURE CODE [15F7KM] TRANSMISSION FORWARD CLUTCH ABUSE............................................................... 571
FAILURE CODE [15G0MW] TROUBLE IN REVERSE CLUTCH SYSTEM (SLIP)......................................................... 572
FAILURE CODE [15G7KM] TRANSMISSION REVERSE CLUTCH ABUSE............................................................... 574
FAILURE CODE [15H0MW] TROUBLE IN HI CLUTCH SYSTEM (SLIP).............................................................. 576
FAILURE CODE [15J0MW] TROUBLE IN L0 CLUTCH SYSTEM (SLIP).............................................................. 578
FAILURE CODE [15K0MW] TROUBLE IN 1ST CLUTCH SYSTEM (SLIP)............................................................. 580
FAILURE CODE [15L0MW] TROUBLE IN 2ND CLUTCH SYSTEM (SLIP)............................................................. 582
FAILURE CODE [15M0MW] TROUBLE IN 3RD CLUTCH SYSTEM (SLIP)............................................................. 584
FAILURE CODE [15SBL1] TROUBLE IN REVERSE CLUTCH PRESSURE CONTROL VALVE I.............................................. 586
FAILURE CODE [15SBMA] TROUBLE IN REVERSE CLUTCH PRESSURE CONTROL VALVE II............................................. 590
FAILURE CODE [15SCL1] TROUBLE IN HI CLUTCH PRESSURE CONTROL VALVE I................................................... 592
FAILURE CODE [15SCMA] TROUBLE IN HI CLUTCH PRESSURE CONTROL VALVE II.................................................. 596
FAILURE CODE [15SDL1] TROUBLE IN LO CLUTCH PRESSURE CONTROL VALVE I................................................... 598
FAILURE CODE [15SDMA] TROUBLE IN LO CLUTCH PRESSURE CONTROL VALVE II.................................................. 600
TROUBLESHOOTING BY FAILURE CODE, PART 2................................................................................... 605
FAILURE CODE [15SEL1] TROUBLE IN 1ST CLUTCH PRESSURE CONTROL VALVE I.................................................. 607
FAILURE CODE [15SEMA] TROUBLE IN 1ST CLUTCH PRESSURE CONTROL VALVE II................................................. 610
FAILURE CODE [15SFL1] TROUBLE IN 2ND CLUTCH PRESSURE CONTROL VALVE I.................................................. 612
FAILURE CODE [15SFMA] TROUBLE IN 2ND CLUTCH PRESSURE CONTROL VALVE II................................................. 616
FAILURE CODE [15SGL1] TROUBLE IN 3RD CLUTCH PRESSURE CONTROL VALVE I.................................................. 618
FAILURE CODE [15SGMA] TROUBLE IN 3RD CLUTCH PRESSURE CONTROL VALVE II................................................. 622
FAILURE CODE [15SJMA] TROUBLE IN LOCKUP CLUTCH PRESSURE CONTROL VALVE II.............................................. 624
FAILURE CODE [15SKMA] TROUBLE IN INTERAXLE DIFFERENTIAL LOCK CLUTCH PRESSURE CONTROL VALVE II......................... 626
FAILURE CODE [2A62L1] TROUBLE IN FRTONT WHEEL DIFFERNETIAL LOCK PRESSURE CONTROL VALVE 2.............................. 628
FAILURE CODE [2A62LH] TROUBLE IN FRONT WHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 1............................... 630
FAILURE CODE [2B62L1] TROUBLE IN REAR SHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 2................................ 632
FAILURE CODE [2B62LH] TROUBLE IN REAR WHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 1................................ 634
FAILURE CODE [2C4MNX] CLOGGING OF RETARDER COOLING OIL FILTER......................................................... 636
FAILURE CODE [2F00KM] DRAGGING OF PARKING BRAKE....................................................................... 638
FAILURE CODE [2G42ZG] LOWERING OF ACCUMULATOR OIL PRESSURE 9FRONT).................................................... 640
FAILURE CODE [2G43ZG] LOWERING OF ACCUMULATOR OIL PRESSURE (REAR)..................................................... 640
FAILURE CODE [989A00] OPERATION OF ENGINE OVERRUN PREVENTION SYSTEM................................................... 641
FAILURE CODE [989D00] REAR SECTION TIPPING OVER ALARM (RAISING OPERATION ON SLOPE).................................... 641
FAILURE CODE [A570NX] CLOGGING OF ENGINE OIL FILTER................................................................... 642
FAILURE CODE [AA10NX] CLOGGING OF AIR CLEANER......................................................................... 644
FAILURE CODE [AG00MA] TROUBLE IN BATTERY CHARGE CIRCUIT............................................................... 646
FAILURE CODE [B@BAZG] LOWERING OF ENGINE OIL PRESSURE................................................................. 647
FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL.................................................................... 648
FAILURE CODE [B@BCNS] OVERHEATING OF ENGINE........................................................................... 649
FAILURE CODE [B@BCZK] LOWERING OF COOLANT LEVEL....................................................................... 650
FAILURE CODE [B@BFZK] LOWERING OF FUEL LEVEL.......................................................................... 652
FAILURE CODE [B@B6NS] OVERHEATING OF GRAKE COOLING OIL (FRONT)........................................................ 653
FAILURE CODE [B@C8NS] OVERHEATING OF BRAKE COOLING OIL (CENTER)....................................................... 653
FAILURE CODE [B&CENS] OVERHEATING OF TORQUE CONVERTER OIL............................................................. 654
