Day: June 8, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator MX352, MX502, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator MX352, MX502 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

054-107-10 – MX45 Operator’s Manual.pdf
054-108-10 – MX27, MX35 Opetator’s Manual.pdf
054-109-10 – MX15 Operatoer’s Manual.pdf
054-110-10 – MX9 Operator’s Manual.pdf
SEAM061600 – Hydraulic Excavator MX352 Operation & Maintenance Manual.pdf
SEAM061700 – Hydraulic Excavator MX502 Operation & Maintenance Manual.pdf
SEBM035400 – MX352, MX502 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,956 pages
File Format: PDF
Language: English

MAIN SECTIONS
054-107-10 – MX45 Operator&’s Manual….2
Cover….2
Foreword….3
Your Machine Serial Numbers and Dealer….3
Safety Information….5
Signal Words….5
Example of Safety Message Using Signal Word….5
Other Signal Words….5
Safety Labels….6
Example of Safety Label Using Words….6
Example of Safety Label Using Pictogram….6
Introduction….7
Directions of Machine….8
Product Information….8
Machine Serial Number Plate and Its Location….8
Engine Serial Number Plate and Its Location….9
Emission Control Information Label and Its Location….9
Service Meter Location….10
Contents….10
Safety….11
Safety Labels….13
Location of Safety Labels….14
Safety Labels….15
Safety Information….21
Safety Rules….21
If Abnormalities Are Found….21
Working Wear and Personal Protective Items….21
Fire Extinguisher and First Aid Kit….22
Safety Equipment….22
Keep Machine Clean….22
Keep Operator’s Compartment Clean….23
Leaving Operator’s Seat with Lock….23
Handrails and Steps….24
Mounting and Dismounting….24
No Persons on Attachments….25
Do Not Get Caught in Articulated Portion….25
Burn Prevention….25
Fire Prevention and Explosion Prevention….26
Action if Fire Occurs….27
Windshield Washer Fluid….27
Falling Objects, Flying Objects and Intruding Objects Prevention….28
Attachment Installation….28
Attachment Combinations….28
Cab Window Glasses….29
Unauthorized Modifications….29
Safety at Jobsite….29
Working on Loose Ground….29
Distance to High Voltage Cables….30
Ensure Good Visibility….30
Ventilation for Enclosed Area….31
Signalman’s Signal and Signs….31
Emergency Exit from Operator’s Cab….31
Asbestos Dust Hazard Prevention….32
Safe Machine Operation….33
Starting Engine….33
Operation….34
Transportation….42
Battery….43
Towing….45
Lifting Objects with Bucket….46
Safe Maintenance Information….47
Warning Tag….47
Keep Work Place Clean and Tidy….47
Appoint Leader When Working with Others….47
Stop Engine Before Carrying Out Maintenance….48
Two Workers for Maintenance When Engine is Running….48
Proper Tools….49
Personnel….49
Attachments….49
Work Under the Machine….50
Noise….50
When Using Hammer….50
Welding Works….50
Removing Battery Terminals….51
Safety First When Using High-Pressure Grease to Adjust Track Tension….51
Do Not Disassemble Recoil Springs….51
Safety Rules for High-Pressure Oil….52
Safety Handling High-Pressure Hoses….52
Waste Materials….53
Air Conditioner Maintenance….53
Compressed Air….53
Periodic Replacement of Safety Critical Parts….53
Operation….55
Machine View Illustrations….57
Overall Machine View….57
Controls and Gauges….58
Detailed Controls and Gauges….59
Monitoring System….59
Switches….64
Control Levers and Pedals….67
Windshield….73
Sliding Door….77
Sliding Window….78
Rear Window….79
Emergency Escape Hammer….80
Cap with Lock….81
Engine Hood….82
Mud Cover….83
Fuse….84
In-Line Fuse….85
Auxiliary Electric Power….86
Operator’s Manual Storage….86
Tool Box….87
Grease Pump Holder….87
Ashtray….87
Machine Operations and Controls….88
Before Starting Engine….88
Starting Engine….100
After Starting Engine….103
Stopping the Engine….106
Check After Shutting Off Engine….106
Machine Operation….107
Steering the Machine….111
Swinging….113
Backhoe Controls and Operations….114
Prohibited Operations….116
General Operation Information….118
Traveling on Slopes….120
Escape from Mud….122
Recommended Applications….123
Bucket Replacement….125
Parking Machine….126
Machine Inspection After Daily Work….127
Locking….128
Rubber Tracks and Turf-Friendly Tracks….129
Transportation….134
Transportation Procedure….134
Loading and Unloading with Trailer….134
Lifting Machine….139
Cold Weather Operation….141
Cold Weather Operation Information….141
Cab Heater in Cold Weather….144
After Daily Work Completion….144
After Cold Weather Season….145
Long-Term Storage….145
Before Storage….145
During Storage….146
After Storage….146
Troubles and Actions….147
Running Out of Fuel….147
Phenomena That Are Not Failures….147
Towing the Machine….148
Severe Job Conditions….148
Discharged Battery….149
Other Trouble….153
Maintenance….157
Maintenance Information….157
Lubricants, Coolant, and Filters….160
Handling Oil, Fuel, and Coolant….160
Electric System Maintenance….162
Lubricants, Fuel, and Coolant Specifications….163
Proper Selection….163
Tightening Torque Specifications….167
Tightening Torque List….167
Maintenance Schedule….169
Maintenance Interval for Hydraulic Breaker….170
Maintenance Procedure….171
Initial 250 Hour Maintenance (Only After the First 250 Hours)….171
When Required….171
Check, Clean, and Replace Air Cleaner Element….171
Clean Inside of Cooling System….174
Clean Water Separator Element….178
Drain Water and Sediment from Fuel Tank….178
Check and Tighten Track Shoe Bolts….179
Check and Adjust Track Tension….180
Check Rubber Tracks or Turf-Friendly Tracks….183
Check and Adjust Rubber Track Tension….185
Replace Bucket Teeth….187
Check Window Washer Fluid Level, Add Fluid….190
Check, Clean and Lubricate Cab Slide Door Rail and Roller….191
Bleeding Air from Hydraulic System….192
Check Before Starting….193
Every 100 Hours Maintenance….194
Lubricating….194
Every 250 Hours Maintenance….195
Replace Engine Oil in Engine Oil Pan….195
Replace Hydraulic Filter Element….196
Check and Adjust Cooling Fan Belt Tension….197
Check Level of Battery Electrolyte….199
Every 500 Hours Maintenance….202
Replace Engine Oil Filter Cartridge….202
Replace Fuel Filter Element….203
Check Oil Level in Final Drive Case, Add Oil….204
Lubricating….205
Clean and Inspect Radiator Fins and Oil Cooler Fins….207
Every 1000 Hours Maintenance….208
Change Oil in Final Drive Case….208
Check Engine Valve Clearance, Adjust….208
Every 2000 Hours Maintenance….209
Change Oil in Hydraulic Tank, Clean Strainer….209
Check Alternator, Starting Motor….211
Specifications….213
Attachments and Options….215
General Information….217
Safety First….217
Attachment Installation….219
Bucket with Hook….220
Hook Condition….220
Prohibited Operations….220
Air Conditioner….221
Control Panel and Components….221
Air Conditioner Controls….223
Air Conditioner Maintenance….223
Defroster Controls….228
Control Panel….228
Machine Ready for Attachment….230
Locations….230
Hydraulic Circuit….233
Attachment Operation….234
Long-Term Storage….236
Changing Machine Control Pattern….237
Control Pattern Change Procedure….237
Machine Control Patterns….238
Telescopic Arm….239
Extension and Retraction of Arm….239
Precautions in Use….241
Maintenance Procedure….244
Specifications….245
Power Angle, Power Tilt Blade….247
Blade Control Lever….247
Every 100 Hours Service….248
Every 500 Hours Service….249
Specifications….249
Attachment Guide….250
Attachment Combinations….250
Recommended Attachment Operations….252
Hydraulic Breaker….252
Support….257
Procedure….257
Resources….257
Publications….257
Ditch Witch Training….257
Warranty….258
054-108-10 – MX27, MX35 Opetator&’s Manual….261
Cover….261
Foreword….262
Your Machine Serial Numbers and Dealer….262
Safety Information….264
Signal Words….264
Example of Safety Message Using Signal Word….264
Other Signal Words….264
Safety Labels….265
Example of Safety Label Using Words….265
Example of Safety Label Using Pictogram….265
Introduction….266
Directions of Machine….267
Product Information….267
Machine Serial Number Plate and Its Location….267
Engine Serial Number Plate and Its Location….268
Emission Control Information Label and Its Location….268
Service Meter Location….269
Contents….269
Safety….270
Chapter Contents….270
Safety Labels….273
Location of Safety Labels….273
Safety Labels….274
Safety Information….277
Safety Rules….277
If Abnormalities Are Found….277
Working Wear and Personal Protective Items….277
Fire Extinguisher and First Aid Kit….278
Safety Equipment….278
Keep Machine Clean….278
Keep Operator’s Compartment Clean….279
Leaving Operator’s Seat with Lock….279
Handrails and Steps….280
Mounting and Dismounting….280
No Persons on Attachments….281
Burn Prevention….281
Fire Prevention and Explosion Prevention….282
Action if Fire Occurs….283
Windshield Washer Fluid….283
Falling Objects, Flying Objects and Intruding Objects Prevention….284
Attachment Installation….284
Attachment Combinations….284
Cab Window Glasses….285
Unauthorized Modifications….285
Safety at Jobsite….285
Working on Loose Ground….285
Distance to High Voltage Cables….286
Ensure Good Visibility….286
Ventilation for Enclosed Area….287
Signalperson’s Signal and Signs….287
Emergency Exit from Operator’s Cab….287
Asbestos Dust Hazard Prevention….288
Safe Machine Operation….289
Starting Engine….289
Operation….290
Transportation….298
Battery….299
Towing….301
Lifting Objects with Bucket….302
Safe Maintenance Information….303
Warning Tag….303
Keep Work Place Clean and Tidy….303
Appoint Leader When Working with Others….303
Stop Engine Before Carrying Out Maintenance….304
Two Workers for Maintenance When Engine is Running….305
Proper Tools….305
Personnel….305
Accumulator….306
Attachements….306
Work Under the Machine….306
Noise….307
When Using Hammer….307
Welding Works….307
Removing Battery Terminals….307
Safety First When Using High-Pressure Grease to Adjust Track Tension….308
Do Not Disassemble Recoil Springs….308
Safety Rules for High-Pressure Oil….309
Safety Handling High-Pressure Hoses….309
Waste Materials….310
Air Conditioner Maintenance….310
Compressed Air….310
Periodic Replacement of Safety Critical Parts….310
Operation….312
Machine View Illustrations….314
Overall Machine View….314
Controls and Gauges….315
Detailed Controls and Gauges….316
Monitoring System….316
Switches….321
Control Levers and Pedals….324
Windshield….330
Sliding Door….335
Rear Window….336
Emergency Escape Hammer….337
Cover with Lock….338
Engine Hood….339
Fuse….340
In-Line Fuse….341
Operator’s Manual Storage….341
Tool Box….342
Grease Gun Holder….342
Machine Operations and Controls….343
Before Starting Engine….343
Starting Engine….355
After Starting Engine….359
Stopping the Engine….362
Check After Engine Shutoff….363
Machine Operation….363
Steering the Machine….367
Swinging….369
Backhoe Controls and Operations….370
Prohibited Operations….372
General Operation Information….375
Traveling on Slopes….376
Escape from Mud….378
Work Possible Using Compact Hydraulic Excavator….379
Bucket Replacement….381
Parking Machine….382
Machine Inspection After Daily Work….384
Locking….384
Rubber Tracks and Turf-Friendly Tracks….385
Transportation….391
Loading and Unloading with Trailer….391
Lifting Machine….398
Cold Weather Operation….400
Cold Weather Operation Information….400
Cab Heater in Cold Weather….402
After Daily Work Completion….402
After Cold Weather Season….402
Long Term Storage….403
Before Storage….403
During Storage….403
After Storage….404
Starting Machine After Long-Term Storage….404
Troubles and Actions….405
Running Out of Fuel….405
Phenomena That Are Not Failures….405
Towing the Machine….406
Severe Job Conditions….406
Discharged Battery….407
Other Trouble….411
Maintenance….416
Maintenance Information….416
Lubricants, Coolant, and Filters….419
Handling Oil, Fuel, and Coolant….419
Electric System Maintenance….421
Lubricants, Fuel, and Coolant Specifications….422
Proper Selection….422
Tightening Torque Specifications….426
Tightening Torque List….426
Maintenance Schedule….428
Maintenance Interval for Hydraulic Breaker….429
Maintenance Procedure….430
Initial 250 Hour Maintenance (Only After the First 250 Hours)….430
When Required….430
Check, Clean, and Replace Air Cleaner Element….430
Clean Inside of Cooling System….433
Check Level of Battery Electrolyte….437
Clean Fuel Filter Element….440
Check and Tighten Track Shoe Bolts….441
Check and Adjust Track Tension….442
Check Rubber Tracks or Turf-Friendly Tracks….445
Replace Bucket Teeth….447
Check, Clean and Lubricate Cab Side Door Rail and Roller….451
Drain Water and Sediment from Fuel Tank….452
Check Before Starting….452
Every 100 Hours Maintenance….453
Lubricating….453
Every 250 Hours Maintenance….456
Replace Engine Oil….456
Check Oil Level in Final Drive Case, Add Oil….457
Replace Hydraulic Filter Element….458
Check and Adjust Cooling Fan Belt Tension….460
Every 500 Hours Maintenance….461
Lubricating….461
Replace Engine Oil Filter Cartridge….462
Replace Fuel Filter Element….463
Clean and Inspect Radiator Fins and Oil Cooler Fins….464
Replace Fuel Feed Pump Pre-Filter….465
Every 1000 Hours Maintenance….466
Change Oil in Final Drive Case….466
Every 2000 Hours Maintenance….467
Change Oil in Hydraulic Tank, Clean Strainer….467
Check Alternator, Starting Motor….469
Check Engine Valve Clearance, Adjust….469
Specifications….470
Attachments and Options….472
General Information….474
Safety First….474
Attachment Installation….476
Bucket with Hook….477
Hook Condition….477
Prohibited Operations….477
Air Conditioner….478
Control Panel and Components….478
Air Conditioner Controls….479
Air Conditioner Maintenance….480
Radio….482
Control Panel….482
Controls of Radio….486
Care for Radio….487
Windshield Washer….488
Windshield Washer Operation….488
Check Window Washer Fluid Level, Add Fluid….488
Machine Ready for Attachment….489
Locations….489
Hydraulic Circuit….491
Attachment Operation….493
Long-Term Storage….495
Specifications….495
Changing Machine Control Pattern….496
Control Pattern Change Procedure….496
Machine Control Patterns….497
Attachment Guide….498
Attachment Combinations….498
Hydraulic Breaker….500
Support….504
Procedure….504
Resources….504
Publications….504
Ditch Witch Training….504
Warranty….505
054-109-10 – MX15 Operatoer&’s Manual….508
Cover….508
Foreword….509
Your Machine Serial Numbers and Dealer….509
Safety Information….511
Signal Words….511
Example of Safety Message Using Signal Word….511
Other Signal Words….511
Safety Labels….512
Example of Safety Label Using Words….512
Example of Safety Label Using Pictogram….512
Introduction….514
Directions of Machine….514
Product Information….515
Machine Serial Number Plate and Its Location….515
Engine Serial Number Plate and Its Location….515
Emission Control Information Label and Its Location….516
Service Meter Location….516
Contents….517
Safety….519
Chapter Contents….519
Safety Labels….522
Location of Safety Labels….522
Safety Labels….523
Safety Information….526
Safety Rules….526
If Abnormalities Are Found….526
Working Wear and Personal Protective Items….526
Fire Extinguisher and First Aid Kit….527
Safety Equipment….527
Keep Machine Clean….527
Keep Operator’s Compartment Clean….528
Leaving Operator’s Seat with Lock….528
Handrails and Steps….529
Crushing or Cutting Prevention….529
Mounting and Dismounting….529
No Persons on Attachments….530
Burn Prevention….530
Fire Prevention and Explosion Prevention….531
Action if Fire Occurs….532
Windshield Washer Fluid….532
Falling Objects, Flying Objects and Intruding Objects Prevention….533
Attachment Installation….533
Attachment Combinations….533
Cab Window Glasses….534
Unauthorized Modifications….534
Safety at Jobsite….534
Working on Loose Ground….534
Distance to High Voltage Cables….535
Ensure Good Visibility….535
Ventilation for Enclosed Area….536
Signalperson’s Signal and Signs….536
Asbestos Dust Hazard Prevention….536
Safe Machine Operation….537
Starting Engine….537
Operation….538
Transportation….546
Battery….547
Towing….549
Lifting Objects with Bucket….550
Safe Maintenance Information….551
Warning Tag….551
Keep Work Place Clean and Tidy….551
Appoint Leader When Working with Others….551
Stop Engine Before Carrying Out Maintenance….553
Two Workers for Maintenance When Engine is Running….553
Proper Tools….553
Personnel….553
Accumulator….554
Attachments….554
Work Under the Machine….554
Noise….555
When Using Hammer….555
Welding Works….555
Removing Battery Terminals….555
Safety First When Using High-Pressure Grease to Adjust Track Tension….556
Do Not Disassemble Recoil Springs….556
Safety Rules for High-Pressure Oil….557
Safety Handling High-Pressure Hoses….557
Waste Materials….558
Air Conditioner Maintenance….558
Compressed Air….558
Periodic Replacement of Safety Critical Parts….558
Operation….559
Machine View Illustrations….561
Overall Machine View….561
Controls and Gauges….562
Detailed Controls and Gauges….563
Machine Monitor….563
Switches….567
Control Levers and Pedals….569
Cover with Lock….577
Engine Hood….578
Fuse….579
In-Line Fuse….579
Operator’s Manual Storage….580
Tipping Operator’s Seat….580
Machine Operations and Controls….581
Before Starting Engine….581
Starting Engine….592
After Starting Engine….596
Stopping the Engine….599
Check After Engine Shutoff….600
Machine Operation….600
Steering the Machine….604
Swinging….606
Backhoe Controls and Operations….607
Prohibited Operations….609
General Operation Information….612
Traveling on Slopes….613
Escape from Mud….615
Work Possible Using Compact Hydraulic Excavator….616
Bucket Replacement….618
Parking Machine….619
Machine Inspection After Daily Work….621
Locking….621
Rubber Tracks and Turf-Friendly Tracks….622
Transportation….628
Loading and Unloading with Trailer….628
Lifting Machine….632
Cold Weather Operation….634
Cold Weather Operation Information….634
After Daily Work Completion….636
After Cold Weather Season….636
Long-Term Storage….637
Before Storage….637
During Storage….637
After Storage….638
Troubles and Actions….639
Running Out of Fuel….639
Phenomena That Are Not Failures….639
Towing the Machine….640
Severe Job Conditions….640
Discharged Battery….641
Other Trouble….645
Maintenance….649
Maintenance Information….649
Lubricants, Coolant, and Filters….652
Handling Oil, Fuel, and Coolant….652
Electric System Maintenance….654
Handling Hydraulic System….655
Lubricants, Fuel, and Coolant Specifications….656
Proper Selection….656
Tightening Torque Specifications….660
Tightening Torque List….660
Maintenance Schedule….662
Maintenance Interval for Hydraulic Breaker….663
Maintenance Procedure….664
Initial 250 Hour Maintenance (Only After the First 250 Hours)….664
When Required….664
Check, Clean, and Replace Air Cleaner Element….664
Clean Inside of Cooling System….667
Check Level of Battery Electrolyte….670
Check Fuel Filter Element….673
Check and Adjust Track Tension….674
Check Rubber Tracks….676
Replace Bucket Teeth….679
Drain Water and Sediment from Fuel Tank….680
Check Before Starting….681
Every 100 Hours Maintenance….681
Lubricating….681
Every 250 Hours Maintenance….683
Replace Engine Oil, Filter….683
Check Oil Level in Final Drive Case, Add Oil….684
Replace Hydraulic Filter Element….685
Check and Adjust Cooling Fan Belt Tension….687
Every 500 Hours Maintenance….688
Lubricating….688
Replace Fuel Filter Element….689
Clean and Inspect Radiator Fins….691
Replace Fuel Feed Pump Pre-Filter….692
Every 1000 Hours Maintenance….693
Change Oil in Final Drive Case….693
Every 2000 Hours Maintenance….694
Change Oil in Hydraulic Tank, Clean Strainer….694
Check Alternator, Starting Motor….696
Check Engine Valve Clearance, Adjust….696
Specifications….697
Attachments and Options….699
General Information….700
Safety First….700
Attachment Installation….702
Bucket with Hook….703
Hook Condition….703
Prohibited Operations….703
Machine Ready for Attachment….704
Locations….704
Hydraulic Circuit….706
Attachment Operation….708
Attachment Guide….710
Attachment Combinations….710
Hydraulic Breaker….712
Support….717
Procedure….717
Resources….717
Publications….717
Ditch Witch Training….717
Warranty….718
054-110-10 – MX9 Operator&’s Manual….721
Cover….721
Foreword….722
Your Machine Serial Numbers and Dealer….722
Safety Information….724
Signal Words….724
Example of Safety Message Using Signal Word….724
Other Signal Words….724
Safety Labels….725
Example of Safety Label Using Words….725
Example of Safety Label Using Pictogram….725
Introduction….726
Directions of Machine….727
Product Information….727
Machine Serial Number Plate and Its Location….727
Engine Serial Number Plate and Its Location….728
Emission Control Information Label and Its Location….728
Service Meter Location….729
Contents….729
Safety….730
Safety Labels….732
Location of Safety Labels….732
Safety Labels….733
Safety Information….735
Safety Rules….735
If Abnormalities Are Found….735
Working Wear and Personal Protective Items….735
Fire Extinguisher and First Aid Kit….736
Safety Equipment….736
Keep Machine Clean….736
Keep Operator’s Compartment Clean….737
Leaving Operator’s Seat with Lock….737
Handrails and Steps….738
Mounting and Dismounting….738
No Persons on Attachments….739
Burn Prevention….739
Fire Prevention and Explosion Prevention….740
Action If Fire Occurs….741
Falling Objects, Flying Objects and Intruding Objects Prevention….742
Attachment Installation….742
Attachment Combinations….742
Unauthorized Modifications….742
Safety at Jobsite….743
Working on Loose Ground….743
Distance to High Voltage Cables….744
Ensure Good Visibility….744
Ventilation for Enclosed Area….745
Signalperson’s Signal and Signs….745
Asbestos Dust Hazard Prevention….745
Safe Machine Operation….746
Starting Engine….746
Operation….747
Transportation….755
Battery….756
Towing….758
Lifting Objects with Bucket….759
Safe Maintenance Information….760
Warning Tag….760
Keep Work Place Clean and Tidy….760
Appoint Leader When Working with Others….760
Stop Engine Before Carrying Out Maintenance….761
Two Workers for Maintenance When Engine Is Running….762
Proper Tools….762
Personnel….762
Attachments….763
Work Under the Machine….763
Noise….763
When Using Hammer….764
Welding Works….764
Removing Battery Terminals….764
Safety First When Using High-Pressure Grease to Adjust Track Tension….765
Safety Rules for High-Pressure Oil….765
Safety Handling High-Pressure Hoses….766
Waste Materials….766
Compressed Air….767
Periodic Replacement of Safety Critical Parts….767
Operation….768
Machine View Illustrations….770
Overall Machine View….770
Controls and Gauges….771
Detailed Controls and Gauges….772
Meters and Lamps….772
Switches….774
Control Levers and Pedals….777
Variable Blade….786
Engine Hood….787
Fuse….787
In-Line Fuse….788
Operator’s Manual Storage….789
Machine Operations and Controls….790
Before Starting Engine….790
Starting Engine….801
After Starting Engine….804
Stopping the Engine….806
Check After Shutting Off Engine….807
Machine Operation….808
Steering the Machine….813
Swinging….815
Backhoe Controls and Operations….816
Prohibited Operations….818
General Operation Information….821
Traveling on Slopes….822
Escape from Mud….824
Recommended Applications….825
Bucket Replacement….827
Parking Machine….829
Machine Inspection After Daily Work….830
Rubber Tracks….831
Transportation….836
Transportation Procedure….836
Loading and Unloading with Trailer….836
Lifting Machine….838
Shipping Machine Information….840
Cold Weather Operation….841
Cold Weather Operation Information….841
After Daily Work Completion….843
After Cold Weather Season….843
Long-Term Storage….844
Before Storage….844
During Storage….844
After Storage….845
Starting Machine After Long-Term Storage….845
Troubles and Actions….846
Running Out of Fuel….846
Conditions That Are Not Failures….846
Towing the Machine….847
Severe Job Conditions….847
Discharged Battery….848
Battery Removal and Installation….849
Battery Charging….848
Starting Engine with Jumper Cables….850
Other Trouble….853
Maintenance….858
Maintenance Information….858
Lubricants, Coolant, and Filters….861
Handling Oil, Fuel, and Coolant….861
Electrical System Maintenance….863
Lubricants, Fuel, and Coolant Specifications….864
Proper Selection….864
Tightening Torque Specifications….868
Tightening Torque List….868
Maintenance Schedule….870
Maintenance Interval for Hydraulic Breaker….871
Maintenance Procedure….872
Initial 250 Hour Maintenance (Only After the First 250 Hours)….872
When Required….873
Clean and Replace Air Cleaner Element….873
Flush Cooling System….875
Check Level of Battery Electrolyte….879
Check Rubber Tracks….882
Check and Adjust Track Tension….884
Drain Water and Sediment from Fuel Tank….887
Checks Before Starting….887
Every 100 Hours Maintenance….888
Lubricating….888
Every 250 Hours Maintenance….889
Lubricating….889
Replace Engine Oil….889
Check Oil Level In Final Drive Case, Add Oil….890
