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KOMATSU MX352 MX502 SERVICE REPAIR MANUAL (SEBM035400) KOMATSU MX352 MX502 – PDF DOWNLOAD
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- KOMATSU MX352 MX502 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM035400
- SERIAL NUMBER
MX352 6Y6089 and up
MX502 6Y7038 and up
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Description
KOMATSU MX352 MX502 SERVICE REPAIR MANUAL (SEBM035400) KOMATSU MX352 MX502
KOMATSU MX352 MX502 SERVICE REPAIR MANUAL (SEBM035400) KOMATSU MX352 MX502 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU MX352 MX502 SERVICE REPAIR MANUAL (SEBM035400) KOMATSU MX352 MX502
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU MX352 MX502 SERVICE REPAIR MANUAL (SEBM035400) KOMATSU MX352 MX502
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
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