FAILURE CODE [B@JANS] OVERHEATING OF STEERING OI;..................................................................... 654
TROUBLESHOOTING BY FAILURE CODE, PART 3................................................................................... 657
FAILURE CODE [CA111] TROUBLE IN ENGINE CONTROLLER..................................................................... 660
FAILURE CODE [CA115] TROUBLE IN ENGINE AND BKUP SPEED SENSORS......................................................... 662
FAILURE CODE [CA122] ABNORMALLY HIGH CHARGE PRESSURE.................................................................. 664
FAILURE CODE [CA123] ABNORMALLY LOW CHARGE PRESSURE................................................................... 666
FAILURE CODE [CA131] ABNORMALLY HIGH THROTTLE SENSOR SIGNAL........................................................... 668
FAILURE CODE [CA132] ABNORMALLY LOW THROTTLE SENSOR SIGNAL............................................................ 670
FAILURE CODE [CA135] ABNORMALLY HIGH ENGINE OIL PRESSURE.............................................................. 672
FAILURE CODE [CA141] ABNORMALLY LOW ENGINE OIL PRESSURE............................................................... 674
FAILURE CODE [CA144] ABNORMALLY HIGH COOLANT TEMPERATURE.............................................................. 676
FAILURE CODE [CA145] ABNORMALLY LOW COOLANT TEMPERATURE............................................................... 678
FAILURE CODE [CA153] ABNORMALLY HIGH CHARGE TEMPERATURE............................................................... 680
FAILURE CODE [CA154] ABNORMALLY LOW CHARGE TEMPERATURE................................................................ 682
FAILURE CODE [CA1878] ABNORMALLY LOW VOLTAGE IN SENSOR POWER SUPPLY 2................................................. 683
FAILURE CODE [CA221] ABNORMALLY HIGH AMBIENT PRESSURE................................................................. 684
FAILURE CODE [CA222] ABNORMALLY LOW AMBIENT PRESSURE.................................................................. 686
FAILURE CODE [CA227] ABNORMALLY HIGH VOLTAGE IN SENSOR POWER SUPPLY 2................................................. 688
FAILURE CODE [CA234] ENGINE OVERSPEED................................................................................. 690
FAILURE CODE [CA238] TROUBLE IN SPEED SENSOR POWER SUPPLY............................................................. 692
FAILURE CODE [CA263] ABNORMALLY HIGH FUEL TEMPERATURE................................................................. 694
FAILURE CODE [CA265] ABNORMALLY LOW FUEL TEMPERATURE.................................................................. 696
FAILURE CODE [CA271] SHORT CIRCUIT IN PCV1............................................................................ 697
FAILURE CODE [CA272] DISCONNECTION IN PCV1............................................................................ 698
FAILURE CODE [CA273] SHORT CIRCUIT IN PCV2............................................................................ 699
FAILURE CODE [CA274] DISCONNECTION IN PCV2............................................................................ 700
FAILURE CODE [CA322] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #1 (L #1)............................................. 702
FAILURE CODE [CA323] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #5 (L #5)............................................. 704
FAILURE CODE [CA324] DISCONNECTION OR SHORT CIRCUIT IN INJECTIOR #3 (L #3)............................................ 706
FAILURE CODE [CA325] DISCONNECTION OR SHORT CIRCUIT IN INJECTOT #6 (L #6)............................................. 708
FAILURE CODE [CA331] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #2 (L #2)............................................. 710
FAILURE CODE [CA332] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #4 (L #4)............................................. 712
FAILURE CODE [CA342] MATCHING ERROR IN ENGINE CONTROLLER DATA......................................................... 714
FAILURE CODE [CA351] TROUBLE IN INJECTOR DRIVE CIRCUIT................................................................ 716
FAILURE CODE [CA352] ABNORMALLY LOW VOLTAGE IN SENSOR POWER SUPPLY 1.................................................. 718
FAILURE CODE [CA386] ABNORMALLY HIGH VOLTAGE IN SENSOR POWER SUPPLY 1................................................. 720
FAILURE CODE [CA272] DISCONNECTION IN PCV1............................................................................ 698
FAILURE CODE [CA273] SHORT CIRCUIT IN PCV2............................................................................ 699
FAILURE CODE [CA274] DISCONNECTION IN PCV2............................................................................ 700
TROUBLESHOOTING BY FAILURE CODE, PART 4................................................................................... 723
FAILURE CODE [CA431] TROUBLE IN IDLE VALIDATION SWITCH................................................................ 726
FAILURE CODE [CA432] TROUBLE IN IDLE VALIDATION PROCESS............................................................... 729
FAILURE CODE [CA441] ABNORMALLY LOW VOLTAGE IN POWER SUPPLY........................................................... 729
FAILURE CODE [CA442} ABNORMALLY HIGH VOLTAGE IN POWER SUPPLY.......................................................... 730