Replace Hydraulic Filter Element….891
Check and Adjust Cooling Fan Belt Tension….892
Every 500 Hours Maintenance….893
Lubricating….893
Replace Engine Oil Filter Element….894
Replace Fuel Filter Element….895
Replace Fuel Feed Pump Pre-Filter….897
Clean and Inspect Radiator Fins and Oil Cooler Fins….898
Every 1000 Hours Maintenance….899
Change Oil In Final Drive Case….899
Every 2000 Hours Maintenance….900
Change Oil In Hydraulic Tank, Clean Strainer….900
Check Alternator and Starting Motor….901
Check and Adjust Engine Valve Clearance….901
Specifications….902
Attachments and Options….904
General Information….905
Safety First….905
Attachment Installation….907
Bucket with Hook….908
Hook Condition….908
Prohibited Operations….908
Attachment Guide….909
Attachment Combinations….909
Handling Arm with Built-In Breaker….911
Bucket Position….911
Removing and Installing Chisel….911
Procedure for Breaker Operations….913
Precautions When Carrying Out Breaker Operations….914
Stowing Chisel, Dummy Chisel….915
Precautions When Carrying Out Bucket Operations….915
Handling Dummy Link….916
Check Before Starting….917
Specifications….918
Handling Bucket Coupler….919
Procedure for Removing Bucket….919
Procedure for Installing Bucket….921
Recommended Attachment Operations….923
Hydraulic Breaker….923
Support….928
Procedure….928
Resources….928
Publications….928
Ditch Witch Training….928
Warranty….929
SEAM061600 – Hydraulic Excavator MX352 Operation & Maintenance Manual….932
COVER….932
FOREWORD….933
FOREWORD….934
SAFETY INFORMATION….937
INTRODUCTION….939
DIRECTIONS OF MACHINE….939
PRODUCT INFORMATION….940
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….940
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….940
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….941
SERVICE METER LOCATION….941
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….941
CONTENTS….942
SAFETY….949
SAFETY INFORMATION….950
SAFETY LABELS….952
LOCATION OF SAFETY LABELS….952
SAFETY LABELS….953
SAFETY INFORMATION….958
SAFETY MACHINE OPERATION….968
STARTING ENGINE….968
OPERATION….970
TRANSPORTATION….976
BATTERY….977
TOWING….979
LIFTING OBJECTS WITH BUCKET….980
SAFETY MAINTENANCE INFORMATION….981
OPERATION….989
MACHINE VIEW ILLUSTRATIONS….990
OVERALL MACHINE VIEW….990
CONTROLS AND GAUGES….991
DETAILED CONTROLS AND GAUGES….992
MONITORING SYSTEM….992
Emergency Monitors….993
Meter Display Portion….995
Pilot Lamps….997
Monitor Switches Portion….998
SWITCHES….1000
CONTROL LEVERS AND PEDALS….1004
WINDSHIELD….1010
SLIDING DOOR….1014
SLIDING WINDOW….1014
EMERGENCY ESCAPE HAMMER….1015
COVER WITH LOCK….1016
Opening and Closing Covers with Lock….1016
ENGINE REAR COVER….1017
COOLING COVER….1018
MUD COVER….1019
METHOD OF OPENING (TILTING) FLOOR….1020
FUSE….1025
BLOCK FUSE….1026
OPERATION MANUAL STORAGE….1026
TOOL BOX….1026
GREASE GUN HOLDER….1027
ASHTRAY….1027
MACHINE OPERATIONS AND CONTROLS….1028
BEFORE STARTING ENGINE….1028
Walk-around Checks….1028
Checks Before Starting….1030
Adjustment….1036
Seat Belt….1038
Operations Before Starting Engine….1040
STARTING ENGINE….1042
Normal Starting….1042
Starting Engine in Cold Weather….1043
AFTER STARTING ENGINE….1046
Breaking-in the New Machine….1046
Warming-up Operation….1047
STOPPING THE ENGINE….1049
MACHINE OPERATION….1050
Preparations for Moving the Machine Off….1050
Moving Machine Forward….1051
Moving Machine Backward….1052
Stopping Machine….1054
STEERING THE MACHINE….1055
Steering….1055
SWINGING….1057
WORK EQUIPMENT CONTROLS AND OPERATIONS….1058
PROHIBITED OPERATIONS….1060
GENERAL OPERATION INFORMATION….1062
TRAVELING ON SLOPES….1064
ESCAPE FROM MUD….1066
Stuck One Side of Track….1066
Stuck Both Sides of Tracks….1066
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….1067
Backhoe work….1067
Ditching work….1067
Loading work….1067
Smoothing work….1068
Side ditching work….1068
BUCKET REPLACEMENT….1069
PARKING MACHINE….1070
MACHINE INSPECTION AFTER DAILY WORK….1071
Before stop engine….1071
After stop engine….1071
LOCKING….1072
RUBBER SHOES AND ROAD LINERS….1073
Rubber Shoes and Road Liners Information….1073
Warranty for Rubber Shoes and Road Liners….1073
Using Rubber Shoes and Road Liners….1074
Long Life Operations….1075
TRANSPORTATION….1079
TRANSPORTATION PROCEDURE….1079
LOADING AND UNLOADING WITH TRAILER….1080
Loading….1081
Securing Machine….1083
Unloading….1084
LIFTING MACHINE….1086
COLD WEATHER OPERATION….1089
COLD WEATHER OPERATION INFORMATION….1089
Fuel and Lubricants….1089
Cooling System Coolant….1089
Battery….1090
CAB HEATER IN COLD WEATHER….1090
AFTER DAILY WORK COMPLETION….1091
AFTER COLD WEATHER SEASON….1091
LONG TERM STORAGE….1092
BEFORE STORAGE….1092
DURING STORAGE….1093
AFTER STORAGE….1093
TROUBLES AND ACTIONS….1094
RUNNING OUT OF FUEL….1094
PHENOMENA THAT ARE NOT FAILURES….1094
TOWING THE MACHINE….1095
SEVERE JOB CONDITION….1095
DISCHARGED BATTERY….1096
Battery Removal and Installation….1097
Battery Charges….1098
Starting Engine with Booster Cables….1099
OTHER TROUBLE….1101
Electrical System….1101
Chassis….1102
Engine….1103
MAINTENANCE….1105
MAINTENANCE INFORMATION….1106
LUBRICANTS, COOLANT AND FILTERS….1109
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1109
Oil….1109
Fuel….1109
Cooling System Coolant….1110
Grease….1110
Carrying Out KOWA (Komatsu Oil Wear Analysis)….1111
Oil and Fuel Storage….1112
Filters….1112
ELECTRIC SYSTEM MAINTENANCE….1112
HANDLING HYDRAULIC SYSTEM….1113
WEAR PARTS….1114
WEAR PARTS LIST….1114
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….1115
TIGHTENING TORQUE SPECIFICATIONS….1119
TIGHTENING TORQUE LIST….1119
SAFETY CRITICAL PARTS….1121
SAFETY CRITICAL PARTS LIST….1121
MAINTENANCE SCHEDULE….1122
MAINTENANCE SCHEDULE CHART….1122
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1123
MAINTENANCE PROCEDURE….1124
WHEN REQUIRED….1124
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1124
CLEAN INSIDE OF COOLING SYSTEM….1126
CHECK LEVEL OF BATTERY ELECTROLYTE….1129
CLEAN WATER SEPARATOR ELEMENT….1131
DRAIN WATER AND SEDIMENT FROM FUEL TANK….1132
CHECK AND TIGHTEN TRACK SHOE BOLTS….1132
CHECK AND ADJUST TRACK TENSION….1133
CHECK, RUBBER SHOES OR ROAD LINERS….1135
CHECK AND ADJUST RUBBER SHOE TENSION….1137
REPLACE RUBBER SHOES….1139
REPLACE ROAD LINERS….1141
REPLACE BUCKET TEETH….1142
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1145
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….1146
LUBRICATING….1146
BLEEDING AIR FROM HYDRAULIC SYSTEM….1147
CHECK BEFORE STARTING….1149
EVERY 500 HOURS MAINTENANCE….1150
LUBRICATING….1150
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1153
REPLACE FUEL FILTER CARTRIDGE….1154
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1156
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….1157
CHECK AND ADJUST COOLING FAN BELT TENSION….1158
EVERY 1000 HOURS MAINTENANCE….1159
REPLACE HYDRAULIC OIL FILTER ELEMENT….1159
CHANGE OIL IN FINAL DRIVE CASE….1161
CHECK ENGINE VALVE CLEARANCE, ADJUST….1161
EVERY 2000 HOURS MAINTENANCE….1162
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….1162
CHECK ALTERNATOR, STARTING MOTOR….1164
SPECIFICATIONS….1165
SPECIFICATIONS….1166
ATTACHMENTS AND OPTIONS….1169
ATTACHMENTS AND OPTIONS – GENERAL INFORAMTION….1170
SAFETY FIRST….1170
ATTACHMENT INSTALLATION….1171
BUCKET WITH HOOK….1172
PROHIBITED OPERATIONS….1172
AIR CONDITIONER….1173
CONTROL PANEL AND COMPONENTS….1173
AIR CONDITIONER CONTROLS….1174
AIR CONDITIONER MAINTENANCE….1175
When Required….1175
Every 250 Hours Maintenance….1176
Every 500 Hours Maintenance….1177
RADIO….1180
CONTROL PANEL….1180
CONTROLS OF RADIO….1181
Listening to radio….1181
Automatic Tuning….1182
Manual Tuning….1182
Preset Station Buttons….1182
Using auto memory….1183
Time Adjustment….1183
Automatic selection of reception for monaural/stereo….1184
Antenna….1184
CARE FOR RADIO….1184
WINDSHIELD WASHER….1185
WINDSHIELD WASHER OPERATION….1185
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1185
MACHINE READY FOR ATTACHMENT….1186
LOCATIONS….1186
HYDRAULIC CIRCUIT….1189
Hydraulic Circuit Connection….1189
ATTACHMENT OPERATIONS….1191
When Using Breaker….1191
When Using General Attachment Such as Crusher….1192
LONG TERM STORAGE….1192
SPECIFICATIONS….1192
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….1193
CONTROL PATTERN CHANGE PROCEDURE….1193
MACHINE CONTROL PATTERNS….1194
ATTACHMENT GUIDE….1195
ATTACHMENT COMBINATIONS….1195
RECOMMENDED ATTACHMENT OPERATIONS….1196
HYDRAULIC BREAKER….1196
INDEX….1201
<A>….1201
<B>….1201
<C>….1201
<D>….1201
<E>….1201
<F>….1201
<G>….1201
<H>….1201
<I>….1201
<L>….1201
<M>….1201
<O>….1201
<P>….1202
<R>….1202
<S>….1202
<T>….1202
<W>….1202
<Y>….1202
COLOPHON….1203
SEAM061700 – Hydraulic Excavator MX502 Operation & Maintenance Manual….1205
COVER….1205
FOREWORD….1206
FOREWORD….1207
SAFETY INFORMATION….1210
INTRODUCTION….1212
DIRECTIONS OF MACHINE….1212
PRODUCT INFORMATION….1213
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1213
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….1213
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….1214
SERVICE METER LOCATION….1214
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….1215
CONTENTS….1216
SAFETY….1220
SAFETY INFORMATION….1221
SAFETY LABELS….1223
LOCATION OF SAFETY LABELS….1223
SAFETY LABELS….1224
SAFETY INFORMATION….1229
SAFETY RULES….1229
IF ABNORMALITIES ARE FOUND….1229
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….1229
FIRE EXTINGUISHER AND FIRST AID KIT….1229
SAFETY EQUIPMENT….1230
KEEP MACHINE CLEAN….1230
KEEP OPERATOR&’S COMPARTMENT CLEAN….1230
LEAVING OPERATOR&’S SEAT WITH LOCK….1230
HANDRAILS AND STEPS….1231
MOUNTING AND DISMOUNTING….1231
NO PERSONS ON ATTACHMENTS….1231
BURN PREVENTION….1232
FIRE PREVENTION AND EXPLOSION PREVENTION….1232
ACTION IF FIRE OCCURS….1233
WINDSHIELD WASHER FLUID….1233
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….1234
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)….1234
ATTACHMENT INSTALLATION….1235
ATTACHMENT COMBINATIONS….1235
CAB WINDOW GLASSES….1235
UNAUTHORIZED MODIFICATIONS….1235
SAFETY AT JOBSITE….1235
WORKING ON LOOSE GROUND….1235
DISTANCE TO HIGH VOLTAGE CABLES….1236
ENSURE GOOD VISIBILITY….1236
VENTILATION FOR ENCLOSED AREA….1236
SIGNALMAN&’S SIGNAL AND SIGNS….1237
EMERGENCY EXIT FROM OPERATOR&’S CAB….1237
ASBESTOS DUST HAZARD PREVENTION….1237
SAFETY MACHINE OPERATION….1238
STARTING ENGINE….1238
CHECKS BEFORE STARTING ENGINE….1238
SAFETY RULES FOR STARTING ENGINE….1239
STARTING ENGINE IN COLD WEATHER….1239
OPERATION….1240
CHECKS BEFORE OPERATION….1240
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….1240
SAFETY RULES FOR TRAVELING….1241
TRAVELING ON SLOPES….1242
OPERATIONS ON SLOPES….1243
PROHIBITED OPERATIONS….1243
OPERATIONS ON SNOW….1245
PARKING MACHINE….1245
TRANSPORTATION….1246
LOADING AND UNLOADING….1246
SHIPPING THE MACHINE….1246
BATTERY….1247
BATTERY HAZARD PREVENTION….1247
STARTING ENGINE WITH BOOSTER CABLES….1248
TOWING….1249
SAFETY RULES FOR TOWING….1249
LIFTING OBJECTS WITH BUCKET….1250
SAFETY RULES FOR LIFTING OBJECTS….1250
SAFETY MAINTENANCE INFORMATION….1251
WARNING TAG….1251
KEEP WORK PLACE CLEAN AND TIDY….1251
APPOINT LEADER WHEN WORKING WITH OTHERS….1251
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….1252
CAUTIONS FOR OPENING (TILTING) FLOOR….1253
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1254
PROPER TOOLS….1254
PERSONNEL….1254
ATTACHMENTS….1255
WORK UNDER THE MACHINE….1255
NOISE….1255
WHEN USING HAMMER….1255
WELDING WORKS….1255
REMOVING BATTERY TERMINALS….1256
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….1256
DO NOT DISASSEMBLE RECOIL SPRINGS….1256
SAFETY RULES FOR HIGH-PRESSURE OIL….1256
SAFETY HANDLING HIGH-PRESSURE HOSES….1257
WASTE MATERIALS….1257
AIR CONDITIONER MAINTENANCE….1257
COMPRESSED AIR….1257
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1257
OPERATION….1258
MACHINE VIEW ILLUSTRATIONS….1259
OVERALL MACHINE VIEW….1259
CONTROLS AND GAUGES….1260
DETAILED CONTROLS AND GAUGES….1261
MONITORING SYSTEM….1261
SWITCHES….1269
CONTROL LEVERS AND PEDALS….1273
WINDSHIELD….1279
SLIDING DOOR….1283
SLIDING WINDOW….1283
EMERGENCY ESCAPE HAMMER….1284
COVER WITH LOCK….1285
ENGINE REAR COVER….1286
COOLING COVER….1286
MUD COVER….1287
METHOD OF OPENING (TILTING) FLOOR….1288
FUSE….1293
BLOCK FUSE….1294
AUXILIARY ELECTRIC POWER….1295
OPERATION MANUAL STORAGE….1296
TOOL BOX….1296
GREASE GUN HOLDER….1296
ASHTRAY….1296
MACHINE OPERATIONS AND CONTROLS….1297
BEFORE STARTING ENGINE….1297
STARTING ENGINE….1311
AFTER STARTING ENGINE….1315
STOPPING THE ENGINE….1318
MACHINE OPERATION….1319
STEERING THE MACHINE….1324
SWINGING….1326
WORK EQUIPMENT CONTROLS AND OPERATIONS….1327
PROHIBITED OPERATIONS….1329
GENERAL OPERATION INFORMATION….1331
TRAVELING ON SLOPES….1332
ESCAPE FROM MUD….1334
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….1335
BUCKET REPLACEMENT….1337
PARKING MACHINE….1338
CHECK AFTER SHUT OFF ENGINE….1339
MACHINE INSPECTION AFTER DAILY WORK….1339
LOCKING….1340
RUBBER SHOES AND ROAD LINERS….1341
TRANSPORTATION….1346
TRANSPORTATION PROCEDURE….1346
LOADING AND UNLOADING WITH TRAILER….1347
LIFTING MACHINE….1353
COLD WEATHER OPERATION….1356
COLD WEATHER OPERATION INFORMATION….1356
CAB HEATER IN COLD WEATHER….1357
AFTER DAILY WORK COMPLETION….1358
AFTER COLD WEATHER SEASON….1358
LONG TERM STORAGE….1359
BEFORE STORAGE….1359
DURING STORAGE….1360
AFTER STORAGE….1360
TROUBLES AND ACTIONS….1361
RUNNING OUT OF FUEL….1361
PHENOMENA THAT ARE NOT FAILURES….1361
TOWING THE MACHINE….1362
SEVERE JOB CONDITION….1362
DISCHARGED BATTERY….1363
OTHER TROUBLE….1367
MAINTENANCE….1372
MAINTENANCE INFORMATION….1373
LUBRICANTS, COOLANT AND FILTERS….1375
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1375
ELECTRIC SYSTEM MAINTENANCE….1377
HANDLING HYDRAULIC SYSTEM….1378
WEAR PARTS….1379
WEAR PARTS LIST….1379
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….1380
TIGHTENING TORQUE SPECIFICATIONS….1384
TIGHTENING TORQUE LIST….1384
SAFETY CRITICAL PARTS….1385
SAFETY CRITICAL PARTS LIST….1385
MAINTENANCE SCHEDULE….1386
MAINTENANCE SCHEDULE CHART….1386
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1387
MAINTENANCE PROCEDURE….1388
WHEN REQUIRED….1388
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1388
CLEAN INSIDE OF COOLING SYSTEM….1393
CHECK LEVEL OF BATTERY ELECTROLYTE….1396
CLEAN WATER SEPARATOR ELEMENT….1398
DRAIN WATER AND SEDIMENT FROM FUEL TANK….1398
CHECK AND TIGHTEN TRACK SHOE BOLTS….1399
CHECK AND ADJUST TRACK TENSION….1400
CHECK, RUBBER SHOES OR ROAD LINERS….1402
CHECK AND ADJUST RUBBER SHOE TENSION….1404
REPLACE RUBBER SHOES….1406
REPLACE ROAD LINERS….1408
REPLACE BUCKET TEETH….1409
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1412
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….1413
LUBRICATING….1413
BLEEDING AIR FROM HYDRAULIC SYSTEM….1414
CHECK BEFORE STARTING….1416
EVERY 500 HOURS MAINTENANCE….1417
LUBRICATING….1417
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1420
REPLACE FUEL FILTER CARTRIDGE….1421
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1423
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….1424
CHECK AND ADJUST COOLING FAN BELT TENSION….1425
EVERY 1000 HOURS MAINTENANCE….1426
REPLACE HYDRAULIC OIL FILTER ELEMENT….1426
CHANGE OIL IN FINAL DRIVE CASE….1427
CHECK ENGINE VALVE CLEARANCE, ADJUST….1427
EVERY 2000 HOURS MAINTENANCE….1428
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….1428
CHECK ALTERNATOR, STARTING MOTOR….1430
SPECIFICATIONS….1432
SPECIFICATIONS….1433
ATTACHMENTS, OPTIONS….1436
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….1437
SAFETY FIRST….1437
ATTACHMENT INSTALLATION….1438
BUCKET WITH HOOK….1439
PROHIBITED OPERATIONS….1439
AIR CONDITIONER….1440
CONTROL PANEL AND COMPONENTS….1440
AIR CONDITIONER CONTROLS….1441
AIR CONDITIONER MAINTENANCE….1442
WINDSHIELD WASHER….1446
WINDSHIELD WASHER OPERATION….1446
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1446
MACHINE READY FOR ATTACHMENT….1447
LOCATIONS….1447
HYDRAULIC CIRCUIT….1449
ATTACHMENT OPERATIONS….1451
LONG TERM STORAGE….1452
SPECIFICATIONS….1452
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….1453
CONTROL PATTERN CHANGE PROCEDURE….1453
MACHINE CONTROL PATTERNS….1454
ATTACHMENT GUIDE….1455
ATTACHMENT COMBINATIONS….1455
RECOMMENDED ATTACHMENT OPERATIONS….1456
HYDRAULIC BREAKER….1456
INDEX….1462
SEBM035400 – MX352, MX502 Shop Manual….1466
COVER….1466
CONTENTS….1467
SAFETY….1468
SAFETY NOTICE….1468
FOREWORD….1470
GENERAL….1470
HOW TO READ THE SHOP MANUAL….1471
HOISTING INSTRUCTIONS….1472
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER….1473
COATING MATERIALS….1475
STANDARD TIGHTENING TORQUE….1477
ELECTRIC WIRE CODE….1480
CONVERSION TABLE….1481
UNITS….1487
01 GENERAL….1488
SPECIFICATION DIMENSION DRAWING….1489
WORKING RANGE DRAWING….1490
SPECIFICATIONS….1491
WEIGHT TABLE….1497
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….1499
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….1502
PTO….1503
COOLING SYSTEM….1505
POWER TRAIN….1507
SWING CIRCLE….1508
SWING MACHINERY….1509
TRACK FRAME….1513
IDLER CUSHION….1514
IDLER….1515
TRACK ROLLER….1517
CARRIER ROLLER….1519
SPROCKET….1520
TRACK SHOE….1521
HYDRAULIC COMPONENTS LAYOUT DRAWING….1529
HYDRAULIC TANK….1531
CENTER SWIVEL JOINT….1534
TRAVEL MOTOR….1536
HYDRAULIC CYLINDER….1544
SOLENOID VALVE….1548
MULTI-CONTROL VALVE….1551
HYDRAULIC PUMP….1552
CONTROL VALVE….1563
CLSS….1577
OPERATION FOR EACH FUNCTION AND VALVE….1581
SWING MOTOR….1603
PPC VALVE….1612
WORK EQUIPMENT….1620
DIMENSIONS OF EACH PART OF WORK EQUIPMENT….1623
FLOOR….1629
AIR CONDITIONER….1630
ENGINE CONTROL….1631
ELECTRIC CONTROL SYSTEM….1633
COMPONENT PARTS OF SYSTEM….1638
MONITOR SYSTEM….1639
MONITOR PANEL….1640
SENSORS….1642
20 TESTING AND ADJUSTING….1644
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS….1645
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS….1647
TESTING AND ADJUSTING….1662
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS….1663
MEASURING ENGINE SPEED….1665
MEASUREMENT OF EXHAUST GAS COLOR….1666
ADJUSTING VALVE CLEARANCE….1667
MEASURING COMPRESSION PRESSURE….1670
MEASURING ENGINE OIL PRESSURE….1671
TESTING AND ADJUSTING FUEL INJECTION TIMING….1672
TESTING AND ADJUSTING ALTERNATOR BELT TENSION….1674
ADJUSTING FUEL CONTROL LEVER….1675
TESTING WEAR OF SPROCKET….1676
TESTING AND ADJUSTING TRACK SHOE TENSION….1677
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING, AND BLADE CIRCUITS….1678
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE….1682
ADJUSTING PC VALVE….1686
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE….1687
MEASURING SOLENOID VALVE OUTPUT PRESSURE….1689
MEASURING PPC VALVE OUTPUT PRESSURE….1691
ADJUSTING PPC VALVE….1694
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE….1695
TESTING AND ADJUSTING TRAVEL DEVIATION….1696
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER….1698
BLEEDING AIR FROM EACH PART….1700
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT….1703
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK….1703
PRESSURIZING HYDRAULIC TANK….1704
INSPECTION PROCEDURES FOR DIODE….1705
TROUBLESHOOTING….1706
POINTS TO REMEMBER WHEN TROUBLESHOOTING….1707
SEQUENCE OF EVENTS IN TROUBLESHOOTING….1708
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….1709
CHECKS BEFORE TROUBLESHOOTING….1717
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING….1718
TYPES AND LOCATIONS OF CONNECTORS….1721
CONNECTOR ARRANGEMENT DIAGRAM….1727
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….1735
T-ADAPTER – BOXES AND T-ADAPTER TABLE….1757
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….1760
BEFORE STARTING E-MODE TROUBLESHOOTING….1761
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….1762
E-1 ENGINE DOES NOT START….1763
E-2 ENGINE DOES NOT STOP….1771
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES….1775
E-4 WINDSHIELD WIPER DOES NOT OPERATE….1779
E-5 WINDSHIELD WASHER DOES NOT OPERATE….1781
E-6 TRAVEL ALARM DOES NOT SOUND….1785
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….1788
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….1789
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW….1790
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS….1794
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK….1795
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP….1798
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW….1798
H-6 SPEED OR POWER OF BOOM IS LOW….1799
H-7 SPEED OR POWER OF ARM IS LOW….1800
H-8 SPEED OR POWER OF BUCKET IS LOW….1801
H-9 SPEED OR POWER OF BOOM SWING IS LOW….1802
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY….1803
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE….1804
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE….1805
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW….1805
H-14 MACHINE DEVIATES DURING TRAVEL….1806
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)….1808
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW….1809
H-17 TRAVEL SPEED DOES NOT CHANGE….1810
H-18 TRAVEL MOTOR DOES NOT WORK….1811
H-19 SPEED OR POWER OF SWING IS LOW….1813
H-20 MACHINE DOES NOT SWING….1815
H-21 SWING ACCELERATION PERFORMANCE IS LOW….1817
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING….1819
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING….1820
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND….1820
H-25 HYDRAULIC DRIFT OF SWING IS LARGE….1821
H-26 SPEED OR POWER OF BLADE IS LOW….1822
H-27 BLADE DOES NOT MOVE….1823
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE….1823
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)….1824
BEFORE STARTING M-MODE TROUBLESHOOTING….1825
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….1826
SYSTEM DIAGRAM RELATED TO MONITOR PANEL….1827
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE….1829
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE….1831
M-3 ALARM BUZZER IS ABNORMAL….1832
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON….1834
M-5 CHARGE LEVEL CAUTION IS TURNED ON….1835
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT….1839
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL….1841
M-8 FUEL LEVEL GAUGE IS ABNORMAL….1846
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING….1850
M-10 2ND TRAVEL SPEED IS NOT SELECTED….1852
M-11 WORKING LAMP DOES NOT LIGHT UP….1857
TROUBLESHOOTING OF ENGINE (S MODE)….1860
METHOD OF USING TROUBLESHOOTING CHARTS….1861
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….1865
S-2 ENGINE DOES NOT START….1867
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….1870
S-4 ENGINE STOPS DURING OPERATIONS….1871
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….1872
S-6 ENGINE LACKS OUTPUT OR LACKS POWER….1873
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….1874
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE….1875
S-9 OIL BECOMES CONTAMINATED QUICKLY….1876
S-10 FUEL CONSUMPTION IS EXCESSIVE….1877
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN….1878
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….1879
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)….1880
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….1881
S-15 ABNORMAL NOISE IS MADE….1882
S-16 VIBRATION IS EXCESSIVE….1883
30 DISASSEMBLY AND ASSEMBLY….1884
HOW TO READ THIS MANUAL….1885
PRECAUTIONS WHEN PERFORMING OPERATION….1887
SPECIAL TOOL LIST….1889
SKETCHES OF SPECIAL TOOLS….1893
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER….1894
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP….1903
REMOVAL AND INSTALLATION OF TRACK SHOE….1910
DISASSEMBLY AND ASSEMBLY OF IDLER….1911
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING….1913
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER….1916
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ….1918
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT….1919
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT….1922
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY….1924
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY….1928
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY….1929
REMOVAL AND INSTALLATION OF WORK EQUIPMENT….1935
REMOVAL AND INSTALLATION OF REVOLVING FRAME….1937
REMOVAL AND INSTALLATION OF SWING CIRCLE….1939
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE….1940
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….1941
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT….1945
90 OTHERS….1948
HYDRAULIC CIRCUIT DIAGRAM MX352….1949
HYDRAULIC CIRCUIT DIAGRAM MX502….1950
HYDRAULIC CIRCUIT DIAGRAM (Additional attachment circuit) MX502….1951
ELECTRICAL CIRCUIT DIAGRAM MX352 (1/2)….1952
ELECTRICAL CIRCUIT DIAGRAM MX352 (2/2)….1953
ELECTRICAL CIRCUIT DIAGRAM MX502 (1/2)….1954

Komatsu Hydraulic Excavator MX352, MX502 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC03-2, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC03-2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 469 pages
File Format: PDF
Language: English

SEBM025000 – Hydraulic Excavator PC03-2 Shop Manual.pdf
SEAM040601 – Hydraulic Excavator PC03-2 Operation & Maintenance Manual.pdf

MAIN SECTIONS
COVER…1
CONTENTS…2
FOREWORD…3
SAFETY…3
FOREWORD…5
HOW TO READ THE SHOP MANUAL…6
HOISTING INSTRUCTIONS…7
STANDARD TIGHTENING TORQUE…8
COATING MATERIALS…9
ELECTRIC WIRE CODE…10
COVERSION TABLE…11
01 GENERAL…17
GENERAL ASSEMBLY DRAWING…18
SPECIFICATIONS…19
WEIGHT TABLE…21
LIST OF LUBRICANT AND WATER…22
10 STRUCTURE…23
ENGINE MOUNT…24
POWER TRAIN…25
SWING CIRCLE…26
TRACK FRAME…27
IDLER…29
TRACK ROLLER…29
HYDRAULIC PIPING…32
HYDRAULIC DIAGRAM…34
HYDRAULIC TANK…38
HYDRAULIC PUMP…40
9-SPOOL CONTROL VALVE…41
SWING MOTOR…43
CENTER SWIVEL JOINT…44
TRAVEL MOTOR…45
VALVE CONTROL…46
HYDRAULIC CYLINDER…47
WORK EQUIPMENT…49
ELECTRICAL CIRCUIT DIAGRAM…51
20 TESTING AND ADJUSTING…53
STANDARD VALVE TABLE FOR ENGINE-RELATED PARTS…54
STANDARD VALVE TABLE FOR CHASSIS-RELATED PARTS…55
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…62
MEASURING ENGINE SPEED…63
MEASURING ENGINE OIL PRESSURE…63
ADJUSTING VALVE CLEARANCE…64
MEASURING COMPRESSION PRESSURE…65
TESTING AND ADJUSTING FUEL INJECTION TIMING…66
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…67
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…68
BLEEDING AIR FROM HYDRAULIC CYLINDERS…69
TROUBLESHOOTING…70
POINTS TO REMEMBER WHEN TROUBLESHOOTING…71
SEQUENCE OF EVENTS IN TROUBLESHOOTING…72
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…73
CHECKS BEFORE TROUBLESHOOTING CHARTS…81
METHOD OF USING TROUBLESHOOTING CHARTS…82
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…84
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVELING, SWINGING ARE SLOW OR LACK POWER…85
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT TRAVELING, SWINGING DO NOT FUNCTION OR ARE…85
H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…86
H-4 CONTROL LEVER IS HEAVY…86
H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET ) IS SLOW EXCESSIVE HYDRAULIC DRIFT…87
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET ) LACKS POWER…87
H-7 EXCESSIVE TIME LAG…87
H-8 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE…88
A) DEVIATES IN SAME DIRECTION IN BOTH FORWARD AND REVERSE…88
B) DEVIATES IN DIFFERENT DIRECTIONS IN BOTH FORWARD AND REVERSE…88
H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW…90
H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)…90
H-11 DOES NOT SWING…91
H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR…92
H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING…92
H-14 EXCESSIVE SHOCK WHEN STOPPING SWING…93
H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING …93
H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING…94
H-17 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING…94
TABLE OD FAILURE MODES AND CAUSES…95
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…96
M-1 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…97
M-2 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)…98
M-3 THE ENGINE COOLING WATER TEMPERATURE CASUTION LAMP WILL LIGHT ON, WHEN TURNING THE ENGINE STARTING SWITCH ON…99
M-4 THE WORKING LAMP DOES NOT LIGHT ON, EVEN THOUGH THE LAMP SWITCH IS TURNED ON…100
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…101
E-1 THE ENGINE DOES NOT START, EVEN THOUGH THE ENGINE STARTING SWITCH IS TURNED ON…102
A) WHEN THE ENGINE STARTING MOTOR DOES NOT ROTATE NORMALLY…102
B) WHEN THE ENGINE STARTING MOTOR ROTATES NORMALLY …104
E-2 THE ENGINE DOES NOT STOP, EVEN THOUGH THE ENGINE STARTING SWITCH IS TURNED OFF…106
30 DISASSEMBLY AND ASSEMBLY…107
METHOD OF USING MANUAL…108
PRECAUTIONS WHEN CARRYING OUT OPERATION…110
SPECIAL TOOL LIST…112
RADIATOR…113
REMOVAL AND INSTALLATION …113
CENTER SWIVEL JOINT…114
DISASSEMBLY AND ASSEMBLY…114
BATTERY…115
REMOVAL AND INSTALLATION …115
ENGINE, MAIN PUMP…116
REMOVAL AND INSTALLATION …117
TRAVEL MOTOR…119
REMOVAL AND INSTALLATION …119
SPROCKET…120
REMOVAL AND INSTALLATION …120
SWING MOTOR…121
REMOVAL AND INSTALLATION …121
REVOLVING FRAME…122
REMOVAL AND INSTALLATION …122
SWING CIRCLE…123
REMOVAL AND INSTALLATION …123
IDLER…124
REMOVAL AND INSTALLATION …124
IDLER…124
DISASSEMBLY AND ASSEMBLY…124
TRACK ROLLER…125
REMOVAL AND INSTALLATION …125
TRACK ROLLER…126
DISASSEMBLY AND ASSEMBLY…126
RUBBER SHOE…127
REMOVAL AND INSTALLATION …127
MAIN PUMP…127
REMOVAL AND INSTALLATION …127
9-SPOOL CONTROL VALVE…128
REMOVAL AND INSTALLATION …128
9-SPOOL CONTROL VALVE…130
DISASSEMBLY…130
ARM CYLINDER…132
REMOVAL AND INSTALLATION …132
BUCKET CYLINDER…133
REMOVAL AND INSTALLATION …133
BOOM CYLINDER…134
REMOVAL AND INSTALLATION …134
BOOM SWING CYLINDER…135
REMOVAL AND INSTALLATION …135
BLADE CYLINDER…136
REMOVAL AND INSTALLATION …136
WORK EQIPMENT…137
REMOVAL AND INSTALLATION …137
BUCKET…138
REMOVAL AND INSTALLATION …138
ARM…139
REMOVAL AND INSTALLATION …139
BOOM…140
REMOVAL…140
INSTALLATION…141
BLADE…142
REMOVAL AND INSTALLATION …142
FUEL TANK…143
REMOVAL AND INSTALLATION …143
MACHINE COVER…144
REMOVAL…144
INSTALLATION…145
HYDRAULIC TANK…146
REMOVAL AND INSTALLATION …146
MONITOR PANEL…147
REMOVAL AND INSTALLATION…147
COUNTERWEIGHT…147
REMOVAL AND INSTALLATION…147
40 MAINTENANCE STANDARD…148
SWING CIRCLE…149
TRACK FRAME…150
IDLER…151
TRACK ROLLER…152
HYDRAULIC PUMP…153
CENTER SWIVEL JOINT…154
9-SPOOL CONTROL VALVE…155
TRAVEL MOTOR…157
HYDRAULIC CYLINDER…158
WORK EQUIPMENT…160
91 ENGINE …164
CONTENTS…166
1. SPECIFICATIONS AND PERFORMANCE…168
1-1 2D68E-3B…168
2. CROSS SECTIONAL VIEWS…169
2-1 SPECIAL SWIRL PRE-COMBUSTION CHAMBER SYSTEM…169
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL…170
3-1 COOLING WATER…170
3-2 LUBRICATING OIL…170
3-3 FUEL OIL…172
4. TROUBLESHOOTING…173
4-1 TROUBLE CAUSES AND REMEDIES…173
4-2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE…175
5. SPECIAL SERVICE TOOLS…176
5-1 SPECIAL SERVICE TOOLS…176
5-2 MEASURING INSTRUMENTS…178
6. MEASUREMENT, INSPECTION AND ADJUSTMENT…181
6-1 MEASURING THE COMPRESSION PRESSURE…181
6-2 ADJUSTING THE VALVE HEAD…183
6-3 CHECKING THE V-BELT TENSION…184
6-4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE…184
6-5 CHECKING AND ADJUSTIONG THE FUEL INJECTION TIMING…188
6-6 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS…189
6-7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR LEAKAGE…189
6-8 CHECKING THE BATTERY…190
6-9 CHECKING SENSORS…192
6-10 CHECKING THE OIL COOLER…193
6-11 CHECKING THE PISTON COOLING NOZZLE…194
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION…195
7-1 CYLINDER HEAD…195
7-2 CYLINDER BLOCK…201
7-3 VALVE ROCKER ARM…204
7-4 PISTON AND PISTON RING…206
7-5 CONNECTING ROD…211
7-6 CAMSHAFT…214
7-7 CRANKSHAFT…216
7-8 GEARS…219
7-9 TROCHOID PUMP…221
8. DISASSEMBLY AND REASSEMBLY…222
8-1 DISASSEMBLY…222
8-2 PRECAUTIONS BEFORE AND DURING REASSEMBLY…227
9. SERVICE DATA…231
9-1 CYLINDER HEAD…231
9-2 CYLINDER BLOCK…232
9-3 VALVE ROCKER ARM…232
9-4 PISTON…233
9-5 PISTON RING…234
9-6 CONNECTING ROD…235
9-7 CAMSHAFT…235
9-8 CRANKSHAFT…235
9-9 SIDE GAP AND BACKLASH…236
9-10 OTHERS…236
10. TIGHENING TORQUJE…237
10-1 MAIN BOLT/NUT…237
10-2 STANDARD BOLT AND NUT…237
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM…238
11-1 EXPLODED VIEWS (YPFR TYPE)…238
11.2 DISASSEMBLY…239
11.3 INSPECTION…240
11-4 REASSEMBLY…242
13. GOVERNOR…243
13-1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM…243
13.3 DISASSEMBLY…244
13.4 INSPECTION…248
13-5 REASSEMBLY…250
ATTACHED DRAWING 1. EXPLODED VIEWS OF ENGINE COMPONENTS…254
ATTACHED DRAWING 2. EXPLODED VIEWS OF ENGINE COMPONENTS…255

COVER…1
1. FOREWORD…2
2. SAFETY INFORMATION…3
3. INTRODUCTION…4
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…5
5. CONTENTS…6
SAFETY…11
6. GENERAL PRECAUTIONS…12
7. PRECAUTIONS DURING OPERATION…18
7.1 BEFORE STARTING ENGINE…18
7.2 OPERATING MACHINE…21
7.3 TRANSPORTATION…27
7.4 BATTERY…28
7.5 TOWING…30
7.6 BUCKET WITH HOOK…31
8. PRECAUTIONS FOR MAINTENANCE…35
8.1 BEFORE CARRYING OUT MAINTENANCE…35
8.2 DURING MAINTENANCE…38
9. POSITION FOR ATTACHING SAFETY LABELS…43
OPERATION…45
10. GENERAL VIEW…46
10.1 GENERAL VIEW OF MACHINE…46
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…47
11. EXPLANATION OF COMPONENTS…48
11.1 METERS,LAMPS…48
11.2 SWITCHES…50
11.3 CONTROL LEVERS,PEDALS…52
11.4 ENGINE HOOD (WITH LOCK)…58
11.5 FUSE BOX…59
11.6 FUSIBLE LINK…60
11.7 OPERATION MANUAL STORAGE…60
12. OPERATION…61
12.1 CHECK BEFORE STARTING ENGINE…61
12.2 STARTING ENGINE…72
12.3 OPERATION AND CHECK AFTER STARTING ENGINE…75
12.4 MOVING MACHINE OFF…78
12.5 STEERING MACHINE…82
12.6 STOPPING MACHINE…84
12.7 SWINGING…85
12.8 OPERATION OF WORK EQUIPMENT…86
12.9 PROHIBITIONS FOR OPERATION…89
12.10 PRECAUTIONS FOR OPERATION…92
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…93
12.12 HOW TO ESCAPE FROM MUD…95
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…96
12.14 REPLACEMENT OF BUCKET…98
12.15 HANDLING RUBBER SHOES…100
12.16 PARKING MACHINE…105
12.17 CHECKS AFTER FINISHING WORK…106
12.18 STOPPING ENGINE…107
12.19 CHECKS AFTER STOPPING ENGINE…107
12.20 LOCKING…108
13. TRANSPORTATION…109
13.1 LOADING,UNLOADING WORK…109
13.2 METHOD OF LIFTING MACHINE…111
13.3 PRECAUTIONS FOR LOADING…113
13.4 PRECAUTIONS FOR TRANSPORTATION…114
14. COLD WEATHER OPERATION…115
14.1 PRECAUTIONS FOR LOW TEMPERATURE…115
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…118
14.3 AFTER COLD WEATHER…119
15. LONG-TERM STORAGE…120
15.1 BEFORE STORAGE…120
15.2 DURING STORAGE…121
15.3 AFTER STORAGE…121
16. TROUBLESHOOTING…122
16.1 PHENOMENA THAT ARE NOT FAILURES…122
16.2 METHOD OF TOWING MACHINE…123
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…123
16.3 IF BATTERY IS DISCHARGED…124
16.4 OTHER TROUBLE…129
MAINTENANCE…133
17. GUIDES TO MAINTENANCE…134
18. OUTLINES OF SERVICE…138
18.1 OUTLINE OF OIL,FUEL…139
18.2 OUTLINE OF ELECTRIC SYSTEM…144
18.3 OUTLINE OF HYDRAULIC SYSTEM…144
19. WEAR PARTS LIST…145
20. USE OF FUEL AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…146
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…150
21.1 INTRODUCTION OF NECESSARY TOOLS…150
21.2 TORQUE LIST…151
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…152
23. MAINTENANCE SCHEDULE CHART…154
23.1 MAINTENANCE SCHEDULE CHART…154
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…156
24. SERVICE PROCEDURE…157
24.1 INITIAL 100 HOURS SERVICE…157
24.2 INITIAL 250 HOURS SERVICE…157
24.3 INITIAL 500 HOURS SERVICE…157
24.4 WHEN REQUIRED…158
24.5 CHECK BEFORE STARTING…173
24.6 EVERY 100 HOURS SERVICE…178
24.7 EVERY 250 HOURS SERVICE…179
24.8 EVERY 500 HOURS SERVICE…183
24.9 EVERY 2000 HOURS SERVICE…187
SPECIFICATIONS…192
25. SPECIFICATIONS…193
OPTIONS,ATTACHMENTS…196
26. GENERAL PRECAUTIONS…197
26.1 PRECAUTIONS RELATED TO SAFETY…197
27. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…198
27.1 SPECIFICATIONS,USES…198
27.2 ATTACHMENTS INSTALLATION COMBINATION…199
28. HANDLING BUCKET WITH HOOK…200
28.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…200
28.2 PROHIBITED OPERATIONS…200
28.3 PRECAUTIONS DURING OPERATIONS…201
29. HANDLING 2-WAY PIPING…202
29.1 SWITCHING BETWEEN 1-WAY AND 2-WAY…202
29.2 OPERATING PEDAL…202
29.3 METHOD OF USING PEDAL LOCK…203
VARIABLE GAUGE…204
30. HANDLING VARIABLE GAUGE SPECIFICATION MACHINE…205
31. PRECAUTIONS DURING OPERATION…206
31.1 TOWING…206
32. POSITION FOR ATTACHING SAFETY LABELS…207
32.1 POSITION FOR ATTACHING SAFETY LABELS…207
33. OPERATIONS…209
33.1 METHOD OF OPERATING VARIABLE GAUGE…209
33.2 PRECAUTIONS WHEN DIGGING…210
33.3 METHOD OF OPERATING VARIABLE BLADE…210
34. SPECIFICATION…211

Komatsu Hydraulic Excavator PC03 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete technical Parts Manual for Komatsu Articulated Dump Trucks HM400 series, with all the OEM parts information to maintain, service, and repair like professional mechanics.