FAILURE CODE [CA449] ABNORMALLY HIGH COMMON RAIL PRESSURE 2........................................................... 730
FAILURE CODE [CA451] ABNORMALLY HIGH COMMON RAIL PRESSURE............................................................. 732
FAILURE CODE [CA452] ABNORMALLY LOW COMMON RAIL PRESSURE.............................................................. 734
FAILURE CODE [CA553] ABNORMALLY HIGH COMMON RAIL PRESSURE 1........................................................... 734
FAILURE CODE [CA554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR.................................................... 735
FAILURE CODE [CA559] SUPPLY PUMP LOW PRESSURE 1....................................................................... 737
FAILURE CODE [CA689] TROUBLE IN ENGINE NE SPEED SENSOR................................................................ 740
FAILURE CODE [CA731] PAHSE ERROR IN ENGINE BKUP SPEED SENSOR.......................................................... 742
FAILURE CODE [CA757] LOSS OF ALL DATA IN ENGINE CONTROLLER............................................................ 742
FAILURE CODE [CA778] TROUBLE IN ENGINE BKUP SPEED SENSOR.............................................................. 744
FAILURE CODE [CA1117] LOSS OF PARTIAL DATA IN ENGINE CONTROLLER....................................................... 746
FAILURE CODE [CA1228] TROUBLE IN EGR VALVE SERVO 1.................................................................... 746
FAILURE CODE [CA1626] SHORT CIRCUIT IN BYPASS VALVE SOLENOID DRIVE CIRCUIT............................................ 748
FAILURE CODE [CA1627] DISCONNECTION IN BYPASS VALVE SOLENOID DRIVE CIRCUIT............................................ 750
FAILURE CODE [CA1628] TROUBLE IN BYPASS VALVE SERVO 1................................................................. 751
FAILURE CODE [CA1629] TROUBLE IN BYPASS VALVE SERVO 2................................................................. 752
FAILURE CODE [CA1631] ABNORMALLY HIGH SIGNAL IN BYPASS VALVE LIFT SENSOR.............................................. 754
FAILURE CODE [CA1632] ABNORMALLY LOW SIGNAL IN BYPASS VALVE LIFT SENSOR............................................... 756
FAILURE CODE [CA1633] TROUBLE IN KOMNET............................................................................... 758
FAILURE CODE [CA1642] ABNORMALLY LOW SIGNAL IN EGT INLET PRESSURE SENSOR.............................................. 760
FAILURE CODE [CA1653] ABNORMALLY HIGH SIGNAL IN EGR INLET PRESSURE SENSOR............................................. 762
FAILURE CODE [CA2185] ABNORMALLY HIGH VOLTAGE IN THROTTLE SENSOR POWER SUPPLY......................................... 764
FAILURE CODE [CA1286] ABNORMALLY LOW VOLTAVE IN THROTTLE SENSOR POWER SUPPLY.......................................... 766
FAILURE CODE [CA2249] LOW PRESSURE IN SUPPLY PUMP 2................................................................... 766
FAILURE CODE [CA2271] ABNORMALLY HIGH SIGNAL VOLTAGE IN EGT VALVE LIFT SENSOR......................................... 768
FAILURE CODE [CA2272] ABNORMALLY LOW SIGNAL VOLTAVE IN EGR VALVE LIFT SENSOR.......................................... 770
FAILURE CODE [CA2351] SHORT CIRCUIT IN EGR VALVE SOLENOID DRIVE CIRCUIT............................................... 772
FAILURE CODE [CA2352] DISCONNECTION IN EGR VALVE SOLENOID DRIVE CIRCUIT............................................... 774
FAILURE CODE [CA2555] DISCONNECTION IN INTAKE AIR HEATER RELAY........................................................ 774
FAILURE CODE [CA2556] SHORT CIRCUIT IN INTAKE AIR HEATER RELAY........................................................ 776
FAILURE CODE [CA1625] TROUBLE IN EGR VALVE SERVO 2.................................................................... 747
TROUBLESHOOTING BY FAILURE CODE, PART 5................................................................................... 779
FAILURE CODE [DAF9KM] WRONG CONNECTION OF CONNECTOR................................................................... 781
FAILURE CODE [DAFRKR] TROUBLE IN CAN COMMUNICATION (MACHINE MONITOR).................................................. 782
FAILURE CODE [DAQ0KK] LOWERING OF SOURCE VOLTAGE...................................................................... 784
FAILURE CODE [DAQOKT] TROUBLE IN NON-VOLITLE MEMORY................................................................... 786
FAILURE CODE [DAQ2KK] TROUBLE IN SOLENOID POWER SUPPLY SYSTEM......................................................... 788
FAILURE CODE [DAQ9KQ] DISAGREEMENT OF MODEL SELECTION (TRANSMISSION CONTROLLER] ...................................... 790
FAILURE CODE [DAQRKR] TROUBLE IN CAN COMMUNICATION (TRANSMISSION CONTROLLER).......................................... 792
FAILURE CODE [DAQRMA] DISAGREEMENT OF OPTION SETTING (TRANSMISSION CONTROLLER)........................................ 794
FAILURE CODE [DB10KT] TROUBLE IN NON-VOLITLE MEMORY................................................................... 794
FAILURE CODE [DB12KK] TROUBLE IN SOLENOID POWER SUPPLY SYSTEM......................................................... 796
FAILURE CODE [DB13KK] LOWERING OF BATTERY DIRECT VOLTAGE.............................................................. 798
FAILURE CODE [DB19KQ] DISAGREEMENT OF MODEL SELECTION (RETARDER CONTROLLER)........................................... 800