0000864C – Komatsu Articulated Dump Trucks HM400-5 (S_N 10001-UP) Parts Catalog.pdf

PRODUCT DETAILS:
Total Pages: 817 pages
File Format: PDF
Language: English
Document Type: Parts Catalog
NOTES: Repair Service Manual (Electrical Wiring Diagrams included) available upon request

TABLE OF CONTENTS…2
AUXILIARY PARTS AND TOOL…3
AUXILIARY PARTS AND TOOL…4
General Tool Set 10001 …5
General Tool Set EU Safety Reg…7
General Tool Set…8
Jack 10001 …9
Jack…10
Payload Meter Soft 10001 …11
Payload Meter Soft 10446 …12
Payload Meter Soft Version 1 7…13
Payload Meter Soft Version 1 8…14
Payload Meter Soft Version 2 0…15
Spare Parts 10001 …16
Spare Parts With Body Heating…17
Spare Parts Without Body Heati…18
USB Serial Converter 10446 …19
USB Serial Converter…20
BODY…21
Body 10001 …22
Body With Body Heating Side E…23
Body With Body Heating Tail G…24
Body With Body Heating…25
Body With Side Extension 200mm…26
Body With Steel Liners Body H…27
Body With Tail Gate Side Exte…28
Body With Tail Gate…29
Body Related Parts 10001 …30
Body Related Parts With Body H…32
Body Related Parts Without Bod…33
Body Tail Gate 10001 …34
Body Tail Gate…36
Body…37
Hoist Cylinder L H 10001 …38
Hoist Cylinder Piping 10001 …40
Hoist Cylinder R H 10001 …42
Hoist Cylinder…44
COOLING SYSTEM…45
Aftercooler 10001 …46
Aftercooler Baffle 10001 …47
Aftercooler Bracket 10001 …48
Aftercooler Cover Mounting Bra…50
Aftercooler Fan 10001 …51
Aftercooler Fan Guard 10001 …52
Aftercooler Fan Motor 1 3 …53
Aftercooler Fan Motor 2 3 …54
Aftercooler Fan Motor 3 3 …56
Aftercooler Fan Motor Piping …58
Aftercooler Fan Motor Wiring H…60
Aftercooler…61
Brake Oil Cooler 10001 …62
Brake Oil Cooler…64
COOLING SYSTEM…65
Radiator 10001 …66
Radiator Coolant Piping 1 2 …67
Radiator Coolant Piping 2 2 …69
Radiator Cover 10001 …70
Radiator Fan 10001 …71
Radiator Fan Motor 1 3 100…72
Radiator Fan Motor 2 3 100…74
Radiator Fan Motor 3 3 100…75
Radiator Fan Motor Mounting Br…76
Radiator Fan Motor Piping 10…77
Radiator Freon Piping 10001 …78
Radiator Sheet 10001 …79
Radiator Related Miscellaneous …80
Radiator…81
ELECTRICAL SYSTEM…82
Battery Box Battery 10001 …84
Battery Box Battery Mounting …85
Battery Box Box 10001 …86
Battery Box Cab Tilt Pump 10…87
Battery Box Circuit Breaker …89
Battery Box Cover 10001 …91
Battery Box Disconnect Switch …93
Battery Box Handrail 10001 …94
Battery Box Parts for Less Cab…95
Battery Box Relay 10001 1023…96
Battery Box Relay 10233 …97
Battery Box Wiring Harness 1…98
Battery Box With Cab Tilt Pump…99
Battery Box With Fog Lamp…100
Battery Box With Large Capacit…101
Battery Box Without Large Capa…102
Battery Related Parts Battery …103
Battery Related Parts Heater W…104
Battery Related Parts Secondar…105
Battery Related Parts Starting…107
Battery Related Parts…108
ELECTRICAL SYSTEM…109
Front Wiring Harness Articulat…110
Front Wiring Harness Ground Ca…111
Front Wiring Harness Mounting …112
Front Wiring Harness Wiring Ha…114
Front Wiring Harness With Payl…115
Front Wiring Harness Without P…116
Payload Meter Wiring Harness F…117
Payload Meter Wiring Harness R…118
Payload Meter Wiring Harness S…119
Payload Meter Wiring Harness…120
Rear Combination Lamp and Backu…121
Rear Wiring Harness 10001 1…123
Rear Wiring Harness 10399 …125
Rear Wiring Harness…127
Side Lamp 10001 …128
Side Lamp…129
ENGINE RELATED PARTS…130
Cab AM FM Radio AUX North Am…133
Cab Accelerator Pedal 10001 …135
Cab Accelerator Pedal Mounting…136
Cab Accessory 10001 …137
Cab Air Conditioner Duct 100…139
Cab Air Conditioner Duct Fron…140
Cab Air Conditioner Duct Rear…141
Cab Air Conditioner Fresh Air …142
Cab Air Conditioner Piping 1…143
Cab Air Conditioner Recirculat…144
Cab Auxiliary Seat 10001 …145
Cab Body 10001 …146
Cab Box 10001 …147
Cab Brake Pedal 10001 …148
Cab Brake Piping 10001 …150
Cab Column Switch 10001 …151
Cab Console Box Case 10001 …152
Cab Console Box Switch 10001…153
Cab Controller 10001 …154
Cab Cover 10001 …155
Cab Dashboard 10001 …156
Cab Dashboard Cover 10001 …157
Cab Dashboard Mounting 10001…158
Cab Decal 10001 …159
Cab Door L H 10001 …160
Cab Door Closer and Door Lock …161
Cab Door Cover L H 10001 …162
Cab Door Lock 10001 …163
Cab Drink Box 10001 …164
Cab Dump Control 1 2 10001…165
Cab Dump Control 2 2 10001…166
Cab Dump Lever 10001 …167
Cab Front and Rear Wiper 100…168
Cab Gear Shift Lever 10001 …170
Cab Glass Window 10001 …171
Cab Heater Piping 10001 …172
Cab Inner Parts Air Condition…173
Cab Inner Parts Operator s Se…174
Cab Instrument Panel Switch …175
Cab KOMATSU Mark 10001 …176
Cab KOMTRAX Controller and Ant…177
Cab Monitor 10001 …178
Cab Operator s Seat Mounting …179
Cab Payload Meter Controller …180
Cab Radio 10001 …181
Cab Radio Antenna 10001 …182
Cab Rear Cover 10001 …183
Cab Roof Pad 10001 …184
Cab Seat Belt 10001 …185
Cab Sheet 10001 …186
Cab Side Cover 10001 …187
Cab Starting Switch 10001 …188
Cab Steering Column 1 2 10…189
Cab Steering Column 2 2 10…191
Cab Steering Piping 10001 …192
Cab Steering Valve 10001 …194
Cab Steering Wheel 10001 …195
Cab Ventilator 10001 …196
Cab Wiring Harness Mounting …197
Cab Working Lamp 10001 …199
ENGINE RELATED PARTS…200
Engine Mounting 10001 …201
Engine Mounting…202
Engine Related Parts 140 Amp …203
Engine Related Parts 90Amp Al…204
Engine Related Parts Aftercool…205
Engine Related Parts Air Intak…206
Engine Related Parts Cooling P…207
Engine Related Parts Damper …208
Exhaust Piping 10001 …209
Exhaust Piping With Body Heati…211
Exhaust Piping Without Body He…212
FIELD REPAIR SERVICE PARTS…213
FIELD REPAIR SERVICE PARTS…214
Service Kit Parts…215
FRAME AND ITS RELATED PARTS…218
Articulate Lock Bar 10001 …220
Articulate Lock Bar…221
Body Positioner 10001 10398…222
Body Positioner 10399 …223
Body Positioner…225
Exhaust Piping DEF Mixing Tube…226
Exhaust Piping Komatsu Diesel …227
Exhaust Piping Protection Cove…228
Exhaust Piping SCR Assembly …229
Exhaust Piping SCR Assembly Co…231
Exhaust Piping SCR Assembly Mo…232
Exhaust Piping SCR Assembly Ou…233
Exhaust Piping SCR Assembly Wi…234
Exhaust Piping With Body Heati…235
Exhaust Piping Without Body He…236
FRAME AND ITS RELATED PARTS…237
Front Frame 10001 …238
Front Frame With Payload Meter…239
Front Frame Without Payload Me…240
Hinge Pin 10001 …241
Hinge Pin…242
Hitch Frame 10001 …243
Hitch Frame Hinge 10001 …244
Hitch Frame Sub 10001 …245
Hitch Frame Sub…246
Hitch Frame…247
Rear Exhaust Piping 10001 …248
Rear Exhaust Piping Hoist Pipi…250
Rear Exhaust Piping With Body …251
Rear Exhaust Piping Without Bo…252
Rear Frame 10001 …253
Rear Frame With Payload Meter…254
Rear Frame With Tire Stopper …255
Rear Frame With Tire Stopper…256
Rear Frame Without Tire Stoppe…257
Steering Cylinder L H 10001…258
Steering Cylinder L H 10043…260
Steering Cylinder Pin 10001 …262
Steering Cylinder R H 10001…263
Steering Cylinder R H 10043…265
Steering Cylinder Steering Cyl…267
Steering Cylinder…268
Tire Stopper 10001 …269
Tire Stopper…270
FUEL SYSTEM…271
FUEL SYSTEM…272
Fuel Piping 10001 …273
Fuel Piping Fuel Tank Breather…274
Fuel Piping…276
Fuel Tank Group Cover 10001 …277
Fuel Tank Group DEF Pump 100…279
Fuel Tank Group DEF Related Pa…280
Fuel Tank Group DEF Tank 100…282
Fuel Tank Group Fuel Tank 10…284
Fuel Tank Group…286
Fuel Tank Related Parts Air Cl…287
Fuel Tank Related Parts Partit…288
Fuel Tank Related Parts Tank M…289
Fuel Tank Related Parts…290
GUARDS AND COVERS…291
Battery Box Mounting 10001 …293
Battery Box Mounting…294
Bumper Unit 10001 …295
Bumper Unit…296
Engine Hood Related Parts Cove…297
Engine Hood Related Parts Gril…298
Engine Hood Related Parts Hing…299
Engine Hood Related Parts Pipi…300
Engine Hood Related Parts Rela…301
Engine Hood Related Parts Rese…302
Engine Hood Related Parts…304
Engine Under Guard 10001 …305
Engine Under Guard…306
Fender Related Parts Exterior …307
Fender Related Parts Fender Co…309
Fender Related Parts Mounting …311
Fender Related Parts Mudguard …312
Fender Related Parts…313
GUARDS AND COVERS…314
Hood 10001 …315
Hood Accessory 10001 …317
Hood Catch 10001 …318
Hood Headlamp and Horn 10001…319
Hood Lock 10001 …321
Hood Mounting Bracket 10001 …323
Hood Seal 10001 …324
Hood With Fog Lamp…325
Hood Without Fog Lamp…326
Left Fender Fender 10001 103…327
Left Fender Fender 10368 …328
Left Fender Guard 10001 1036…329
Left Fender Guard 10368 …330
Left Fender Mudguard 10001 1…331
Left Fender Mudguard 10368 …332
Left Fender Side Mirror 1000…333
Left Fender Side Mirror 1036…334
Left Fender Side Mirror and Ha…335
Left Fender With Payload Meter…336
Left Fender With Rearview Mirr…337
Left Fender Without Payload Me…338
Right Fender Cover and Guard …339
Right Fender DEF Tank Coolant …341
Right Fender Fender 10001 …342
Right Fender Heater Mirror Wir…343
Right Fender Piping Mounting …344
Right Fender Side Mirror 100…345
Right Fender With Rearview Mir…347
Right Fender Without Rearview …348
Step Front L H 10001 …349
Step Rear R H 10001 …350
Step…351
Transmission Under Guard 1000…352
Transmission Under Guard…353
HYDRAULIC SYSTEM…354
Accumulator Charge Valve 100…356
Accumulator Cooling Oil Filter…358
Accumulator For USA and Canada…359
Accumulator Inner Parts 1000…360
Accumulator Inner Parts 1024…361
Accumulator Inner Parts R2 Ty…362
Accumulator Mounting Bracket …363
Accumulator Piping 10001 …365
Accumulator Wiring Harness 1…367
Accumulator Mounting 10001 …368
Accumulator Mounting…370
Accumulator…371
Brake Oil Cooling Piping Front…372
Brake Oil Cooling Piping Rear …373
Brake Oil Sub tank 10001 …375
Brake Oil Sub tank…377
Front Brake Oil Piping Breathe…378
Front Brake Oil Piping EPC Val…379
Front Brake Oil Piping Front S…380
Front Brake Oil Piping Piping …381
Front Brake Oil Piping Shuttle…383
Front Brake Oil Piping Slack A…384
Front Brake Oil Piping Solenoi…385
Front Brake Oil Piping With Au…387
Front Brake Oil Piping With Pa…388
Front Brake Oil Piping Without…389
Front Steering and Hoist Hydrau…390
HYDRAULIC SYSTEM…392
Hydraulic Tank 10001 …393
Hydraulic Tank Coupling 1000…395
Hydraulic Tank Fuel Tank Breat…396
Hydraulic Tank Mounting Parts …397
Hydraulic Tank Piping 1 3 …398
Hydraulic Tank Piping 2 3 …399
Hydraulic Tank Piping 3 3 …400
Hydraulic Tank Secondary Steer…401
Hydraulic Tank Wiring Harness …402
Hydraulic Tank Mounting and Cov…403
Hydraulic Tank Related Parts C…404
Hydraulic Tank Related Parts…405
Hydraulic Tank…406
Rear Brake Oil Piping EPC Valv…407
Rear Brake Oil Piping Piping M…408
Rear Brake Oil Piping Shuttle …410
Rear Brake Oil Piping With Aut…411
Rear Brake Oil Piping Without …412
Rear Steering and Hoist Hydraul…413
Transmission Oil Filter 10001…415
Transmission Oil Filter…417
MARKS AND PLATES…418
MARKS AND PLATES…419
Marks and Name Plates 1 3 …420
Marks and Name Plates 2 3 …421
Marks and Name Plates 3 3 …422
Marks and Name Plates English …423
Marks and Name Plates French …424
OPERATOR S COMPARTMENT AND CONT…425
Cab 12V converter 10001 …428
Cab AM FM Radio AUX Europe …429
Cab AM FM Radio AUX North Am…431
Cab Accelerator Pedal 10001 …433
Cab Accelerator Pedal Mounting…434
Cab Accessory 10001 …435
Cab Air Conditioner Duct 100…437
Cab Air Conditioner Duct Fron…438
Cab Air Conditioner Duct Rear…439
Cab Air Conditioner Fresh Air …440
Cab Air Conditioner Piping 1…441
Cab Air Conditioner Recirculat…442
Cab Auxiliary Seat 10001 …443
Cab Body 10001 …444
Cab Box 10001 …445
Cab Brake Pedal 10001 …446
Cab Brake Piping 10001 …448
Cab Column Switch 10001 …449
Cab Console Box Case 10001 …450
Cab Console Box Switch 10001…451
Cab Controller 10001 …452
Cab Cover 10001 …453
Cab Dashboard 10001 …454
Cab Dashboard Cover 10001 …455
Cab Dashboard Mounting 10001…456
Cab Decal 10001 …457
Cab Door L H 10001 …458
Cab Door Closer and Door Lock …459
Cab Door Cover L H 10001 …460
Cab Door Lock 10001 …461
Cab Drink Box 10001 …462
Cab Dump Control 1 2 10001…463
Cab Dump Control 2 2 10001…464
Cab Dump Lever 10001 …465
Cab Electric Parts 10001 …466
Cab Floor Wiring Harness 100…467
Cab Front and Rear Wiper 100…469
Cab Gear Shift Lever 10001 …471
Cab Glass Window 10001 …472
Cab Heater Piping 10001 …473
Cab Inner Parts Air Condition…474
Cab Inner Parts Operator s Se…475
Cab Instrument Panel Switch …476
Cab KOMATSU Mark 10001 …477
Cab KOMTRAX Controller and Ant…478
Cab Monitor 10001 …479
Cab Operator s Seat Mounting …480
Cab Payload Meter Controller …481
Cab Radio 10001 …482
Cab Radio Antenna 10001 …483
Cab Radio Less 10001 …484
Cab Rear Cover 10001 …485
Cab Relay 10001 …486
Cab Roof Pad 10001 …487
Cab Seat Belt 10001 …488
Cab Sheet 10001 …489
Cab Side Cover 10001 …490
Cab Speakers and Radio Wiring …492
Cab Starting Switch 10001 …494
Cab Steering Column 1 2 10…495
Cab Steering Column 2 2 10…497
Cab Steering Piping 10001 …498
Cab Steering Valve 10001 …500
Cab Steering Wheel 10001 …501
Cab Switch 10001 …502
Cab Ventilator 10001 …503
Cab Wiring Harness Mounting …504
Cab Working Lamp 10001 …506
Cab Guard 10001 …507
Cab Guard…508
Cab Mounting 10001 10367 …509
Cab Mounting 10368 …511
Cab Mounting…513
Cab Option Switch 10001 …514
Cab Option Switch Amber Color …516
Cab Option Switch Auto Idle St…517
Cab Option Switch Automatic Re…518
Cab Option Switch Fog Lamp…519
Cab Option Switch Parts for Le…520
Cab Option Switch Payload Mete…521
Cab Option Switch Rearview Mir…522
Cab Option Switch…523
Cab Tilt Bar Tilt Bar 10001 …524
Cab Tilt Bar…525
Cab Tilt Cylinder and Its Relat…526
Floor Mat 10001 10244 …528
Floor Mat 10245 …529
Floor Mat…530
OPERATOR S COMPARTMENT AND CONT…531
OTHER EQUIPMENT…532
Air Conditioner Related Parts …533
Air Conditioner Related Parts…535
Cap Lock 10001 …536
Cap Lock…537
OTHER EQUIPMENT…538
Parts For Less Fire Extinguishe…539
Rearview Camera 10001 …540
Rearview Camera…541
POWER TRANSMITTING SYSTEM…542
Axle Support Mounting 10001 …545
Axle Support Mounting…546
Center Axle Brake Cooling Pipi…547
Center Axle Brake Piping 100…548
Center Axle Breather 10001 …550
Center Axle Cover 10001 …552
Center Axle Differential 100…553
Center Axle Differential Pini…555
Center Axle Drive Shaft Guard …557
Center Axle Final Drive Brake…558
Center Axle Final Drive L H …560
Center Axle Final Drive R H …562
Center Axle Housing 10001 …564
Center Axle Input Shaft 1000…565
Center Axle Output Shaft 100…567
Center Axle Piping L H 100…568
Center Axle Piping R H 100…569
Center Axle Sensor Clamp 100…570
Center Axle Support 10001 …571
Center Axle…572
Front Axle Brake Cooling Pipin…573
Front Axle Brake Piping 1000…575
Front Axle Drive Shaft 10001…576
Front Axle Final Drive Brake …577
Front Axle Final Drive L H …578
Front Axle Final Drive R H …580
Front Axle Piping L H 1000…582
Front Axle Piping R H 1000…583
Front Axle Related Parts 100…584
Front Axle Support 10001 …585
Front Axle…587
Front Lubrication Piping L H …588
Front Lubrication Piping R H …589
Front Lubrication Piping…590
POWER TRANSMITTING SYSTEM…591
Parking Brake 10001 …592
Parking Brake…594
Rear Axle Differential 10001…595
Rear Axle Final Drive L H 1…597
Rear Axle Final Drive R H 1…599
Rear Axle Housing 10001 …601
Rear Axle Pinion and Cage 10…602
Rear Axle Support 10001 …603
Rear Axle…604
Rear Drive Shaft 10001 …605
Rear Drive Shaft…607
Rear Lubrication Piping 10001…608
Rear Lubrication Piping…609
Transmission Group 2nd and 3rd…610
Transmission Group Accessory …612
Transmission Group Aftercooler…614
Transmission Group Block Pipin…615
Transmission Group Case 1000…617
Transmission Group Center Brak…619
Transmission Group Charge Pump…620
Transmission Group Connecting …621
Transmission Group Control Val…622
Transmission Group Differentia…624
Transmission Group Drive Case …626
Transmission Group Drive Shaft…627
Transmission Group EPC Valve P…628
Transmission Group Elbow 100…629
Transmission Group Forward Hig…630
Transmission Group Forward Low…631
Transmission Group Front Diffe…632
Transmission Group Input Coupl…633
Transmission Group Mounting …634
Transmission Group Oil Cooler …635
Transmission Group Oil Filter …636
Transmission Group Output Coup…638
Transmission Group PTO Power …640
Transmission Group Piping 10…641
Transmission Group Piping Moun…643
Transmission Group Power Train…644
Transmission Group Pump Piping…645
Transmission Group Pump Relate…646
Transmission Group Pump and Tu…647
Transmission Group Radiator Fa…648
Transmission Group Relief Valv…649
Transmission Group Sensor 10…650
Transmission Group Steering an…651
Transmission Group Suction Pip…652
Transmission Group Trunnion …654
Transmission Group…655
SAA006D140E-7B (S_N 830022-UP)…657
Air Connection 830022 …661
Air Connection…662
Air Intake Manifold and Connect…663
Alternator 140 Amp …665
Alternator 90Amp …666
Alternator Alternator and Moun…667
Alternator Freon Compressor …669
Alternator Inner Parts 83002…670
Alternator Mounting Parts 83…672
Cam Follower Cover 830022 …674
Cam Follower Cover…675
Camshaft 830022 …676
Camshaft Related Parts Cam Fol…677
Camshaft Related Parts Rocker …678
Camshaft Related Parts…679
Camshaft…680
Crank Pulley 830022 …681
Crank Pulley…682
Crankshaft 830022 …683
Crankshaft…685
Cylinder Block 830022 …686
Cylinder Block Related Parts …688
Cylinder Block Related Parts…690
Cylinder Block…691
Cylinder Head 830022 …692
Cylinder Head…694
ENGINE ACCESSORIES AND OTHERS…695
ENGINE COOLING SYSTEM…696
ENGINE CYLINDER BLOCK AND ITS R…697
ENGINE CYLINDER HEAD AND ITS RE…698
ENGINE ELECTRICAL SYSTEM…699
ENGINE FUEL SYSTEM…700
ENGINE LUBRICATION SYSTEM…701
ENGINE MARKS AND PLATES…702
Engine Controller 830022 …703
Engine Controller For EU Exhau…705
Engine Controller For North Am…706
Engine Oil Cooler 830022 …707
Engine Oil Cooler…708
Engine Oil Filter 830022 …709
Engine Oil Filter…711
Engine Oil Pump 830022 …712
Engine Oil Pump…713
Engine Support 830022 …714
Engine Support…715
Exhaust Gas Re circulation EGR…716
Exhaust Manifold 830022 …718
Exhaust Manifold…719
Flywheel 830022 …720
Flywheel Housing 830022 …721
Flywheel Housing…722
Flywheel…723
Front Cover 830022 …724
Front Cover Accessory 830022 …725
Front Cover Accessory…726
Front Cover…727
Fuel Filter Air Vent 830022 …728
Fuel Filter Filter Bracket 8…729
Fuel Filter Piping 1 2 830…730
Fuel Filter Piping 2 2 830…732
Fuel Filter Priming Pump 830…733
Fuel Filter…735
Fuel Injection Nozzle 830022 …736
Fuel Injection Nozzle…737
Fuel Prefilter 830022 …738
Fuel Prefilter…739
Fuel Return 830022 …740
Fuel Return…741
Fuel Supply Pump Common Rail …742
Fuel Supply Pump Inner Parts …743
Fuel Supply Pump Piping 8300…744
Fuel Supply Pump Pump Mounting…746
Fuel Supply Pump Bracket and Pi…747
Fuel Supply Pump Drive 830022…748
Fuel Supply Pump Drive…749
Fuel Supply Pump…750
Head Cover 830022 …751
Head Cover…752
Heat Shield 830022 …753
Heat Shield…755
Idle Gears 830022 …756
Idle Gears…757
Komatsu Closed Crankcase Ventil…758
Name Plate and Caution Plate …760
Name Plate and Caution Plate F…761
Oil Pan and Suction Tube Oil G…762
Oil Pan and Suction Tube Oil P…763
Oil Pan and Suction Tube…765
Piston and Connecting Rod 830…766
Piston and Connecting Rod…767
Starting Motor Inner Parts 8…768
Starting Motor Mounting 8300…770
Starting Motor…771
Variable Geometry Turbocharger …772
Vibration Damper 830022 …774
Vibration Damper…775
Water Pump Air Vent and Thermo…776
Water Pump Inner Parts 83002…778
Water Pump…780
Wiring Harness 1 4 830022 …781
Wiring Harness 2 4 830022 …783
Wiring Harness 3 4 830022 …785
Wiring Harness 4 4 830022 …787
Wiring Harness…789
SUSPENSION WHEEL AND THEIR REL…790
Front Suspension Cylinder L H …791
Front Suspension Cylinder R H …793
Parts For Less Rim Mounting Pa…795
Parts For Less Rim Tires and R…796
Rear Suspension Equalizer Bar …797
Rear Suspension Inner Parts …798
Rear Suspension With Payload M…800
Rear Suspension With Tail Gate…801
Rear Suspension Without Payloa…802
Rim 10001 …803
Rim For Wide Tire…804
Rim Mounting Parts 10001 …805
Rim Without Wide Tire…806
SUSPENSION WHEEL AND THEIR REL…807
Tire 10001 …808
Tire 29 50 R25 E2 VLT Bridges…809
Tire 29 50 R25 E3 T351 Toyo…810
Tire 29 50 R25 E3T XADN Mich…811
Tire 29 50 R25 E4 VLTS Bridge…812
Tire 29 50 R25 E4 XADT Michel…813
Tire 29 50 R25 Two Star RT41 …814
Tire 29 50 R25 VKT Bridgeston…815
Tire 29 50 R25 X SUPER TERRAIN…816
Tire 875 65 R29 SUPER E3T XAD6…817