FAILURE CODE [DB1QMA] DISAGREEMENT OF OPTION SETTING (RETARDER CONTROLLER)............................................ 800
FAILURE CODE [DB1RKR] TROUBLE IN CAN COMMUNICATION (RETARTER CONTROLLER).............................................. 802
FAILURE CODE [DB2RKR] TROUBLE IN CAN COMMUNICATION (ENGINE CONTROLLER)................................................ 804
FAILURE CODE [DD1ML4] DISAGREEMENT OF ACCELERATOR-LINKED RETARDER SWITCH SIGNAL....................................... 806
FAILURE CODE [DDTHKA] TROUBLE IN HI CLUTCH FLOW SENSOR VALVE.......................................................... 808
FAILURE CODE [DDTJKA] TROUBLE IN LO CLUTCH FLOW SENSOR VALVE.......................................................... 809
FAILURE CODE [DDTKKA] TROUBLE IN 1ST CLUTCH FLOW SENSOR VALVE......................................................... 810
FAILURE CODE [DDTLKA] TROUBLE IN 2ND CLUTCH FLOW SENSOR VALVE......................................................... 811
FAILURE CODE [DDTMKA] TROUBLE IN 3RD CLUTCH FLOW SENSOR VALVE......................................................... 812
FAILURE CODE [DDTNKA] TROUBLE IN REVERSE CLUTCH FLOW SENSOR VALVE..................................................... 813
FAILURE CODE [DF10KA] INUPT OF NO LEVER SIGNALS....................................................................... 814
FAILURE CODE [DF10KB] INPUT OF MULTIPLE LEVER SIGNALS................................................................. 818
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE OUT OF RANGE....................................................... 822
FAILURE CODE [DGR3KZ] GROUND FAULT IN BRAKE OIL TEMPERATURE SENSOR (DENTER)........................................... 824
FAILURE CODE [DGR3L8] DISCONNECTION IN BRAKE OIL TEMPERATURE SENSOR (CENTER).......................................... 826
FAILURE CODE [DGR4ZK] GROUND FAULT IN BRAKE OIL TEMPERATURE SENSOR (FRONT)............................................ 828
FAILURE CODE [DGR4L8] DISCONNECTION IN BRAKE OIL TEMPERATURE SENSOR (FRONT)........................................... 830
FAILURE CODE {DGR6KX] STEERING OIL TEMPERATURE OUT OF RANGE........................................................... 832
TROUBLESHOOTING BY FAILURE CODE, PART 6................................................................................... 835
FAILURE CODE [DGT1KX] SHORT CIRCUIT IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM................................. 838
FAILURE CODE [DHT5KX] DISCONNECTION GROUND FAULT, OR SHORT CIRCUIT IN TORQUE CONVERTER OIL PRESSURE SENSOR SYSTEM..... 840
FAILURE CODE [DHT5L6] TROUBLE IN TORQUE CONVERTER OIL PRESSURE SENSOR................................................. 842
FAILURE CODE [DHU2KX] TROUBLE IN ACCUMULATOR OIL PRESSURE SENSOR (FRONT) SYSTEM....................................... 844
FAILURE CODE [DHU3KX] TROUBLE IN ACCUMULATOR OIL PRESSURE SENSOR (REAR) SYSTEM........................................ 846
FAILURE CODE [DJF1KA] DISCONNECTION IN FUEL LEVEL SENSOR SYSTEM....................................................... 848
FAILURE CODE [DK51LG] TROUBLE IN MANUAL RETARDER POTENTIOMETER AND RVS................................................ 850
FAILURE CODE [DK52KX] TROUBLE IN DUMP LEVER POTENTIOMETER 1........................................................... 852
FAILURE CODE [DK53L8] TROUBLE IN DUMP LEVER POTENTIOMETER 2........................................................... 854
FAILURE CODE [DK54KX] TROUBLE IN DUMP POSITIONER SENSOR............................................................... 856
FAILURE CODE [DKH0KX] PITCH ANGLE SENSOR SIGNAL OUT OF RANGE.......................................................... 858
FAILURE CODE [DLF1KA] DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR SYSTEM................................... 860
FAILURE CODE [DLF1LC] TROUBLE IN TRANSMISSION INPUT SHAFT SPEED SENSOR................................................ 861
FAILURE CODE [DLF2KA] TROUBLE IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR......................................... 862
FAILURE CODE [DLF2LC] DISCONNECTION IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR SYSTEM............................ 863
FAILURE CODE [DLF4KA] DISCONNECTION IN TRANSMISSION DIFFERENTIAL SPEED SENSOR SYSTEM.................................. 864
FAILURE CODE [DLT3KA] DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM.................................. 865
FAILURE CODE [DV00KB] SHORT CIRCUIT IN BUZZER OUTPUT CIRCUIT.......................................................... 866
FAILURE CODE [DW72KZ] TROUBLE (DISCONNECTION OR GROUND FAULT) IN KICK-OUT SOLENOID OUTPUT SYSTEM...................... 868
FAILURE CODE [DW73KZ] TROUBLE IN DUMP SELECTOR VALVE OUTPUT SYSTEM.................................................... 870
FAILURE CODE [DW78KZ] TROUBLE IN REAR WHEEL BCV COMMAND OUTPUT SYSTEM................................................. 872
FAILURE CODE [DW79KZ] TROUBLE IN FRONT WHEEL BCV COMMAND OUTPUT SYSTEM................................................ 874
FAILURE CODE [DX11K4] TROUBLE IN REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 1........................... 876
FAILURE CODE [DX114KA] DISCONNECTION IN OUTPUT CIRCUIT OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE.... 878
FAILURE CODE [ DX11KB] GROUND FAULT IN OUTPUT CIRCUIT OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE..... 880
FAILURE CODE [DX11KY] HOT SHORT IN OUTPUT CIRCUTI OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE......... 882