Komatsu Articulated Dump Trucks HM400 series Parts Catalog

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM350-2R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM350-2R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN03017-08 – Articulated Dump Truck HM350-2R Shop Manual.pdf
PEN00476-11 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual.pdf
PEN00380-00 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual.pdf
PEN00223-06 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual.pdf
GEN00080-00 – Articulated Dump Truck GALEO HM350-2R Field Assembly Instruction.pdf

PRODUCT DETAILS:
Total Pages: 2,346 pages
File Format: PDF
Language: English

MAIN SECTIONS
GEN00080-00 – Articulated Dump Truck GALEO HM350-2R Field Assembly Instruction….2
COVER….2
CONTENTS….3
1 DRAWINGS OF REMOVED UNITS….5
2 DIMENSIONS OF REMOVED UNITS….5
3 ASSEMBLY PROCEDURE, NECESSARY EQUIPMENTS, AND SCHEDULE….6
4 NECESSARY TOOLS AND EQUIPMENTS….6
5 ASSEMBLY PROCEDURE….7
0100 POSITIONING BARE MACHINE….7
0200 INSTALLATION OF RIGHT AND LEFT MUDGUARDS….8
0300 INSTALLATION OF REAR MONITOR….9
0400 INSTALLING ENGINE HOOD MIRROR….10
0500 ADJUSTING N2 GAS OF FRONT AND REAR SUSPENSIONS….11
ATTACHED SHEET: MIRROR ADJUSTMENT PROCEDURE….12
PEN00223-06 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual….15
COVER….15
FOREWORD….16
BEFORE READING THIS MANUAL….17
SAFETY INFORMATION….18
INTENDED USE….19
USE OF MACHINE….19
DIRECTIONS OF MACHINE….19
VISIBILITY FROM OPERATOR'S SEAT….19
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….20
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….20
EPA REGULATIONS, ENGINE NUMBER PLATE….20
SERVICE METER POSITION….21
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….21
CONTENTS….22
SAFETY….26
SAFETY….27
SAFETY LABELS….30
POSITION FOR ATTACHING SAFETY LABELS….31
SAFETY LABELS….32
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….38
PRECAUTIONS BEFORE STARTING OPERATION….38
PREPARATIONS FOR SAFE OPERATION….38
FIRE PREVENTION….40
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….41
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY….43
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….43
UNAUTHORIZED MODIFICATION….43
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….44
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….44
PRECAUTIONS FOR OPERATION….45
PRECAUTIONS FOR JOBSITE….45
STARTING ENGINE….47
OPERATION….50
TRANSPORTATION….54
TOWING….55
PRECAUTIONS FOR MAINTENANCE….56
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….56
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….61
TIRES….66
OPERATION….68
GENERAL VIEW….69
GENERAL VIEW OF MACHINE….69
GENERAL VIEW OF CONTROLS AND GAUGES….70
EXPLANATION OF COMPONENTS….72
MACHINE MONITOR….72
OTHER FUNCTIONS OF MACHINE MONITOR….93
SWITCHES….97
CONTROL LEVERS AND PEDALS….108
BODY PIVOT PIN….113
ARTICULATE LOCK….113
LOCATION OF FIRE EXTINGUISHER….114
DUST INDICATOR….114
CIRCUIT BREAKER….114
FUSES….115
CAR RADIO….118
CAR STEREO….124
AIR CONDITIONER….132
OPERATION….137
CHECK BEFORE STARTING ENGINE….137
STARTING ENGINE….151
OPERATIONS, CHECKS AFTER STARTING ENGINE….153
STOPPING ENGINE….154
CHECKS AFTER STOPPING ENGINE….154
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….155
SHIFTING GEAR….160
TRAVELING DOWNHILL….162
STEERING THE MACHINE….168
OPERATION USING DIFFERENTIAL LOCK….168
LOADING OPERATIONS….171
DUMP OPERATIONS….172
CAB TILT OPERATION….174
PRECAUTIONS FOR OPERATION….177
PARKING MACHINE….178
CHECKS AFTER COMPLETION OF WORK….179
LOCKING….179
HANDLING TIRES….180
DETERMINING AND MAINTAINING TRAVEL ROAD….181
DETERMINING TRAVEL ROAD….181
MAINTAINING TRAVEL ROAD….181
TRANSPORTATION….182
PRECAUTIONS WHEN TRANSPORTING….182
STEPS FOR TRANSPORTATION….182
METHOD OF SECURING MACHINE….183
METHOD OF LIFTING MACHINE….184
COLD WEATHER OPERATION….188
PRECAUTIONS FOR LOW TEMPERATURE….188
PRECAUTIONS AFTER COMPLETION OF WORK….189
AFTER COLD WEATHER….190
LONG-TERM STORAGE….191
BEFORE STORAGE….191
DURING STORAGE….191
AFTER STORAG….191
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….191
TROUBLESHOOTING….192
AFTER RUNNING OUT OF FUEL….192
IF TRANSMISSION HAS TROUBLE….193
METHOD OF LOWERING DUMP BODY IN EMERGENCY….193
METHOD OF TOWING MACHINE….194
IF BATTERY IS DISCHARGED….198
OTHER TROUBLE….201
MAINTENANCE….208
GUIDES TO MAINTENANCE….209
OUTLINE OF SERVICE….211
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….211
OUTLINE OF ELECTRIC SYSTEM….215
WEAR PARTS….216
WEAR PARTS LIST….216
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….217
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….218
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….219
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….220
TORQUE LIST….220
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….222
SAFETY CRITICAL PARTS….223
MAINTENANCE SCHEDULE CHART….224
MAINTENANCE SCHEDULE CHART….224
SERVICE PROCEDURE….227
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….227
WHEN REQUIRED….228
CHECK BEFORE STARTING….245
EVERY 50 HOURS SERVICE….246
EVERY 250 HOURS SERVICE….247
EVERY 500 HOURS SERVICE….261
EVERY 1000 HOURS SERVICE….268
EVERY 2000 HOURS SERVICE….280
EVERY 4000 HOURS SERVICE….287
EVERY 6000 HOURS SERVICE….290
EVERY 8000 HOURS SERVICE….291
SPECIFICATIONS….292
SPECIFICATIONS….293
ATTACHMENTS, OPTIONS….294
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTIROL(ARAC)….295
EXPLANATION OF COMPONENTS….295
METHOD OF OPERATION….296
USE OF REAR VIEW MONITOR….297
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….297
SETTING OF REAR VIEW MONITOR….300
CAUTIONS WHEN USING REAR VIEW MONITOR….300
HANDLING DUMPING COUNTER….301
HANDLING BATTERY DISCONNECTOR SWITCH….302
HANDLING MACHINES EQUIPPED WITH KOMTRAX….304
BASIC PRECAUTIONS….304
INDEX….306
PEN00380-00 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual….310
COVER….310
FOREWORD….311
BEFORE READING THIS MANUAL….312
SAFETY INFORMATION….313
INTENDED USE….314
USE OF MACHINE….314
DIRECTIONS OF MACHINE….314
VISIBILITY FROM OPERATOR'S SEAT….314
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….315
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….315
ENGINE SERIAL NO. PLATE….315
SERVICE METER POSITION….316
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….316
CONTENTS….317
SAFETY….321
SAFETY….322
SAFETY LABELS….325
POSITION FOR ATTACHING SAFETY LABELS….326
SAFETY LABELS….327
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….332
PRECAUTIONS BEFORE STARTING OPERATION….332
PREPARATIONS FOR SAFE OPERATION….332
FIRE PREVENTION….334
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….335
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY….337
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….337
UNAUTHORIZED MODIFICATION….337
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….338
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….338
PRECAUTIONS FOR OPERATION….339
PRECAUTIONS FOR JOBSITE….339
STARTING ENGINE….341
OPERATION….344
TRANSPORTATION….348
TOWING….349
PRECAUTIONS FOR MAINTENANCE….350
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….350
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….355
TIRES….360
OPERATION….363
GENERAL VIEW….364
GENERAL VIEW OF MACHINE….364
GENERAL VIEW OF CONTROLS AND GAUGES….365
EXPLANATION OF COMPONENTS….367
MACHINE MONITOR….367
OTHER FUNCTIONS OF MACHINE MONITOR….388
SWITCHES….392
CONTROL LEVERS AND PEDALS….403
BODY PIVOT PIN….408
ARTICULATE LOCK….408
LOCATION OF FIRE EXTINGUISHER….409
DUST INDICATOR….409
CIRCUIT BREAKER….409
FUSES….410
CAR RADIO….413
CAR STEREO….419
AIR CONDITIONER….427
OPERATION….432
CHECK BEFORE STARTING ENGINE….432
STARTING ENGINE….448
OPERATIONS, CHECKS AFTER STARTING ENGINE….450
STOPPING ENGINE….451
CHECKS AFTER STOPPING ENGINE….451
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….452
SHIFTING GEAR….457
TRAVELING DOWNHILL….459
STEERING THE MACHINE….465
OPERATION USING DIFFERENTIAL LOCK….465
LOADING OPERATIONS….468
DUMP OPERATIONS….469
CAB TILT OPERATION….471
PRECAUTIONS FOR OPERATION….474
PARKING MACHINE….475
CHECKS AFTER COMPLETION OF WORK….476
LOCKING….476
HANDLING TIRES….477
DETERMINING AND MAINTAINING TRAVEL ROAD….478
DETERMINING TRAVEL ROAD….478
MAINTAINING TRAVEL ROAD….478
TRANSPORTATION….479
PRECAUTIONS WHEN TRANSPORTING….479
STEPS FOR TRANSPORTATION….479
METHOD OF SECURING MACHINE….480
METHOD OF LIFTING MACHINE….481
COLD WEATHER OPERATION….485
PRECAUTIONS FOR LOW TEMPERATURE….485
PRECAUTIONS AFTER COMPLETION OF WORK….486
AFTER COLD WEATHER….487
LONG-TERM STORAGE….488
BEFORE STORAGE….488
DURING STORAGE….488
AFTER STORAGE….488
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….488
TROUBLESHOOTING….489
AFTER RUNNING OUT OF FUEL….489
IF TRANSMISSION HAS TROUBLE….489
METHOD OF LOWERING DUMP BODY IN EMERGENCY….489
METHOD OF TOWING MACHINE….490
IF BATTERY IS DISCHARGED….494
OTHER TROUBLE….498
MAINTENANCE….505
GUIDES TO MAINTENANCE….506
OUTLINE OF SERVICE….508
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….508
OUTLINE OF ELECTRIC SYSTEM….512
WEAR PARTS….513
WEAR PARTS LIST….513
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….514
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….515
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….516
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….517
TORQUE LIST….517
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….519
SAFETY CRITICAL PARTS….520
MAINTENANCE SCHEDULE CHART….521
MAINTENANCE SCHEDULE CHART….521
SERVICE PROCEDURE….524
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….524
WHEN REQUIRED….525
CHECK BEFORE STARTING….546
EVERY 50 HOURS SERVICE….547
EVERY 250 HOURS SERVICE….548
EVERY 500 HOURS SERVICE….562
EVERY 1000 HOURS SERVICE….569
EVERY 2000 HOURS SERVICE….580
EVERY 4000 HOURS SERVICE….587
EVERY 6000 HOURS SERVICE….590
EVERY 8000 HOURS SERVICE….591
SPECIFICATIONS….593
SPECIFICATIONS….594
ATTACHMENTS, OPTIONS….595
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)….596
EXPLANATION OF COMPONENTS….596
METHOD OF OPERATION….597
USE OF REAR VIEW MONITOR….598
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….598
SETTING OF REAR VIEW MONITOR….601
CAUTIONS WHEN USING REAR VIEW MONITOR….601
HANDLING DUMPING COUNTER….602
HANDLING BATTERY DISCONNECTOR SWITCH….603
HANDLING MACHINES EQUIPPED WITH KOMTRAX….605
BASIC PRECAUTIONS….605
INDEX….607
PEN00476-11 – Articulated Dump Truck HM350-2R Operation & Maintenance Manual….611
COVER….611
FOREWORD….612
BEFORE READING THIS MANUAL….613
SAFETY INFORMATION….614
INTENDED USE….615
USE OF MACHINE….615
DIRECTIONS OF MACHINE….615
VISIBILITY FROM OPERATOR'S SEAT….616
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….617
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….617
ENGINE SERIAL NO. PLATE….617
SERVICE METER POSITION….618
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….618
CONTENTS….619
SAFETY….622
SAFETY….623
SAFETY LABELS….626
POSITION FOR ATTACHING SAFETY LABELS….627
SAFETY LABELS….628
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….634
PRECAUTIONS BEFORE STARTING OPERATION….634
PREPARATIONS FOR SAFE OPERATION….634
FIRE PREVENTION….636
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….637
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY….639
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….639
UNAUTHORIZED MODIFICATION….639
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….640
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….640
PRECAUTIONS FOR OPERATION….641
PRECAUTIONS FOR JOBSITE….641
STARTING ENGINE….643
OPERATION….646
TRANSPORTATION….650
TOWING….651
PRECAUTIONS FOR MAINTENANCE….652
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….652
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….657
TIRES….662
OPERATION….664
GENERAL VIEW….665
GENERAL VIEW OF MACHINE….665
GENERAL VIEW OF CONTROLS AND GAUGES….666
EXPLANATION OF COMPONENTS….668
MACHINE MONITOR….668
OTHER FUNCTIONS OF MACHINE MONITOR….689
SWITCHES….693
CONTROL LEVERS AND PEDALS….704
BODY PIVOT PIN….709
ARTICULATE LOCK….709
LOCATION OF FIRE EXTINGUISHER….710
DUST INDICATOR….710
CIRCUIT BREAKER….710
FUSES….711
CAR RADIO….714
CAR STEREO….720
AIR CONDITIONER….728
OPERATION….733
CHECK BEFORE STARTING ENGINE….733
STARTING ENGINE….750
OPERATIONS, CHECKS AFTER STARTING ENGINE….752
STOPPING ENGINE….753
CHECKS AFTER STOPPING ENGINE….753
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….754
SHIFTING GEAR….759
TRAVELING DOWNHILL….761
STEERING THE MACHINE….767
OPERATION USING DIFFERENTIAL LOCK….768
LOADING OPERATIONS….771
DUMP OPERATIONS….772
CAB TILT OPERATION….774
PRECAUTIONS FOR OPERATION….777
PARKING MACHINE….778
CHECKS AFTER COMPLETION OF WORK….779
LOCKING….779
HANDLING TIRES….780
DETERMINING AND MAINTAINING TRAVEL ROAD….781
DETERMINING TRAVEL ROAD….781
MAINTAINING TRAVEL ROAD….781
TRANSPORTATION….782
PRECAUTIONS WHEN TRANSPORTING….782
STEPS FOR TRANSPORTATION….782
METHOD OF SECURING MACHINE….783
METHOD OF LIFTING MACHINE….784
COLD WEATHER OPERATION….788
PRECAUTIONS FOR LOW TEMPERATURE….788
PRECAUTIONS AFTER COMPLETION OF WORK….789
AFTER COLD WEATHER….790
LONG-TERM STORAGE….791
BEFORE STORAGE….791
DURING STORAGE….791
AFTER STORAGE….791
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….791
TROUBLESHOOTING….792
AFTER RUNNING OUT OF FUEL….792
IF TRANSMISSION HAS TROUBLE….792
METHOD OF LOWERING DUMP BODY IN EMERGENCY….793
METHOD OF TOWING MACHINE….794
IF BATTERY IS DISCHARGED….798
OTHER TROUBLE….802
MAINTENANCE….808
GUIDES TO MAINTENANCE….809
OUTLINE OF SERVICE….811
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….811
OUTLINE OF ELECTRIC SYSTEM….815
WEAR PARTS….816
WEAR PARTS LIST….816
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….817
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….818
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THANK OMATSU GENUINE OIL….820
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….821
TORQUE LIST….821
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….823
SAFETY CRITICAL PARTS….824
MAINTENANCE SCHEDULE CHART….825
MAINTENANCE SCHEDULE CHART….825
SERVICE PROCEDURE….828
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….828
WHEN REQUIRED….829
CHECK BEFORE STARTING….848
EVERY 50 HOURS SERVICE….849
EVERY 250 HOURS SERVICE….850
EVERY 500 HOURS SERVICE….864
EVERY 1000 HOURS SERVICE….871
EVERY 2000 HOURS SERVICE….891
EVERY 4000 HOURS SERVICE….898
EVERY 6000 HOURS SERVICE….901
EVERY 8000 HOURS SERVICE….902
SPECIFICATIONS….904
SPECIFICATIONS….905
ATTACHMENTS, OPTIONS….908
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)….909
EXPLANATION OF COMPONENTS….909
METHOD OF OPERATION….910
USE OF REAR VIEW MONITOR….911
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….911
SETTING OF REAR VIEW MONITOR….914
CAUTIONS WHEN USING REAR VIEW MONITOR….914
HANDLING DUMPING COUNTER….915
HANDLING BATTERY DISCONNECTOR SWITCH….916
HANDLING MACHINES EQUIPPED WITH KOMTRAX….918
BASIC PRECAUTIONS….918
INDEX….920
SEN03017-08 – Articulated Dump Truck HM350-2R Shop Manual….924
COVER….924
00 Index and foreword….0
Index….926
Composition of shop manual….927
Table of contents….929
Foreword and general information….940
Safety notice….941
How to read the shop manual….946
Explanation of terms for maintenance standard….948
Handling of electric equipment and hydraulic component….950
Handling of connectors newly used for engines….959
How to read electric wire code….962
Precautions when carrying out operation….965
Method of disassembling and connecting push-pull type coupler….968
Standard tightening torque table….971
Conversion table….975
01 Specification….0
Specification and technical data….982
Specification drawings….983
Specifications….984
Weight table….987
Fuel, coolant and lubricants….988
10 Structure, function and maintenance standard….0
Engine and cooling system….992
Radiator, oil cooler, aftercooler….993
Output shaft….994
Power train, Part 1….998
Power train skeleton….999
Torque converter and transmission hydraulic piping….1003
Brake cooling oil control valve (BCV)….1005
Power train pump….1006
Torque converter….1009
Transmission….1015
Transmission control valve….1043
ECMV….1044
Main relief, torque converter relief valve….1051
Power train, Part 2….1054
Drive shaft….1055
Axle….1059
Differential….1063
Limited slip differential….1077
Final drive….1081
Steering system….1088
Steering column….1089
Brake system….1092
Brake piping….1093
Brake valve….1095
Accumulator charge valve….1098
Accumulator….1102
Slack adjuster….1103
Brake….1105
Proportional reducing valve….1110
Brake system tank….1111
Parking brake….1113
Parking brake caliper….1115
Spring cylinder….1116
Parking brake solenoid….1117
Undercarriage and frame….1120
Suspension….1121
Suspension cylinder….1126
Oscillation hitch….1128
Hydraulic system….1132
Steering, hoist oil hydraulic piping diagram….1133
Dump body control….1134
Hydraulic tank and filter….1135
Flow amp valve….1136
Steering valve….1139
Steering cylinder….1143
Hoist valve….1145
EPC valve….1151
Pilot check valve….1152
Hoist cylinder….1153
Hydraulic pump….1154
Cab and its attachments….1158
ROPS cab….1159
Cab tilt….1160
Air conditioner….1161
Rear view monitor….1169
Controller related….1172
Electrical system, Part 1….1174
Machine monitor system….1175
Electrical system, Part 2….1196
Automatic shift control system….1197
Transmission controller….1200
Retarder control system….1229
Auto emergency steering system….1241
Dump control lever….1242
Electrical system, Part 3….1248
Sensors, switches….1249
KOMTRAX terminal system (if equipped)….1256
20 Standard value table….0
Standard service value table….1260
Standard value table for engine….1261
Standard value table for chassis….1262
30 Testing and adjusting….0
Testing and adjusting, Part 1….1268
Tools for testing, adjusting, and troubleshooting….1270
Sketches of special tools….1274
Measuring engine speed….1275
Testing intake air pressure (boost pressure)….1276
Testing exhaust temperature….1277
Testing exhaust gas color….1278
Adjusting valve clearance….1279
Testing compression pressure….1280
Testing blow-by pressure….1282
Testing engine oil pressure….1283
Handling of fuel system devices….1284
Releasing residual pressure from fuel system….1284
Testing fuel pressure….1285
Testing fuel return and leakage amount….1286
Bleeding air from fuel circuit….1289
Testing the fuel circuit for leakage….1291
Testing and adjusting fan belt tension….1292
Testing and adjusting alternator belt tension….1293
Testing and adjusting air conditioner compressor belt tension….1294
Adjusting the body mount….1295
Testing and adjusting, Part 2….1298
Testing torque converter stalls peed….1300
Testing power train oil pressure….1301
Testing and adjusting of differential lock oil pressure (differential lock spec.)….1309
Adjusting transmission speed sensor….1314
Testing and adjusting brake oil pressure….1316
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas….1320
Testing brake performance….1323
Bleeding air from brake circuit….1324
Testing wear of wheel brake disc….1325
Testing the parking brake pad wear….1326
Emergency release of the parking brake….1327
Testing and adjusting steering circuit oil pressure….1328
Testing and adjusting suspension cylinder….1330
Method of tilting cab up….1334
Testing and adjusting dump circuit oil pressure….1336
Adjusting body positioner sensor….1338
Adjusting length of spring in body heating spherical joint….1339
Handling of voltage circuit of engine controller….1339
Adjusting transmission controller….1339
Method for emergency escape at electrical system failure….1340
Testing and adjusting, Part 3….1346
Setting and adjusting various equipments….1347
Special function of machine monitor….1356
How to start operation of KOMTRAX terminal….1400
Lamp display of KOMTRAX terminal….1405
Pm Clinic check sheet….1408
40 Troubleshooting….0
Failure code table and fuse locations….1412
Failure codes table….1413
Fuse locations….1420
General information on troubleshooting….1428
Points to remember when troubleshooting….1429
Sequence of events in troubleshooting….1430
Check before troubleshooting….1431
Classification and procedures for troubleshooting….1432
Information in troubleshooting table….1435
Connection table for connector pin numbers….1437
T- branch box and T- branch adapter table….1473
Troubleshooting by failure code (Display of code), Part 1….1478
Failure code [1500L0] Detecting dual engagement….1480
Failure code [15B0NX] Transmission oil filter: Clogging….1481
Failure code [15F0KM] R → F gear shift abuse 1….1483
Failure code [15F0MB] R → F gear shift abuse 2….1483
Failure code [15F7KM] Transmission forward clutch abuse….1484
Failure code [15G0MW] Reverse clutch system failure (Slip is detected)….1485
Failure code [15G7KM] Transmission reverse clutch abuse….1487
Failure code [15H0MW] Hi clutch system failure (Slip is detected)….1489
Failure code [15J0MW] Lo clutch system failure (Slip is detected)….1491
Failure code [15K0MW] 1st clutch system failure (Slip is detected)….1493
Failure code [15L0MW] 2nd clutch system failure (Slip is detected)….1495
Failure code [15M0MW] 3rd clutch system failure (Slip is detected)….1497
Failure code [15SBL1] Reverse clutch pressure control valve failure I….1499
Failure code [15SBMA] Reverse clutch pressure control valve failure II….1503
Failure code [15SCL1] Hi clutch pressure control valve failure I….1505
Failure code [15SCMA] Hi clutch pressure control valve failure II….1509
Failure code [15SDL1] Lo clutch pressure control valve failure I….1511
Failure code [15SDMA] Lo clutch pressure control valve failure II….1513
Troubleshooting by failure code (Display of code), Part 2….1518
Failure code [15SEL1] 1st clutch pressure control valve failure I….1520
Failure code [15SEMA] 1st clutch pressure control valve failure II….1523
Failure code [15SFL1] 2nd clutch pressure control valve failure I….1525
Failure code [15SFMA] 2nd clutch pressure control valve failure II….1529
Failure code [15SGL1] 3rd clutch pressure control valve failure I….1531
Failure code [15SGMA] 3rd clutch pressure control valve failure II….1535
Failure code [15SJMA] Lockup clutch pressure control valve failure II….1537
Failure code [15SKMA] Interaxle differential lock clutch pressure control valve failure II….1539
Failure code [2A62L1] Front wheel differential lock pressure control valve failure II….1541
Failure code [2A62LH] Front wheel differential lock pressure control valve failure I….1543
Failure code [2B62L1] Rear wheel differential lock pressure control valve failure II….1545
Failure code [2B62LH] Rear wheel differential lock pressure control valve failure I….1547
Failure code [2C4MNX] Retarder cooling oil filter clogging….1549
Failure code [2F00KM] Dragging of parking brake….1551
Failure code [2G42ZG] Lowering of accumulator oil pressure (front)….1553
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)….1553
Failure code [989A00] Engine overrun prevention activated….1554
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)….1554
Failure code [A570NX] Engine oil filter clogging….1555
Failure code [AA10NX] Air cleaner clogging….1557
Failure code [AB00MA] Battery charge circuit failure….1559
Failure code [B@BAZG] Lowering of engine oil pressure….1560
Failure code [B@BAZK] Lowering of engine oil level….1561
Failure code [B@BCNS] Engine overheat….1562
Failure code [B@BCZK] Lowering of coolant level….1563
Failure code [B@C6NS] Overheat of brake cooling oil temperature (front)….1565
Failure code [B@C8NS] Overheat of brake cooling oil temperature (center)….1565
Failure code [B@CENS] Overheat of torque converter oil temperature….1566
Failure code [B@JANS] Overheat of steering oil temperature….1566
Troubleshooting by failure code (Display of code), Part 3….1568
Failure code [CA111] Engine controller critical internal failure….1571
Failure code [CA115] Engine Ne and Bkup speed sensors error….1573
Failure code [CA122] Charge air pressure high error….1575
Failure code [CA123] Charge air pressure low error….1577
Failure code [CA131] Throttle sensor signal high error….1579
Failure code [CA132] Throttle sensor signal low error….1581
Failure code [CA135] Engine oil pressure sensor high error….1583
Failure code [CA141] Engine oil pressure sensor low error….1585
Failure code [CA144] Coolant temperature sensor high error….1586
Failure code [CA145] Coolant temperature sensor low error….1587
Failure code [CA153] Charge air temperature sensor high error….1589
Failure code [CA154] Charge air temperature sensor low error….1591
Failure code [CA187] Sensor power supply 2 voltage low error….1592
Failure code [CA221] Ambient pressure sensor high error….1593
Failure code [CA222] Ambient pressure sensor low error….1595
Failure code [CA227] Sensor power supply 2 voltage high error….1597
Failure code [CA234] Engine overspeed….1599
Failure code [CA238] Ne speed sensor power supply voltage error….1601
Failure code [CA263] Fuel temperature sensor high error….1603
Failure code [CA265] Fuel temperature sensor low error….1605
Failure code [CA271] PCV1 short circuit….1606
Failure code [CA272] PCV1 disconnection….1607
Failure code [CA273] PCV2 short circuit….1608
Failure code [CA274] PCV2 disconnection….1609
Failure code [CA322] Disconnection or short circuit in injector No. 1….1610
Failure code [CA323] Disconnection or short circuit in injector No. 5….1611
Failure code [CA324] Disconnection or short circuit in injector No. 3….1612
Failure code [CA325] Disconnection or short circuit in injector No. 6….1613
Failure code [CA331] Disconnection or short circuit in injector No. 2….1614
Failure code [CA332] Disconnection or short circuit in injector No. 4….1615
Failure code [CA342] Calibration code incompatibility in engine controller data….1616
Failure code [CA351] Injector drive circuit error….1617
Failure code [CA352] Sensor power supply 1 voltage low error….1619
Failure code [CA386] Sensor power supply 1 voltage high error….1621
Troubleshooting by failure code (Display of code), Part 4….1624
Failure code [CA431] Idle validation switch error….1627
Failure code [CA432] Idle validation process error….1630
Failure code [CA441] Power supply voltage low error….1630
Failure code [CA442] Power supply voltage high error….1631
Failure code [CA449] Common rail pressure high error 2….1631
Failure code [CA451] Common rail pressure high error….1633
Failure code [CA452] Common rail pressure low error….1635
Failure code [CA553] Common rail pressure high error 1….1635
Failure code [CA554] Common rail pressure sensor: In-range error….1636
Failure code [CA559] Supply pump low pressure feed error 1….1638
Failure code [CA689] Engine Ne speed sensor error….1641
Failure code [CA731] Engine Bkup speed sensor phase error….1643
Failure code [CA757] Lost error of all engine controller data….1643
Failure code [CA778] Engine Bkup speed sensor error….1645
Failure code [CA1633] KOMNET error….1647
Failure code [CA2185] Throttle sensor power supply voltage high error….1649
Failure code [CA2186] Throttle sensor power supply voltage low error….1651
Failure code [CA2249] Supply pump low pressure feed error 2….1651
Failure code [CA2555] Disconnection in intake air heater relay….1652
Failure code [CA2556] Short circuit in intake air heater relay….1653
Troubleshooting by failure code (Display of code), Part 5….1656
Failure code [DAF9KM] Wrong connection of connector….1658
Failure code [DAFRKR] CAN communication error (machine monitor)….1659
Failure code [DAQ0KK] Lowering of power supply voltage….1661
Failure code [DAQ0KT] Non-volatile memory error….1663
Failure code [DAQ2KK] Solenoid power supply system error….1665
Failure code [DAQ9KQ] Inconsistent model selection (Transmission controller)….1667
Failure code [DAQRKR] CAN communication error (Transmission controller)….1669
Failure code [DAQRMA] Inconsistent option setting (Transmission controller)….1671
Failure code [DB10KT] Non-volatile memory error….1671
Failure code [DB12KK] Solenoid power supply system error….1673
Failure code [DB13KK] Lowering of battery direct voltage….1675
Failure code [DB19KQ] Inconsistent model selection (Retarder controller)….1677
Failure code [DB1QMA] Inconsistent option setting (Retarder controller)….1677
Failure code [DB1RKR] CAN communication error (Retarder controller)….1679
Failure code [DB2RKR] CAN communication error (Engine controller)….1681
Failure code [DD1ML4] Inconsistent signal of accelerator-linked retarder switch….1683
Failure code [DDTHKA] Hi clutch fill switch circuit disconnect….1685
Failure code [DDTJKA] Lo clutch fill switch circuit disconnect….1686
Failure code [DDTKKA] 1st clutch fill switch circuit disconnect….1687
Failure code [DDTLKA] 2nd clutch fill switch circuit disconnect….1688
Failure code [DDTMKA] 3rd clutch fill switch circuit disconnect….1689
Failure code [DDTNKA] Reverse clutch fill switch circuit disconnect….1690
Failure code [DF10KA] Lever signals non-input….1691
Failure code [DF10KB] Multiple lever signals input….1695
Failure code [DGF1KX] Transmission oil temperature out of range….1699
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) system….1701
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) system….1703
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) system….1705
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) system….1707
Failure code [DGR6KX] Steering oil temperature out of range….1709
Troubleshooting by failure code (Display of code), Part 6….1712
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system….1715
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system….1717
Failure code [DHT5L6] Torque converter oil pressure sensor failure….1719
Failure code [DHU2KX] Accumulator oil pressure sensor (front) system failure….1721
Failure code [DHU3KX] Accumulator oil pressure sensor (rear) system failure….1723
Failure code [DJF1KA] Disconnection in fuel level sensor system….1725
Failure code [DK51L5] Manual retarder potentiometer and RVS failure….1727
Failure code [DK52KX] Dump lever potentiometer 1 failure….1729
Failure code [DK53L8] Dump lever potentiometer 2 failure….1731
Failure code [DK54KX] Body positioner sensor failure….1733
Failure code [DKH0KX] Pitch angle sensor signal out of range….1735
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system….1737
Failure code [DLF1LC] Transmission input shaft speed sensor failure….1738
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system….1739
Failure code [DLF2LC] Transmission intermediate shaft speed sensor failure….1740
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system….1741
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system….1742
Failure code [DV00KB] Short circuit in buzzer output circuit….1743
Failure code [DW72KZ] Kick-out solenoid output system failure (disconnection or ground fault)….1745
Failure code [DW73KZ] Dump selector valve output system failure….1747
Failure code [DW78KZ] Rear wheel BCV command output system failure….1749
Failure code [DW79KZ] Front wheel BCV command output system failure….1751
Failure code [DX11K4] Rear wheel proportional solenoid pressure reducing valve failure 1….1753
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve….1755
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve….1757
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve….1759
Failure code [DX11MA] Rear wheel proportional solenoid pressure reducing valve failure 2….1761
Failure code [DX12K4] Front wheel proportional solenoid pressure reducing valve failure 1….1763
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve….1765
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve….1767
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve….1769
Failure code [DX12MA] Front wheel proportional solenoid pressure reducing valve failure 2….1771
Troubleshooting by failure code (Display of code), Part 7….1774
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve….1777
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve….1779
Failure code [DX13KY] Hot short in output circuit of dump EPC valve….1781
Failure code [DX14KZ] Rear wheel differential lock command output system failure….1783
Failure code [DX15KZ] Front wheel differential lock command output system failure….1785
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid….1787
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid….1789
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid….1791
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid….1792
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid….1793
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid….1795
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch ECMV solenoid….1797
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid….1799
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid….1801
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch ECMV solenoid….1805
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid….1807
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid….1809
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch ECMV solenoid….1813
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid….1815
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid….1817
Troubleshooting by failure code (Display of code), Part 8….1822
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid….1823
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid….1825
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid….1827
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid….1831
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid….1833
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid….1835
Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid….1839
Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid….1841
Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid….1843
Troubleshooting of electrical system (E-mode)….1848
Before troubleshooting for electrical system….1850
Information in troubleshooting table….1856
E-1 Engine does not start….1857
E-2 Auto preheater does not operate….1862
E-3 When starting switch is turned ON, machine monitor displays nothing….1865
E-4 When starting switch is turned OFF, machine monitor cannot be operated….1867
E-5 Alarm buzzer does not sound….1869
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section….1871
E-7 Display of character display section cannot be changed….1872
E-8 Power mode selection function does not operate normally….1875
E-9 AISS function does not operate normally….1877
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)….1879
E-11 Interaxle differential lock-up function does not operate normally….1883
E-12 Display of seat belt caution lamp is abnormal….1885
E-13 Both turn signal lamps and hazard lamps do not operate normally….1887
E-14 Night lighting is abnormal….1892
E-15 Backup lamp and backup buzzer operate abnormally….1899
E-16 Emergency steering system does not operate….1903
E-17 Indication of the fuel gauge is abnormal….1907
E-18 Dump lever does not operate normally….1909
E-19 KOMTRAX system does not operate normally….1911
E-20 Electric priming pump does not operate or does not stop automatically….1915
E-21 Air conditioner does not operate normally….1917
Troubleshooting of hydraulic and mechanical system (H-mode)….1924
Information in troubleshooting table….1926
H-1 Machine does not start….1927
H-2 Travel is not smooth (Machine hunts)….1929
H-3 Lockup is not reset….1929
H-4 Start shock and gear shift shock are abnormally large….1930
H-5 Gear is not shifted up….1931
H-6 Travel speed or power is low….1933
H-7 Start and gearshift time lag is large….1937
H-8 Torque converter oil temperature is high….1939
H-9 Torque converter oil temperature is low….1940
H-10 Front brake does not work fully….1941
H-11 Center brake does not work fully….1942
H-12 Rear brake does not work fully….1943
H-13 Steering wheel is heavy….1944
H-14 Steering wheel does not move….1945
H-15 Steering wheel waggle….1946
H-16 Dump body raising speed is low….1947
H-17 Dump body does not move….1948
H-18 Hydraulic drift of dump body is large….1949
Troubleshooting of engine (S-mode)….1952
Method of using troubleshooting chart….1954
S-1 Starting performance of engine is poor….1957
S-2 Engine does not start….1958
S-3 Engine does not pick up smoothly….1961
S-4 Engine stops during operation….1962
S-5 Engine does not rotate smoothly….1963
S-6 Engine lack output (or lacks power)….1964
S-7 Exhaust gas is black (incomplete combustion)….1965
S-8 Oil consumption is excessive (or exhaust gas is blue)….1966
S-9 Oil becomes dirty quickly….1967
S-10 Fuel consumption is excessive….1968
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….1969
S-12 Oil pressure drops….1970
S-13 Oil level rises (Entry of coolant or fuel)….1971
S-14 Coolant temperature becomes too high (Overheating)….1972
S-15 Abnormal noise is made….1973
S-16 Vibration is excessive….1974
S-17 Air cannot be bled from fuel circuit….1975
50 Disassembly and assembly….0
General information on disassembly and assembly….1978
How to read this manual….1979
Coating materials list….1981
Special tool list….1984
Sketches of special tools….1989
Engine and cooling system (SAA6D140E-5)….2004
Removal and installation of engine assembly….2005
Removal and installation of radiator assembly….2014
Removal and installation of cooling assembly….2018
Removal and installation of aftercooler assembly….2022
Removal and installation of output shaft assembly….2025
Disassembly and assembly of output shaft assembly….2030
Engine (SAA6D140E-5)….2034
Removal and installation of fuel supply pump assembly….2035
Removal and installation of cylinder head assembly….2040
Removal and installation of fuel injector assembly….2056
Removal and installation of engine front seal….2060
Removal and installation of engine rear seal….2062
Replacement procedure of exhaust pipe fire prevention cover….2066
Power train, Part 1….2076
Removal and installation of transmission and front differential assembly….2077
Disconnection and coupling of front differential and transmission….2084
Disassembly and assembly of torque converter assembly….2085
Disassembly and assembly of transmission assembly….2093
Power train, Part 2 (Differential)….2138
Disassembly and assembly of front differential assembly….2139
Removal and installation of center differential assembly….2156
Disassembly and assembly of center differential assembly….2159
Removal and installation of rear differential assembly….2174
Disassembly and assembly of rear differential assembly….2176
Power train, Part 3 (Final drive, brake, axle)….2190
Removal and installation of front final drive and brake assembly….2191
Disassembly and assembly of front final drive and brake assembly….2194
Removal and installation of center final drive and brake assembly….2208
Disassembly and assembly of center final drive and brake assembly….2210
Removal and installation of rear final drive assembly….2221
Disassembly and assembly of rear final drive assembly….2223
Undercarriage and frame….2232
Removal and installation of front suspension cylinder assembly….2233
Removal and installation of rear suspension cylinder assembly….2235
Removal and installation of equalizer bar assembly….2237
Removal and installation of front wheel assembly….2239
Removal and installation of rear front wheel assembly….2240
Removal and installation of rear rear wheel assembly….2240
Removal and installation of hitch frame assembly….2241
Disassembly and assembly of hitch frame….2249
Removal and installation of body assembly….2254
Hydraulic system….2258
Disassembly and assembly of steering valve….2259
Removal and installation of flow amplifier valve assembly….2269
Removal and installation of hoist valve assembly….2271
Disassembly and assembly of hoist valve assembly….2273
Disassembly and assembly of steering cylinder assembly….2275
Disassembly and assembly of hoist cylinder assembly….2281
Cab and its attachments….2288
Removal and installation of operator’s cab….2289
Removal and installation of operator’s cab glass (Stuck glass)….2294
Disassembly and assembly of operator’s seat assembly (If equipped)….2301
Electrical system….2312
Removal and installation of air conditioner unit assembly….2313
Removal and installation of engine controller….2318
Removal and installation of retarder controller….2321
Removal and installation of transmission controller assembly….2323
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….2326
Power train hydraulic circuit diagram….2328
Steering and hoist hydraulic circuit diagram….2329
Brake hydraulic circuit diagram….2330
Brake cooling hydraulic circuit diagram….2331
Differential lock hydraulic circuit diagram….2332
Electrical diagrams and drawings….2335
Electrical circuit diagram for inside cab (1/4)….2337
Electrical circuit diagram for inside cab (2/4)….2338
Electrical circuit diagram for inside cab (3/4)….2339
Electrical circuit diagram for inside cab (4/4)….2340
Electrical circuit diagram for outside cab (1/3)….2341
Electrical circuit diagram for outside cab (2/3)….2342
Electrical circuit diagram for outside cab (3/3)….2343
Connectors table and arrangement drawing….2344