FAILURE CODE [DX11MA] TROUBLE IN REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 2........................... 884
FAILURE CODE [DX12K4] TROUBLE IN FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 1.......................... 886
FAILURE CODE [DX12KB] GROUND FAULT IN OUTPUT CIRCUIT OF FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE..... 890
FAILURE CODE [DX12KY] HOT SHORT IN OUTPUT CIRCUIT OF FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE........ 892
FAILURE CODE [DX12MA] TROUBLE IN FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 2.......................... 894
TROUBLESHOOTING BY FAILURE CODE, PART 7................................................................................... 897
FAILURE CODE [DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF DUMP EPC VALVE............................................... 900
FAILURE CODE [DX13KB] GROUND FAULT IN OUTPUT CIRCUIT OF DUMP EPC VALVE................................................ 902
FAILURE CODE [DX13KY] HOT SHORT IN OUTPUT CIRCUIT OF DUMP EPC VALVE................................................... 904
FAILURE CODE [DX14KZ] TROUBLE IN REAR WHEEL DIFFERENTIAL LOCK COMMAND OUTPUT SYSTEM................................... 906
FAILURE CODE [DX14KZ] TROUBLE IN FRONT WHEEL DIFFERENETIAL LOCK COMMAND OUTPUT SYSTEM................................. 908
FAILURE CODE [DXH0KA] DISCONNECTION IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID.................. 910
FAILURE CODE [DXH0KB] GROUND FAULT IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID................... 912
FAILURE CODE [DXH0KY] HOT SHORT IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID...................... 914
FAILURE CODE [DXH1KA] DISCONNECTION IN UTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID........................................ 915
FAILURE CODE [DXH1KB] GROUND FAULT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID........................................ 916
FAILURE CODE [DXH1KY[] HOT SHORT IN OTUPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID.......................................... 918
FAILURE CODE [DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID........................................... 920
FAILURE CODE [DXH2KB] GROUND FAULT IN OUTPUT CIRCUIT OF HI CLUTCH ECMV SOLENOID VALVE................................. 922
FAILURE CODE [DXH2KY] HOT SHORT IN OUTPUT CIRCUIT OF HI CLUTCH ECMV SOLENOID VALVE.................................... 924
FAILURE CODE [DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID........................................... 928
FAILURE CODE [DXH3KB] GROUND FAULT IN OUTPUT CIRCUIT OF LO CLUTCH ECMV SOLENOID VALVE................................. 930
FAILURE CODE [DXH3KY] HOT SHORT IN OUTPUT CIRCUIT OF LO CLUTCH ECMV SOLENOID VALVE.................................... 932
FAILURE CODE [DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID.......................................... 936
FAILURE CODE [DXH4KB] GROUND FAULT IN OUTPUT CIRCUIT OF 1ST CLUTCH ECMV SOLENOID VALVE................................ 938
FAILURE CODE [DXH4KY] HOT SHORT IN OUTPUT CIRCUIT OF 1ST CLUTCH ECMV SOLENOID VALVE................................... 940
TROUBLESHOOTING BY FAILURE CODE, PART 8................................................................................... 945
FAILURE CODE [DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID.......................................... 946
FAILURE CODE [DXH5KB] GROUND FAULT IN OUTPUT CIRCUIT OF 2ND CLUTCH ECMV SOLENOID VALVE................................ 948
FAILURE CODE [DXH5KY] HOT SHORT IN OUTPUT CIRCUIT OF 2ND CLUTCH ECMV SOLENOID VALVE................................... 950
FAILURE CODE {DXH6KA] DISCONNECTION IN OUTUT CIRCUIT OF 3RD CLUTCH SOLENOID........................................... 954
FAILURE CODE [DXH6KB] GROUND FAULT IN OUTPUT CIRCUIT OF 3RD CLUTCH ECMV SOLENOID VALVE................................ 956
FAILURE CODE [DXH6KY] HOT SHORT IN OUTPUT CIRCUIT OF 3RD CLUTCH ECMV SOLENOID VALVE................................... 958
FAILURE CODE [DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF REVERSE CLUTCH SOLENOID...................................... 962
FAILURE CODE [DXH7KB] GROUND FAULT IN OUTPUT CIRCUIT OF REVERSE CLUTCH ECMV SOLENOID VALVE............................ 964
FAILURE CODE [DXH7KY] HOT SHORT IN OUTPUT CIRCUIT OF REVERSE CLUTCH ECMV SOLENOID VALVE............................... 966
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)............................................................................ 971
BEFORE TROUBLESHOOTING FOR ELECTRICAL SYSTEM.......................................................................... 973
INFORMATION IN TROUBLESHOOTING TABLE.................................................................................. 979
E-1 ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN0.............................................................. 980
E-2 AUTO PREHEATER DOES NOT OPERATE................................................................................... 984
E-3 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DISPLAYS NOTHING............................................... 988
E-4 WHEN STARTING SWITCH IS TURNED OFF, MACHINE MONITOR CANNOT BE OPERATED............................................ 990
E-5 ALARM BUZZER DOES NOT STOP SOUNDING............................................................................... 992
E-6 MACHINE MONITOR DOES NOT NORMALLY DISPLAY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY SECTION.................... 993
E-7 DISPLAY OF CHARACTER DISPLAY SECTION CANNOT BE CHANGED............................................................ 994
E-8 POWER MODE SELECTION FUNTION DOES NOT OPERATE NORMALLY............................................................ 998
E-9 AISS FUNCTION DOES NOT OPERATE NORMALLY...........................................................................1000
E-10 RIGHT AND LEFT DIFFERENTIAL LOCK FUNCTION DOES NOT OPERATE NORMALLY (DIFFERENTIAL LOCK-UP SPECIFICATION).........1002
E-11 INTERAXLE DIFFERENTIAL LOCK-UP FUNCTION DOES NOT OPERATE NORMALLY................................................1006
E-12 DISPLAY OF SEAT BELT CAUTION LAMP IS ABNORMAL....................................................................1008
E-13 TURN SIGNAL LAMPS AND PILOT LAMPS DO NOT OPERATE NORMALLY........................................................1010
E-14 NIGHT LIGHTING IS ABNORMAL.......................................................................................1015
E-15 BACKUP LAMP AND BACKUP BUZZER OPERATE ABNORMALLY.................................................................1021
E-16 EMERGENCY STEERING SYSTEM DOES NOT OPERATE.......................................................................1025
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...............................................................1031
INFORMATION IN TROUBLESHOOTING TABLE..................................................................................1033
H-1 MACHINE DOES NTO START............................................................................................1034
H-2 TRAVEL IS NOT SMOOTH (MACHINE HUNTS)..............................................................................1036
H-3 LOCKUP IS NOT RESET...............................................................................................1036
H-4 START SHOCK AND GEAR SHIFT SHOCK ARE ABNORMALLY LARGE.............................................................1037
H-5 GEAR IS NOT SHIFTED UP............................................................................................1038
H-6 TRAVEL SPEED OR POWER IS LOW......................................................................................1040
H-7 START AND GEARSHIFT TIME LAG IS LARGE.............................................................................1044
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..........................................................................1046
H-9 TORQUE CONVERTER OIL TEMPERATURE IS LOW...........................................................................1047
H-10 FRONT BRAKE DOES NOT WORK FULLY..................................................................................1048
H-11 CENTER BRAKE DOES NOT WORK FULLY.................................................................................1049
H-12 REAR BRAKE DOES NOT WORK FULLY...................................................................................1050
H-13 STEERING WHEEL IS HEAVY..........................................................................................1051
H-14 STEERING WHEEL DOES NOT MOVE.....................................................................................1052
H-15 STEERING WHEEL WAGGLE............................................................................................1053
H-16 DUMP BODY RAISING SPEED IS LOW...................................................................................1054
H-17 DUMP BODY DOES NOT MOVE..........................................................................................1055
H-18 HYDRUALIC DRIFT OF DUMP BODY IS LARGE............................................................................1056
TROUGLESHOOTING OF ENGINE (S-MODE)........................................................................................1059
METHOD OF USING TROUBLE SHOOTING CHART................................................................................1062
S-1 STARTING PERFORMANCE OF ENGINE IS POOR............................................................................1066
S-2 ENGINE DOES NOT START.............................................................................................1068
S-3 ENGINE DOES NOT PICK UP SMOOTHLY..................................................................................1072
S-4 ENGINE STOPS DURING OPERATION.....................................................................................1073
S-5 ENGINE DOES NOT ROTATE SMOOTHLY...................................................................................1074
S-6 ENGINE LACK OUTPUT (OR LACKS POWER)...............................................................................1075
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMPUSTION)......................................................................1076
S-8 OIL CONSUMPTION IS EXCESSIIVE (OR EXHAUST GAS IS BLUE)............................................................1078
S-9 OIL BECOMES DIRTY QUICKLY.........................................................................................1079
S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................1080
S-11 OIL IS IN COOLAND (OR COOLANT SPRAYS BACK OR COOLANT LEVEL GOES DOWN)............................................1081