Komatsu Articulated Dump Truck HM350-2R Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM350-1, HM350-2, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM350-1, HM350-2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 16,294 pages
File Format: PDF
Language: English

SEBM024910 – Articulated Dump Truck HM350-1 Shop Manual.pdf
SEBM024912 – Articulated Dump Truck HM350-1 Shop Manual.pdf
SEBM030302 – Articulated Dump Truck HM350-1 (-40C degree Spec.) Shop Manual.pdf
SEN00238-08 – Articulated Dump Truck HM350-2 Shop Manual.pdf
SEN00238-13 – Articulated Dump Truck HM350-2 Shop Manual.pdf
SEN00238-15 – Articulated Dump Truck HM350-2 Shop Manual.pdf
CEBM007801 – Articulated Dump Truck HM350-2 Shop Manual.pdf
CEAM017703 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
CEAM017704 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
EEAM022502 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual.pdf
EEAM0024900 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
EEAM027403 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
EPAM022502 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual.pdf
EPAM024900 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção.pdf
EPAM027403 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção.pdf
EPAM027602 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção.pdf
GEN00021-00 – Articulated Dump Truck GALEO HM350-1 Field Assembly Instruction.pdf
GEN00041-03 – Articulated Dump Truck HM350-2 Field Assembly Instruction.pdf
PEN00045-01 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual.pdf
PEN00045-10 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual.pdf
PEN00119-01 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual.pdf
PEN00119-04 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual.pdf
PEN00177-06 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual.pdf
PEN00232-06 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
PEN00240-00 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual.pdf
PEN00379-00 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
PEN00475-11 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
TEN00047-10 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual.pdf
TEN00129-04 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual.pdf
TEN00229-06 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
TEN00239-00 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual.pdf
TEN00349-00 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
TEN00443-07 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf
TEN00443-11 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual.pdf