S-12 OIL PRESSURE DROPS...............................................................................................1082
S-13 OIL LEVEL RISES (TRNTY OF COOLANT OR FUEL).......................................................................1084
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...............................................................1086
S-15 ABNORMAL NOISE IS MADE...........................................................................................1087
S-16 VIBRATION IS EXCESSIVE...........................................................................................1088
50 DISASSEMBLY AND ASSEMBLY...................................................................................................1091
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................................................1091
HOW TO READ THIS MANUAL...............................................................................................1092
LIST OF ADHESIVES.....................................................................................................1094
SPECIAL TOOL LIST.....................................................................................................1097
SKETCHES OF SPECIAL TOOLS.............................................................................................1103
ENGINE AND COOLING SYSTEM.................................................................................................1117
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP..........................................................................1118
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...........................................................................1121
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY....................................................................1129
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY....................................................................1142
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY.........................................................................1147
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY..........................................................................1151
REMOVAL AND INSTALLATION OF AFTERCOOLER...............................................................................1155
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.........................................................................1158
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL..........................................................................1160
POWER TRAIN, PART 1.......................................................................................................1165
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY.....................................................................1166
DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY.....................................................................1170
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY..............................................1173
DISCONNECTION AND COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION.....................................................1181
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY.................................................................1182
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY.....................................................................1190
POWER TRAIN, PART 2.......................................................................................................1235
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY...............................................................1236
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY..............................................................1255
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY..............................................................1259
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY................................................................1275
DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY................................................................1277
POWER TRAIN, PART 3.......................................................................................................1291
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY......................................................1292
DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY......................................................1294
REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY.....................................................1307
DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY.....................................................1309
REMOVAL AND INSTALLATION OF REAR FINAL DRIVE ASSEMBLY.................................................................1320
DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY.................................................................1322
REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY......................................................................1329
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY........................................................................1332
UNDERCARRIAGE AND FRAME...................................................................................................1337