MAIN SECTIONS
CEAM017703 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..4
CEAM017704 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..302
  INTRODUCTION…..306
    FOREWORD…..307
    SAFETY INFORMATION…..308
      Safety Labels…..309
        Safety Label Using Words…..309
        Safety Labels Using Pictogram…..309
    INTRODUCTION…..310
      Intended Use…..310
        Use of Machine…..310
        Directions of Machine…..310
        Visibility From Operator&apos;s Seat…..310
        Breaking in a New Machine…..311
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..312
      Product Identification Number (Pin)/Machine Serial No. Plate…..312
      EPA Regulations, Engine Serial No. Plate Position…..312
      Service Meter Position…..313
      Table to Enter Serial Numbers and Distributor…..313
    TABLE OF CONTENTS…..314
  SAFETY…..326
    SAFETY LABELS…..327
    SAFETY AND WARNING DECALS…..328
      Location of Safety Decals…..329
      Safety Labels…..329
    GENERAL SAFETY RULES AND PRECAUTIONS…..334
      General Safety Rules…..334
      Safety Features…..335
      Personal Protective Equipment…..335
      Fire and Explosion Prevention…..336
        Fire Caused by Fuel or Oil…..336
        Fire Caused by Accumulation of Flammable Material…..336
        Fire Coming from Electric Wiring…..337
        Fire Coming from Hydraulic Line…..337
        Windshield Washer Fluid…..337
      Action if Fire Occurs…..337
      Fire Extinguisher and First Aid Kit…..337
      Fire Prevention and Suppression…..338
        Fire Prevention Steps…..338
        Fixed Fire Detection System…..338
        Fixed Fire Suppression System…..338
        Fire Prevention Procedures…..338
      Dust Hazard Precautions…..339
      Keep Operator&apos;s Cab Clean…..339
      Unauthorized Modifications…..339
      Leaving Operator’s Compartment…..340
      Mounting and Dismounting…..341
      Crush or Pinch Point Dangers…..341
      Inside Operator’s Compartment…..342
      Precautions When Using ROPS…..342
    PRECAUTIONS BEFORE STARTING OPERATIONS…..343
      Pre-Operational Checks…..343
      Starting Your Work Operations…..343
      Work Site Hazards…..343
      Avoiding Dangerous Situations…..344
      Working Clearances…..346
      Operating on Snow or Icy Surfaces…..346
      Asbestos Hazard Alert…..347
    RULES FOR ROAD TRAVEL…..348
      Precautions When Traveling…..348
      When Traveling on Slopes…..348
      When Dumping a Load…..349
      Ensure Good Visibility…..349
      When Traveling in Reverse…..350
      Parking the Machine…..351
    PRECAUTIONS DURING MAINTENANCE OPERATIONS…..353
      Warning Tags…..353
      Equipment Storage…..353
      Working Under the Machine…..354
      Using Drop Lamps…..354
      Keeping the Machine Clean…..354
      Performing General Maintenance Procedures…..355
      Running the Engine During Maintenance…..356
      Proper Tools…..357
      Engine System High-voltage…..357
      Welding, Grinding or Cutting…..358
      When Using Hammer…..358
      Refueling the Machine…..358
      Cooling System Precautions…..359
      Battery Precautions…..360
      Starting the Machine…..360
      High Pressure Hoses…..361
      Safety Handling High-pressure Hoses…..361
      Precaution for High Fuel Pressure…..361
      High Temperature Areas…..361
      Disposal of Waste Materials…..362
      Accumulator…..362
      Critical Parts…..362
    HANDLING TIRES…..363
      Precautions When Storing Tires…..363
    TRANSPORTATION…..364
      Precautions When Transporting…..364
      Steps for Transportation…..364
      Method of Securing Machine…..364
      Method of Lifting Machine…..365
      Location of Lifting Points…..366
    TOWING MACHINE…..367
  OPERATION…..368
    GENERAL VIEW…..369
      Machine…..369
      Controls and Gauges…..370
      Machine Monitor…..371
    EXPLANATION OF COMPONENTS…..372
      Machine Monitor…..372
        Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps, And Meters…..373
        Character Display Portion…..373
        Caution Items…..378
        Emergency Stop Item…..381
        Pilot Display Portion…..385
        Meter Display Portion…..389
        Central Warning Lamp…..391
        Other Functions of Machine Monitor…..392
      Switches…..395
        Ignition Switch…..396
        Lamp Switch…..396
        Turn Signal Lever…..396
        Dimmer Switch…..397
        Hazard Lamp Switch…..397
        Night Lighting Dimmer Switch…..397
        Power Mode Selector Switch…..397
        Emergency Steering Switch…..398
        Shift Hold Switch…..398
        Parking Brake Switch…..399
        AISS Low Switch…..399
        Inter-axle Differential Lock Switch…..400
        Left and Right Differential Lock Switch…..400
        Fog Lamp Switch…..401
        Side Lamp Switch…..401
        Working Lamp (Front) Switch…..401
        Switch For Rear Window Defogger…..401
        Yellow Rotating Lamp Switch…..402
        Power Window Switch (Right) (Left)…..402
        Machine Monitor Mode Selector Switch 1, 2…..402
        Cigarette Lighter…..403
        Horn Button…..403
        Wiper, Window Washer Switch…..403
        Room Lamp Switch…..404
      Control Levers And Pedals…..405
        Brake Pedal…..405
        Accelerator Pedal…..406
        Gear Shift Lever…..406
        Dump Lever…..408
        Retarder Control Lever…..408
        Left and Right Differential Lock Pedal…..408
        Dump Lever Safety Lock Knob…..409
      Body Pivot Pin…..410
        Stowing Body Pivot Pin…..410
      Articulate Lock…..411
      Location of Fire Extinguisher…..411
      Dust Indicator…..411
      Circuit Breaker…..412
      Fuses…..412
        Fuse Capacity and Circuit Name…..412
      AM/FM Radio-cassette Stereo…..415
        Radio Operation…..416
        Radio Features…..420
        Listening to Radio…..421
        Listening to Cassette Tape…..421
        Precautions When Using Radio…..422
    AIR CONDITIONER…..423
      General Locations on Control Panel…..423
        ON/OFF Switch…..423
        Fan Switch…..423
        Air Conditioner Switch…..423
        Mode Selector Switch…..424
        DEF (Defrost) Switch…..424
        RECIRC/FRESH Selector Switch…..424
        Temperature Control Switch…..425
      Method of Operation…..425
        Cooling…..425
        Heating…..425
        Dehumidifying, Defrosting…..426
        Precautions When Using Air Conditioner…..426
        Inspection and Maintenance…..426
    OPERATION…..427
      Check Before Starting Engine…..427
        Walk-around Check…..427
      Checks Before Starting…..429
        Check Coolant Level, Add Coolant…..429
        Check Dust Indicator…..429
      Check Water Separator, Drain Water (If Equipped)…..431
        Check Oil Level in Engine Oil Pan, Add Oil…..433
        Check Oil Level in Transmission Case, Add Oil…..434
        Check Oil Level In Hydraulic Tank, Add Oil…..434
        Drain Water, Sediment From Fuel Tank…..434
        Check Fuel Level, Add Fuel…..435
        Check Wheel Hub Bolts, Tighten…..436
        Check Inflation Pressure Of Tires…..436
        Check Central Warning Lamp, Alarm Buzzer, Monitor Lamps and Meters…..437
        Check Braking Effect…..437
        Check Emergency Steering…..437
        Check Back-Up Alarm…..437
        Check Electrical Wiring…..438
        Check Water Separator…..438
        Check Body Positioner Operation…..439
        Check Cab Mounting Bolts and Pins For Looseness and Breakage…..439
      Adjustments Before Operation…..440
        Adjusting Operator&apos;s Seat…..440
        Adjust Seat Belt…..441
        Adjust Steering Wheel Tilt…..442
        Adjusting Mirror…..443
      Operations, Checks Before Starting…..444
      Starting the Engine…..446
      Operations, Checks After Starting Engine…..448
        Breaking-In the Machine…..448
        Warming-Up Operation…..448
        Canceling Dump Body Hold Condition…..449
      Stopping Engine…..449
        Checks After Stopping Engine…..449
      Moving the Machine…..450
        Moving Machine Forward…..450
        Moving Machine in Reverse…..452
        Stopping the Machine…..453
        Shifting Gears…..454
        Traveling Downhill…..456
        Brake Performance Curve…..458
      Steering the Machine…..462
        Operation Using Differential Lock…..462
      Loading Operations…..464
      Handling Tailgate…..464
      Dump Operations…..465
      Cab Tilt Operation…..467
        When Using Crane…..468
        When Using Tilt Cylinder…..469
        Precautions for Operation…..470
      Permissible Water Depth…..470
      Parking Machine…..471
      Checks After Completion of Work…..472
        Locking…..472
      Handling of KOMTRAX…..473
        Outline of System…..473
        Basic Precautions…..474
        Check Before Starting…..474
      Handling Tires…..475
        Precautions When Handling Tires…..475
        Precautions for Long Distance Travel…..475
      Determining and Maintaining Travel Road…..476
        Determining Travel Road…..476
        Maintaining Travel Road…..476
    TRANSPORTATION…..477
      Precautions When Transporting…..477
      Steps for Transportation…..477
      Method of Securing Machine…..477
      Method of Lifting Machine…..479
        Location of Lifting Position Mark…..480
        Weight Table…..480
        Lifting Procedure…..481
    COLD WEATHER OPERATION…..483
      Precautions for Low Temperature…..483
        Fuel and Lubricants…..483
        Coolant…..483
        Installation of Radiator Curtain…..483
        Battery…..484
      Precautions After Completion of Work…..484
      After Cold Weather…..484
    LONG-TERM STORAGE…..485
      Before Storage…..485
      During Storage…..485
      After Storage…..485
        Precautions Before Traveling After Long-term Storage…..485
    TROUBLESHOOTING…..486
      After Running Out of Fuel…..486
      If Transmission has Trouble…..486
      Method of Lowering Dump Body in Emergency…..486
      Method of Towing Machine…..487
        When Engine Runs…..489
        When Engine Does Not Run…..489
      When Parking Brake has Been Actuated in Emergency…..490
      Method of Releasing Parking Brake…..490
      When Final Drive, Differential, Transmission, Transfer Have Broken Down…..490
    PRECAUTIONS FOR CHARGING BATTERY…..491
      Charging Battery when Mounted on Machine…..491
      If Battery is Discharged…..491
      Removal and Installation of Battery…..492
      Starting Engine with Booster Cable…..492
        Precautions When Connecting and Disconnecting Booster Cable…..492
        Connecting the Booster Cables…..493
        Starting the Engine…..493
        Disconnecting the Booster Cables…..493
    OTHER TROUBLE…..494
      Electrical System…..494
      Chassis…..495
      If Accelerator Pedal has Failed…..496
      Engine…..497
    ACTION CODE…..499
  MAINTENANCE…..500
    GUIDES TO MAINTENANCE…..501
      Check Service Meter…..501
      Komatsu Genuine Replacement Parts…..501
      Komatsu Genuine Oils…..501
      Always Use Clean Washer Fluid…..501
      Always Use Clean Oil and Grease…..501
      Checking Foreign Materials in Drained Oil and on Filters…..501
      Fueling…..501
      Welding Instructions…..501
      Do Not Drop Things Inside Machine:…..501
      Dusty Work Sites…..502
      Avoid Mixing Oil…..502
      Locking Inspection Covers…..502
      Bleeding Air From Hydraulic Circuit…..502
      Precautions When Installing Hydraulic Hoses…..502
      Checks After Inspection and Maintenance…..502
    OUTLINES OF SERVICE…..503
      Handling Oil, Fuel, Coolant, and Performing Oil Clinic…..504
        Oil…..504
        Fuel…..504
        Coolant and Water for Dilution…..505
        Grease…..505
        Performing KOWA (Komatsu Oil Wear Analysis)…..506
        Storing Oil and Fuel…..507
        Filters…..507
      Outline of Electric System…..507
    WEAR PARTS LIST…..508
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..509
    USE OF FUEL, COOLANT AND LUBRICANTS…..511
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..514
      Torque List…..514
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..516
      Safety Critical Parts…..516
    REGULAR SCHEDULED MAINTENANCE…..517
      Maintenance Schedule Chart…..517
      Initial 250 Hours Service (Only After the First 250 Hours)…..519
      When Required…..520
        Check, Clean or Replace Air Cleaner…..520
        Clean Inside of Cooling System…..526
        Check Level of Window Washer Fluid, Add Fluid…..529
        Clean Air Conditioner Air Filter…..529
        Check Refrigerant (Freon) Level…..530
        Check Dump Body…..530
        Check Water Separator, Wash inside of Filter Case…..531
        Procedure for Bleeding Air From Fuel Circuit…..533
          Machines Equipped with Manual Priming Pump…..533
          Machines Equipped with Electric Priming Pump…..534
        Bleed Air From Front Brake…..537
        Bleed Air From Center Brake…..538
        Bleed Air From Rear Brake…..539
        Check Output Coupling Play of Output Shaft…..540
        Selection and Inspection of Tires…..541
      Check Before Starting…..543
      Every 50 Hours Service…..544
        Lubrication…..544
      Every 250 Hours Service…..545
        Lubrication…..545
        Lubricate Drive Shaft…..547
        Check Drive Shaft…..547
        Clean Breathers…..548
        Clean Overflow Hose…..550
        Check Level of Battery Electrolyte…..551
        When Checking Electrolyte Level From Side of Battery…..551
        When Impossible to Check Electrolyte Level From Side of Battery…..552
        When Possible to Use Indicator to Check Electrolyte Level…..552
        Check Alternator Belt Tension, Adjust…..553
        Check Air Conditioner Compressor Belt Tension, Adjust…..554
        Check Frame, A-Arm…..555
        Check Braking Capacity of Foot Brake…..556
        Check Braking Capacity of Retarder Brake…..556
        Check Braking Capacity of Parking Brake…..557
        Check Wear of Parking Brake Pads…..557
        Check Length of Suspension Cylinder…..558
        Check of Accumulator Gas Pressure…..558
      Every 500 Hours Service…..559
        Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge…..559
        Replace Fuel Prefilter Cartridge…..560
        Lubrication Cab Mount Pin…..561
        Check Oil Level In Final Drive Case, Add Oil…..561
        Check Oil Level In Differential Case, Add Oil…..562
        Clean, Check Radiator Fins and After Cooler Fins…..563
        Check Fan Belt Tension, Adjust…..564
        Recover Oil Leaking From Floating Seal…..565
      Every 1000 Hours Service…..566
        Replace Fuel Main Filter Cartridge…..566
        Replace Fuel Tank Breather Element…..567
        Replace Corrosion Resistor Cartridge…..567
        Replace Transmission Filter Element…..568
        Change Oil in Transmission Case…..569
        Change Brake Oil in Tank, Replace Brake Oil Filter Element…..571
        Lubrication…..573
        Lubricating Parking Brake…..574
        Check Wear of Brake Disc…..575
        Check Engine Air Intake Piping Clamps for Looseness…..576
      Every 2000 Hours Service…..577
        Change Oil in Final Drive Case…..577
        Change Oil in Differential Case…..578
        Clean Hydraulic Tank Strainer…..580
        Replace Hydraulic Filter Element…..581
        Clean Transmission Case Strainer…..581
        Clean Strainer In Differential Lock Hydraulic Circuit…..582
        Clean Breathers…..583
        Check Accumulator Gas Pressure…..584
        Check, Adjust Engine Valve Clearance…..584
        Check Vibration Damper…..584
      Every 4000 Hours Service…..585
        Change Oil in Hydraulic Tank…..585
        Lubricate Fan Pulley…..585
        Check Alternator, Starting Motor…..585
        Check Water Pump…..585
        Check Air Compressor…..585
        Check Fan Pulley And Tension Pulley…..585
        Checking for Looseness of High-pressure Clamp, Hardening of Rubber…..586
        Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber…..587
        Check Exhaust Pipe Fire Prevention Cover…..587
      Every 6000 Hours Service…..588
        Lubricate Drive Shaft…..588
      Every 8000 Hours Service…..589
        Replace High-Pressure Piping Clamp…..589
        Replace Fuel Spray Prevention Cap…..589
        Overhaul Starting Motor and Alternator…..589
  SPECIFICATIONS…..590
    SPECIFICATIONS…..591
  OPTIONS, ATTACHMENTS…..592
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..593
      Explanation of Components…..593
        Automatic Retarder, Accelerator Control Switch…..594
        Retarder Control Lever…..594
        Accelerator Pedal…..594
        Brake Pedal…..594
        Retarder Pilot Lamp…..594
      Method Of Operation…..594
        Actuation of ARAC System…..594
    USE OF REAR VIEW MONITOR…..595
      Name and Function of Each Part of Rear View Monitor…..595
        Auto Switch…..596
        Manual Switch…..596
        Zoom/IRIS Switch (Reverse Light Compensation Switch)…..596
        Bright/Dim Light Selector Switch…..597
        Mark Switch…..597
        Contrast Adjustment Knob…..597
        Brightness Adjustment Knob…..598
      Setting of Rear View Monitor…..598
      Cautions When Using Rear View Monitor…..598
    HANDLING DUMPING COUNTER…..599
      Method of Displaying, Resetting Dumping Counter…..599
    HANDLING BATTERY DISCONNECTOR SWITCH…..600
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..601
      Basic Precautions…..601
CEBM007801 – Articulated Dump Truck HM350-2 Shop Manual…..602
  COVER…..602
  00 INDEX AND FOREWORD…..604
    INDEX…..604
      COMPOSITION OF SHOP MANUAL…..605
      TABLE OF CONTENTS…..607
    FOREWORD AND GENERAL INFORMATION…..618
      SAFETY NOTICE…..619
      HOW TO READ THE SHOP MANUAL…..624
      HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…..628
      HANDLING OF CONNECTORS NEWLY USED FOR ENGINES…..637
      HOW TO READ ELECTRIC WIRE CODE…..640
      PRECAUTIONS WHEN CARRYING OUT OPERATION…..643
      METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER…..646
      STANDARD TIGHTENING TORQUE TABLE…..649
      CONVERSION TABLE…..653
  01 SPECIFICATION…..660
    SPECIFICATION AND TECHNICAL DATA…..660
      SPECIFICATION DRAWINGS…..661
      SPECIFICATIONS…..662
      WEIGHT TABLE…..665
      FUEL, COOLANT AND LUBRICANTS…..666
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..672
    ENGINE AND COOLING SYSTEM…..672
      RADIATOR, OIL COOLER, AFTERCOOLER…..673
      OUTPUT SHAFT…..674
    POWER TRAIN, PART 1…..678
      POWER TRAIN SKELETON…..679
      MACHINE WITH LIMITED SLIP DIFFERENTIAL…..681
      TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…..683
      BRAKE COOLING OIL CONTROL VALVE (BCV)…..685
      POWER TRAIN PUMP…..686
        BRAKE COOLING, BRAKE SYSTEM PUMP…..687
        TRANSMISSION PUMP (MACHINE WITH LIMITED SLIP DIFFERENTIAL)…..688
      TORQUE CONVERTER…..689
      TRANSMISSION…..695
      TRANSMISSION CONTROL VALVE…..723
      ECMV…..724
      MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…..731
    POWER TRAIN, PART 2…..734
      DRIVE SHAFT…..735
      AXLE…..739
      DIFFERENTIAL…..743
      MACHINE WITH LIMITED SLIP DIFFERENTIA;…..749
      LIMITED SLIP DIFFERENTIAL…..755
      FINAL DRIVE…..759
    STEERING SYSTEM…..768
      STEERING COLUMN…..769
    BRAKE SYSTEM…..772
      BRAKE PIPING…..773
      BRAKE VALVE…..775
      ACCUMULATOR CHARGE VALVE…..778
      ACCUMULATOR…..782
      SLACK ADJUSTER…..783
      BRAKE…..785
      PROPORTIONAL REDUCING VALVE…..790
      BRAKE SYSTEM TANK…..791
      PARKING BRAKE…..793
      PARKING BRAKE SOLENOID VALVE…..797
    UNDERCARRIAGE AND FRAME…..800
      SUSPENSION…..801
      SUSPENSION CYLINDER…..806
      OSCILLATION HITCH…..808
    HYDRAULIC SYSTEM…..812
      STEERING, HOIST OIL PRESSURE PIPING DIAGRAM…..813
      DUMP BODY CONTROL…..814
      HYDRAULIC TANK AND FILTER…..815
      FLOW AMP VALVE…..816
      STEERING VALVE…..819
      STEERING CYLINDER…..823
      HOIST VALVE…..825
      DUMP CONTROL VALVE (EPC VALVE)…..831
      PILOT CHECK VALVE…..835
      HOIST CYLINDER…..836
      HYDRAULIC PUMP…..837
    CAB AND ITS ATTACHMENTS…..842
      ROPS CAB…..843
      CAB TILT…..844
      AIR CONDITIONER…..845
      REAR VIEW MONITOR …..853
      CONTROLLER RELATED…..856
    ELECTRICAL SYSTEM, PART 1…..858
      MACHINE MONITOR SYSTEM…..859
    ELECTRICAL SYSTEM, PART 2…..880
      AUTOMATIC SHIFT CONTROL SYSTEM…..881
      TRANSMISSION CONTROLLER…..884
      HOIST CONTROL FUNCTION…..911
      RETARDER CONTROL SYSTEM…..913
      AUTO EMERGENCY STEERING SYSTEM…..925
      BATTERY DISCONNECT SWITCH…..927
      DUMP CONTROL LEVER…..929
    ELECTRICAL SYSTEM, PART 3…..934
      SENSORS, SWITCHES…..935
      KOMTRAX TERMINAL SYSTEM (IF EQUIPPED(…..943
  20 STANDARD VALUE TABLE…..946
    STANDARD SERVICE VALUE TABLE…..946
      STANDARD VALUE TABLE FOR ENGINE…..947
      STANDARD VALUE TABLE FOR CHASSIS…..948
  30 TESTING AND ADJUSTING…..954
    TESTING AND ADJUSTING, PART 1…..954