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY........................................................1338
REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY.........................................................1340
REMOVAL AND INSTALLATION OF EQUILIZER BAR ASSEMBLY....................................................................1341
REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY......................................................................1343
REMOVAL AND INSTALLATION OF REAR FRONT WHEEL ASSEMBLY.................................................................1344
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY......................................................................1345
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME...............................................................................1351
REMOVAL AND INSTALLATION OF BODY ASSEMBLY.............................................................................1354
HYDRAULIC SYSTEM..........................................................................................................1357
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE............................................................................1358
REMOVAL AND INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY.............................................................1368
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY......................................................................1370
DISASSEMBLY AND ASSEMBLY OF HOIST VALVE ASSEMBLY......................................................................1372
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY................................................................1374
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY...................................................................1380
CAB AND ITS ATTACHMENTS...................................................................................................1389
REMOVAL AND INSTALLATION OF OPERATOR'S CAB............................................................................1390
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)........................................................1395
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY..................................................................1402
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.............................................................1412
ELECTRICAL SYSTEM.........................................................................................................1419
REMOVAL AND INSTALLATION OF RETARDER CONTROLLER ASSEMBLY..............................................................1420
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY..........................................................1422
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY................................................................1424
90 DIAGRAMS AND DRAWINGS......................................................................................................1427
HYDRAULIC DIAGRAMS AND DRAWINGS...........................................................................................1427
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.: PREVIOUS DESIGN)............................................1429
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.: NEW DESIGN).................................................1431
BRAKE HYDRAULIC CIRCUIT DIAGRAM,......................................................................................1433
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM...............................................................................1435
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM...........................................................................1437
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................. 0
ELECTRICAL DIAGRAMS AND DRAWINGS..........................................................................................1442
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/4).......................................................................1444
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4)(SERIAL NO.: PREVIOUS DESIGN)..........................................1446
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4)(SERIAL NO.: NEW DESIGN)...............................................1448
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: PREVIOUS DESIGN).........................................1450
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: NEW DESIGN)..............................................1452
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (4/4).......................................................................1454
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3)......................................................................1456
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3)......................................................................1458
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3)......................................................................1460
CONNECTORS TABLE AND ARRANGEMENT DRAWING HM350-2......................................................................1462
KOMATSU HM350-2 ARTICULATED DUMP TRUCK SHOP MANUAL CEBM007801 – PDF DOWNLOAD:
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