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..956
      MEASURING ENGINE SPEED…..960
      TESTING INTAKE AIR PRESSURE (BOOST PRESSURE)…..961
      TESTING EXHAUST TEMPERATURE…..962
      TESTING EXHAUST GAS COLOR…..963
      ADJUSTING VALVE CLEARANCE…..964
      TESTING COMPRESSION PRESSURE…..965
      TESTING BLOW-BY PRESSURE…..967
      TESTING ENGINE OIL PRESSURE…..968
      TESTING EGR VALVE AND BYPASS VALVE DRIVE OIL PRESSURE…..969
      HANDLING OF FUEL SYSTEM DEVICES…..970
      RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…..970
      TESTING FUEL PRESSURE…..971
      TESTING FUEL RETURN AND LEAKAGE AMOUNT…..972
      BLEEDING AIR FROM FUEL CIRCUIT…..975
      TESTING THE FUEL CIRCUIT FOR LEAKAGE…..977
      TESTING AND ADJUSTING FAN BELT TENSION…..978
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION…..979
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..980
    TESTING AND ADJUSTING, PART 2…..982
      TESTING TORQUE CONVERTER STALL SPEED…..984
      TESTING POWER TRAIN OIL PRESSURE…..985
      TESTING AND ADJUSTING OF DIFFERENTIAL LOCK OIL PRESSURE (DIFFERENTIAL LOCK SPEC.)…..993
      ADJUSTING TRANSMISSION SPEED SENSOR…..998
      TESTING AND ADJUSTING BRAKE OIL PRESSURE…..1000
      TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS…..1004
      TESTING BRAKE PERFORMANCE…..1008
      BLEEDING AIR FROM BRAKE CIRCUIT…..1009
      TESTING WEAR OF WHEEL BRAKE DISC…..1010
      TESTING THE PARKING BRAKE PAD WEAR…..1011
      EMERGENCY RELEASE OF THE PARKING BRAKE…..1012
      TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE…..1013
      TESTING AND ADJUSTING SUSPENSION CYLINDER…..1015
      METHOD OF TILTING CAB UP…..1019
      TESTING AND ADJUSTING DUMP CIRCUIT OIL PRESSURE…..1021
      ADJUSTING BODY POSITIONER SENSOR…..1023
      ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT…..1024
      HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..1024
      ADJUSTING TRANSMISSION CONTROLLER…..1024
      METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILURE…..1025
    TESTING AND ADJUSTING, PART 3…..1030
      SETTING AND ADJUSTING VARIOUS EQUIPMENT…..1031
      SPECIAL FUNCTION OF MACHINE MONITOR…..1040
      HOW TO START OPERATION OF KOMTRAX TERMINAL…..1085
      LAMP DISPLAY OF KOMTRAX TERMINAL…..1090
      PM CLINIC CHECK SHEET…..1093
  40 TROUBLESHOOTING…..1098
    GENERAL INFORMATION ON TROUBLESHOOTING…..1098
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…..1099
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…..1100
      CHECK BEFORE TROUBLESHOOTING…..1101
      CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING…..1102
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..1105
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…..1141
    TROUBLE SHOOTING BY FAILURE CODE, GENERAL…..1146
      FAILURE CODES TABLE…..1147
      BEFORE TROUBLESHOOTING BY FAILURE CODE…..1155
      INFORMATION IN TROUBLESHOOTING TABLE…..1163
    TROUBLESHOOTING BY FAILURE CODE, PART 1…..1166
      FAILURE CODE [1500L0] DOUBLE ENGAGEMENT…..1168
      FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER:  CLOGGED…..1169
      FAILURE CODE [15F0KM] R-F SHIFTING ABIUSE 1…..1171
      FAILURE CODE [15F0MB] R-F SHIFTING ABIUSE 2…..1171
      FAILURE CODE [15F7KM] TRANSMISSION FORWARD CLUTCH ABUSE…..1172
      FAILURE CODE [15G0MW] TROUBLE IN REVERSE CLUTCH SYSTEM (SLIP)…..1173
      FAILURE CODE [15G7KM] TRANSMISSION REVERSE CLUTCH ABUSE…..1175
      FAILURE CODE [15H0MW] TROUBLE IN HI CLUTCH SYSTEM (SLIP)…..1177
      FAILURE CODE [15J0MW] TROUBLE IN L0 CLUTCH SYSTEM (SLIP)…..1179
      FAILURE CODE [15K0MW] TROUBLE IN 1ST CLUTCH SYSTEM (SLIP)…..1181
      FAILURE CODE [15L0MW] TROUBLE IN 2ND CLUTCH SYSTEM (SLIP)…..1183
      FAILURE CODE [15M0MW] TROUBLE IN 3RD CLUTCH SYSTEM (SLIP)…..1185
      FAILURE CODE [15SBL1] TROUBLE IN REVERSE CLUTCH PRESSURE CONTROL VALVE I…..1187
      FAILURE CODE [15SBMA] TROUBLE IN REVERSE CLUTCH PRESSURE CONTROL VALVE II…..1191
      FAILURE CODE [15SCL1] TROUBLE IN HI CLUTCH PRESSURE CONTROL VALVE I…..1193
      FAILURE CODE [15SCMA] TROUBLE IN HI CLUTCH PRESSURE CONTROL VALVE II…..1197
      FAILURE CODE [15SDL1] TROUBLE IN LO CLUTCH PRESSURE CONTROL VALVE I…..1199
      FAILURE CODE [15SDMA] TROUBLE IN LO CLUTCH PRESSURE CONTROL VALVE II…..1201
    TROUBLESHOOTING BY FAILURE CODE, PART 2…..1206
      FAILURE CODE [15SEL1] TROUBLE IN 1ST CLUTCH PRESSURE CONTROL VALVE I…..1208
      FAILURE CODE [15SEMA] TROUBLE IN 1ST CLUTCH PRESSURE CONTROL VALVE II…..1211
      FAILURE CODE [15SFL1] TROUBLE IN 2ND CLUTCH PRESSURE CONTROL VALVE I…..1213
      FAILURE CODE [15SFMA] TROUBLE IN 2ND CLUTCH PRESSURE CONTROL VALVE II…..1217
      FAILURE CODE [15SGL1] TROUBLE IN 3RD CLUTCH PRESSURE CONTROL VALVE I…..1219
      FAILURE CODE [15SGMA] TROUBLE IN 3RD CLUTCH PRESSURE CONTROL VALVE II…..1223
      FAILURE CODE [15SJMA] TROUBLE IN LOCKUP CLUTCH PRESSURE CONTROL VALVE II…..1225
      FAILURE CODE [15SKMA] TROUBLE IN INTERAXLE DIFFERENTIAL LOCK CLUTCH PRESSURE CONTROL VALVE II…..1227
      FAILURE CODE [2A62L1] TROUBLE IN FRTONT WHEEL DIFFERNETIAL LOCK PRESSURE CONTROL VALVE 2…..1229
      FAILURE CODE [2A62LH] TROUBLE IN FRONT WHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 1…..1231
      FAILURE CODE [2B62L1] TROUBLE IN REAR SHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 2…..1233
      FAILURE CODE [2B62LH] TROUBLE IN REAR WHEEL DIFFERENTIAL LOCK PRESSURE CONTROL VALVE 1…..1235
      FAILURE CODE [2C4MNX] CLOGGING OF RETARDER COOLING OIL FILTER…..1237
      FAILURE CODE [2F00KM] DRAGGING OF PARKING BRAKE…..1239
      FAILURE CODE [2G42ZG] LOWERING OF ACCUMULATOR OIL PRESSURE 9FRONT)…..1241
      FAILURE CODE [2G43ZG] LOWERING OF ACCUMULATOR OIL PRESSURE (REAR)…..1241
      FAILURE CODE [989A00] OPERATION OF ENGINE OVERRUN PREVENTION SYSTEM…..1242
      FAILURE CODE [989D00] REAR SECTION TIPPING OVER ALARM (RAISING OPERATION ON SLOPE)…..1242
      FAILURE CODE [A570NX] CLOGGING OF ENGINE OIL FILTER…..1243
      FAILURE CODE [AA10NX] CLOGGING OF AIR CLEANER…..1245
      FAILURE CODE [AG00MA] TROUBLE IN BATTERY CHARGE CIRCUIT…..1247
      FAILURE CODE [B@BAZG] LOWERING OF ENGINE OIL PRESSURE…..1248
      FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL…..1249
      FAILURE CODE [B@BCNS] OVERHEATING OF ENGINE…..1250
      FAILURE CODE [B@BCZK] LOWERING OF COOLANT LEVEL…..1251
      FAILURE CODE [B@BFZK] LOWERING OF FUEL LEVEL…..1253
      FAILURE CODE [B@B6NS] OVERHEATING OF GRAKE COOLING OIL (FRONT)…..1254
      FAILURE CODE [B@C8NS] OVERHEATING OF BRAKE COOLING OIL (CENTER)…..1254
      FAILURE CODE [B&CENS] OVERHEATING OF TORQUE CONVERTER OIL…..1255
      FAILURE CODE [B@JANS] OVERHEATING OF STEERING OI;…..1255
    TROUBLESHOOTING BY FAILURE CODE, PART 3…..1258
      FAILURE CODE [CA111] TROUBLE IN ENGINE CONTROLLER…..1261
      FAILURE CODE [CA115] TROUBLE IN ENGINE AND BKUP SPEED SENSORS…..1263
      FAILURE CODE [CA122] ABNORMALLY HIGH CHARGE PRESSURE…..1265
      FAILURE CODE [CA123] ABNORMALLY LOW CHARGE PRESSURE…..1267
      FAILURE CODE [CA131] ABNORMALLY HIGH THROTTLE SENSOR SIGNAL…..1269
      FAILURE CODE [CA132] ABNORMALLY LOW THROTTLE SENSOR SIGNAL…..1271
      FAILURE CODE [CA135] ABNORMALLY HIGH ENGINE OIL PRESSURE…..1273
      FAILURE CODE [CA141] ABNORMALLY LOW ENGINE OIL PRESSURE…..1275
      FAILURE CODE [CA144] ABNORMALLY HIGH COOLANT TEMPERATURE…..1277
      FAILURE CODE [CA145] ABNORMALLY LOW COOLANT TEMPERATURE…..1279
      FAILURE CODE [CA153] ABNORMALLY HIGH CHARGE TEMPERATURE…..1281
      FAILURE CODE [CA154] ABNORMALLY LOW CHARGE TEMPERATURE…..1283
      FAILURE CODE [CA1878] ABNORMALLY LOW VOLTAGE IN SENSOR POWER SUPPLY 2…..1284
      FAILURE CODE [CA221] ABNORMALLY HIGH AMBIENT PRESSURE…..1285
      FAILURE CODE [CA222] ABNORMALLY LOW AMBIENT PRESSURE…..1287
      FAILURE CODE [CA227] ABNORMALLY HIGH VOLTAGE IN SENSOR POWER SUPPLY 2…..1289
      FAILURE CODE [CA234] ENGINE OVERSPEED…..1291
      FAILURE CODE [CA238] TROUBLE IN SPEED SENSOR POWER SUPPLY…..1293
      FAILURE CODE [CA263] ABNORMALLY HIGH FUEL TEMPERATURE…..1295
      FAILURE CODE [CA265] ABNORMALLY LOW FUEL TEMPERATURE…..1297
      FAILURE CODE [CA271] SHORT CIRCUIT IN PCV1…..1298
      FAILURE CODE [CA272] DISCONNECTION IN PCV1…..1299
      FAILURE CODE [CA273] SHORT CIRCUIT IN PCV2…..1300
      FAILURE CODE [CA274] DISCONNECTION IN PCV2…..1301
      FAILURE CODE [CA322] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #1 (L #1)…..1303
      FAILURE CODE [CA323] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #5 (L #5)…..1305
      FAILURE CODE [CA324] DISCONNECTION OR SHORT CIRCUIT IN INJECTIOR #3 (L #3)…..1307
      FAILURE CODE [CA325] DISCONNECTION OR SHORT CIRCUIT IN INJECTOT #6 (L #6)…..1309
      FAILURE CODE [CA331] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #2 (L #2)…..1311
      FAILURE CODE [CA332] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR #4 (L #4)…..1313
      FAILURE CODE [CA342] MATCHING ERROR IN ENGINE CONTROLLER DATA…..1315
      FAILURE CODE [CA351] TROUBLE IN INJECTOR DRIVE CIRCUIT…..1317
      FAILURE CODE [CA352] ABNORMALLY LOW VOLTAGE IN SENSOR POWER SUPPLY 1…..1319
      FAILURE CODE [CA386] ABNORMALLY HIGH VOLTAGE IN SENSOR POWER SUPPLY 1…..1321
      FAILURE CODE [CA272] DISCONNECTION IN PCV1…..1299
      FAILURE CODE [CA273] SHORT CIRCUIT IN PCV2…..1300
      FAILURE CODE [CA274] DISCONNECTION IN PCV2…..1301
    TROUBLESHOOTING BY FAILURE CODE, PART 4…..1324
      FAILURE CODE [CA431] TROUBLE IN IDLE VALIDATION SWITCH…..1327
      FAILURE CODE [CA432] TROUBLE IN IDLE VALIDATION PROCESS…..1330
      FAILURE CODE [CA441] ABNORMALLY LOW VOLTAGE IN POWER SUPPLY…..1330
      FAILURE CODE [CA442} ABNORMALLY HIGH VOLTAGE IN POWER SUPPLY…..1331
      FAILURE CODE [CA449] ABNORMALLY HIGH COMMON RAIL PRESSURE 2…..1331
      FAILURE CODE [CA451] ABNORMALLY HIGH COMMON RAIL PRESSURE…..1333
      FAILURE CODE [CA452] ABNORMALLY LOW COMMON RAIL PRESSURE…..1335
      FAILURE CODE [CA553] ABNORMALLY HIGH COMMON RAIL PRESSURE 1…..1335
      FAILURE CODE [CA554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR…..1336
      FAILURE CODE [CA559] SUPPLY PUMP LOW PRESSURE 1…..1338
      FAILURE CODE [CA689] TROUBLE IN ENGINE NE SPEED SENSOR…..1341
      FAILURE CODE [CA731] PAHSE ERROR IN ENGINE BKUP SPEED SENSOR…..1343
      FAILURE CODE [CA757] LOSS OF ALL DATA IN ENGINE CONTROLLER…..1343
      FAILURE CODE [CA778] TROUBLE IN ENGINE BKUP SPEED SENSOR…..1345
      FAILURE CODE [CA1117] LOSS OF PARTIAL DATA IN ENGINE CONTROLLER…..1347
      FAILURE CODE [CA1228] TROUBLE IN EGR VALVE SERVO 1…..1347
      FAILURE CODE [CA1626] SHORT CIRCUIT IN BYPASS VALVE SOLENOID DRIVE CIRCUIT…..1349
      FAILURE CODE [CA1627] DISCONNECTION IN BYPASS VALVE SOLENOID DRIVE CIRCUIT…..1351
      FAILURE CODE [CA1628] TROUBLE IN BYPASS VALVE SERVO 1…..1352
      FAILURE CODE [CA1629] TROUBLE IN BYPASS VALVE SERVO 2…..1353
      FAILURE CODE [CA1631] ABNORMALLY HIGH SIGNAL IN BYPASS VALVE LIFT SENSOR…..1355
      FAILURE CODE [CA1632] ABNORMALLY LOW SIGNAL IN BYPASS VALVE LIFT SENSOR…..1357
      FAILURE CODE [CA1633] TROUBLE IN KOMNET…..1359
      FAILURE CODE [CA1642] ABNORMALLY LOW SIGNAL IN EGT INLET PRESSURE SENSOR…..1361
      FAILURE CODE [CA1653] ABNORMALLY HIGH SIGNAL IN EGR INLET PRESSURE SENSOR…..1363
      FAILURE CODE [CA2185] ABNORMALLY HIGH VOLTAGE IN THROTTLE SENSOR POWER SUPPLY…..1365
      FAILURE CODE [CA1286] ABNORMALLY LOW VOLTAVE IN THROTTLE SENSOR POWER SUPPLY…..1367
      FAILURE CODE [CA2249] LOW PRESSURE IN SUPPLY PUMP 2…..1367
      FAILURE CODE [CA2271] ABNORMALLY HIGH SIGNAL VOLTAGE IN EGT VALVE LIFT SENSOR…..1369
      FAILURE CODE [CA2272] ABNORMALLY LOW SIGNAL VOLTAVE IN EGR VALVE LIFT SENSOR…..1371
      FAILURE CODE [CA2351] SHORT CIRCUIT IN EGR VALVE SOLENOID DRIVE CIRCUIT…..1373
      FAILURE CODE [CA2352] DISCONNECTION IN EGR VALVE SOLENOID DRIVE CIRCUIT…..1375
      FAILURE CODE [CA2555] DISCONNECTION IN INTAKE AIR HEATER RELAY…..1375
      FAILURE CODE [CA2556] SHORT CIRCUIT IN INTAKE AIR HEATER RELAY…..1377
      FAILURE CODE [CA1625] TROUBLE IN EGR VALVE SERVO 2…..1348
    TROUBLESHOOTING BY FAILURE CODE, PART 5…..1380
      FAILURE CODE [DAF9KM] WRONG CONNECTION OF CONNECTOR…..1382
      FAILURE CODE [DAFRKR] TROUBLE IN CAN COMMUNICATION (MACHINE MONITOR)…..1383
      FAILURE CODE [DAQ0KK] LOWERING OF SOURCE VOLTAGE…..1385
      FAILURE CODE [DAQOKT] TROUBLE IN NON-VOLITLE MEMORY…..1387
      FAILURE CODE [DAQ2KK] TROUBLE IN SOLENOID POWER SUPPLY SYSTEM…..1389
      FAILURE CODE [DAQ9KQ] DISAGREEMENT OF MODEL SELECTION (TRANSMISSION CONTROLLER] …..1391
      FAILURE CODE [DAQRKR] TROUBLE IN CAN COMMUNICATION (TRANSMISSION CONTROLLER)…..1393
      FAILURE CODE [DAQRMA] DISAGREEMENT OF OPTION SETTING (TRANSMISSION CONTROLLER)…..1395
      FAILURE CODE [DB10KT] TROUBLE IN NON-VOLITLE MEMORY…..1395
      FAILURE CODE [DB12KK] TROUBLE IN SOLENOID POWER SUPPLY SYSTEM…..1397
      FAILURE CODE [DB13KK] LOWERING OF BATTERY DIRECT VOLTAGE…..1399
      FAILURE CODE [DB19KQ] DISAGREEMENT OF MODEL SELECTION (RETARDER CONTROLLER)…..1401
      FAILURE CODE [DB1QMA] DISAGREEMENT OF OPTION SETTING (RETARDER CONTROLLER)…..1401
      FAILURE CODE [DB1RKR] TROUBLE IN CAN COMMUNICATION (RETARTER CONTROLLER)…..1403
      FAILURE CODE [DB2RKR] TROUBLE IN CAN COMMUNICATION (ENGINE CONTROLLER)…..1405
      FAILURE CODE [DD1ML4] DISAGREEMENT OF ACCELERATOR-LINKED RETARDER SWITCH SIGNAL…..1407
      FAILURE CODE [DDTHKA] TROUBLE IN HI CLUTCH FLOW SENSOR VALVE…..1409
      FAILURE CODE [DDTJKA] TROUBLE IN LO CLUTCH FLOW SENSOR VALVE…..1410
      FAILURE CODE [DDTKKA] TROUBLE IN 1ST CLUTCH FLOW SENSOR VALVE…..1411
      FAILURE CODE [DDTLKA] TROUBLE IN 2ND CLUTCH FLOW SENSOR VALVE…..1412
      FAILURE CODE [DDTMKA] TROUBLE IN 3RD CLUTCH FLOW SENSOR VALVE…..1413
      FAILURE CODE [DDTNKA] TROUBLE IN REVERSE CLUTCH FLOW SENSOR VALVE…..1414
      FAILURE CODE [DF10KA] INUPT OF NO LEVER SIGNALS…..1415
      FAILURE CODE [DF10KB] INPUT OF MULTIPLE LEVER SIGNALS…..1419
      FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE OUT OF RANGE…..1423
      FAILURE CODE [DGR3KZ] GROUND FAULT IN BRAKE OIL TEMPERATURE SENSOR (DENTER)…..1425
      FAILURE CODE [DGR3L8] DISCONNECTION IN BRAKE OIL TEMPERATURE SENSOR (CENTER)…..1427
      FAILURE CODE [DGR4ZK] GROUND FAULT IN BRAKE OIL TEMPERATURE SENSOR (FRONT)…..1429
      FAILURE CODE [DGR4L8] DISCONNECTION IN BRAKE OIL TEMPERATURE SENSOR (FRONT)…..1431
      FAILURE CODE {DGR6KX] STEERING OIL TEMPERATURE OUT OF RANGE…..1433
    TROUBLESHOOTING BY FAILURE CODE, PART 6…..1436
      FAILURE CODE [DGT1KX] SHORT CIRCUIT IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM…..1439
      FAILURE CODE [DHT5KX] DISCONNECTION GROUND FAULT, OR SHORT CIRCUIT IN TORQUE CONVERTER OIL PRESSURE SENSOR SYSTEM…..1441
      FAILURE CODE [DHT5L6] TROUBLE IN TORQUE CONVERTER OIL PRESSURE SENSOR…..1443
      FAILURE CODE [DHU2KX] TROUBLE IN ACCUMULATOR OIL PRESSURE SENSOR (FRONT) SYSTEM…..1445
      FAILURE CODE [DHU3KX] TROUBLE IN ACCUMULATOR OIL PRESSURE SENSOR (REAR) SYSTEM…..1447
      FAILURE CODE [DJF1KA] DISCONNECTION IN FUEL LEVEL SENSOR SYSTEM…..1449
      FAILURE CODE [DK51LG] TROUBLE IN MANUAL RETARDER POTENTIOMETER AND RVS…..1451
      FAILURE CODE [DK52KX] TROUBLE IN DUMP LEVER POTENTIOMETER 1…..1453
      FAILURE CODE [DK53L8] TROUBLE IN DUMP LEVER POTENTIOMETER 2…..1455
      FAILURE CODE [DK54KX] TROUBLE IN DUMP POSITIONER SENSOR…..1457
      FAILURE CODE [DKH0KX] PITCH ANGLE SENSOR SIGNAL OUT OF RANGE…..1459
      FAILURE CODE [DLF1KA] DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR SYSTEM…..1461
      FAILURE CODE [DLF1LC] TROUBLE IN TRANSMISSION INPUT SHAFT SPEED SENSOR…..1462
      FAILURE CODE [DLF2KA] TROUBLE IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR…..1463
      FAILURE CODE [DLF2LC] DISCONNECTION IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR SYSTEM…..1464
      FAILURE CODE [DLF4KA] DISCONNECTION IN TRANSMISSION DIFFERENTIAL SPEED SENSOR SYSTEM…..1465
      FAILURE CODE [DLT3KA] DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM…..1466
      FAILURE CODE [DV00KB] SHORT CIRCUIT IN BUZZER OUTPUT CIRCUIT…..1467
      FAILURE CODE [DW72KZ] TROUBLE (DISCONNECTION OR GROUND FAULT) IN KICK-OUT SOLENOID OUTPUT SYSTEM…..1469
      FAILURE CODE [DW73KZ] TROUBLE IN DUMP SELECTOR VALVE OUTPUT SYSTEM…..1471
      FAILURE CODE [DW78KZ] TROUBLE IN REAR WHEEL BCV COMMAND OUTPUT SYSTEM…..1473
      FAILURE CODE [DW79KZ] TROUBLE IN FRONT WHEEL BCV COMMAND OUTPUT SYSTEM…..1475
      FAILURE CODE [DX11K4] TROUBLE IN REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 1…..1477
      FAILURE CODE [DX114KA] DISCONNECTION IN OUTPUT CIRCUIT OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE…..1479
      FAILURE CODE [ DX11KB] GROUND FAULT IN OUTPUT CIRCUIT OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE…..1481
      FAILURE CODE [DX11KY] HOT SHORT IN OUTPUT CIRCUTI OF REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE…..1483
      FAILURE CODE [DX11MA] TROUBLE IN REAR WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 2…..1485
      FAILURE CODE [DX12K4] TROUBLE IN FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 1…..1487
      FAILURE CODE [DX12KB] GROUND FAULT IN OUTPUT CIRCUIT OF FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE…..1491
      FAILURE CODE [DX12KY] HOT SHORT IN OUTPUT CIRCUIT OF FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE…..1493
      FAILURE CODE [DX12MA] TROUBLE IN FRONT WHEEL PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE 2…..1495
    TROUBLESHOOTING BY FAILURE CODE, PART 7…..1498
      FAILURE CODE [DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF DUMP EPC VALVE…..1501
      FAILURE CODE [DX13KB] GROUND FAULT IN OUTPUT CIRCUIT OF DUMP EPC VALVE…..1503
      FAILURE CODE [DX13KY] HOT SHORT IN OUTPUT CIRCUIT OF DUMP EPC VALVE…..1505
      FAILURE CODE [DX14KZ] TROUBLE IN REAR WHEEL DIFFERENTIAL LOCK COMMAND OUTPUT SYSTEM…..1507
      FAILURE CODE [DX14KZ] TROUBLE IN FRONT WHEEL DIFFERENETIAL LOCK COMMAND OUTPUT SYSTEM…..1509
      FAILURE CODE [DXH0KA] DISCONNECTION IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID…..1511
      FAILURE CODE [DXH0KB] GROUND FAULT IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID…..1513
      FAILURE CODE [DXH0KY] HOT SHORT IN OUTPUT CIRCUIT OF INTERAXLE DIFFERENTIAL LOCK CLUTCH SOLENOID…..1515
      FAILURE CODE [DXH1KA] DISCONNECTION IN UTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID…..1516
      FAILURE CODE [DXH1KB] GROUND FAULT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID…..1517
      FAILURE CODE [DXH1KY[] HOT SHORT IN OTUPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID…..1519
      FAILURE CODE [DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID…..1521
      FAILURE CODE [DXH2KB] GROUND FAULT IN OUTPUT CIRCUIT OF HI CLUTCH ECMV SOLENOID VALVE…..1523
      FAILURE CODE [DXH2KY] HOT SHORT IN OUTPUT CIRCUIT OF HI CLUTCH ECMV SOLENOID VALVE…..1525
      FAILURE CODE [DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID…..1529
      FAILURE CODE [DXH3KB] GROUND FAULT IN OUTPUT CIRCUIT OF LO CLUTCH ECMV SOLENOID VALVE…..1531
      FAILURE CODE [DXH3KY] HOT SHORT IN OUTPUT CIRCUIT OF LO CLUTCH ECMV SOLENOID VALVE…..1533
      FAILURE CODE [DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID…..1537
      FAILURE CODE [DXH4KB] GROUND FAULT IN OUTPUT CIRCUIT OF 1ST CLUTCH ECMV SOLENOID VALVE…..1539
      FAILURE CODE [DXH4KY] HOT SHORT IN OUTPUT CIRCUIT OF 1ST CLUTCH ECMV SOLENOID VALVE…..1541
    TROUBLESHOOTING BY FAILURE CODE, PART 8…..1546
      FAILURE CODE [DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID…..1547
      FAILURE CODE [DXH5KB] GROUND FAULT IN OUTPUT CIRCUIT OF 2ND CLUTCH ECMV SOLENOID VALVE…..1549
      FAILURE CODE [DXH5KY] HOT SHORT IN OUTPUT CIRCUIT OF 2ND CLUTCH ECMV SOLENOID VALVE…..1551
      FAILURE CODE {DXH6KA] DISCONNECTION IN OUTUT CIRCUIT OF 3RD CLUTCH SOLENOID…..1555
      FAILURE CODE [DXH6KB] GROUND FAULT IN OUTPUT CIRCUIT OF 3RD CLUTCH ECMV SOLENOID VALVE…..1557
      FAILURE CODE [DXH6KY] HOT SHORT IN OUTPUT CIRCUIT OF 3RD CLUTCH ECMV SOLENOID VALVE…..1559
      FAILURE CODE [DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF REVERSE CLUTCH SOLENOID…..1563
      FAILURE CODE [DXH7KB] GROUND FAULT IN OUTPUT CIRCUIT OF REVERSE CLUTCH ECMV SOLENOID VALVE…..1565
      FAILURE CODE [DXH7KY] HOT SHORT IN OUTPUT CIRCUIT OF REVERSE CLUTCH ECMV SOLENOID VALVE…..1567
    TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…..1572
      BEFORE TROUBLESHOOTING FOR ELECTRICAL SYSTEM…..1574
      INFORMATION IN TROUBLESHOOTING TABLE…..1580
      E-1 ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN0…..1581
      E-2 AUTO PREHEATER DOES NOT OPERATE…..1585
      E-3 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DISPLAYS NOTHING…..1589
      E-4 WHEN STARTING SWITCH IS TURNED OFF, MACHINE MONITOR CANNOT BE OPERATED…..1591
      E-5 ALARM BUZZER DOES NOT STOP SOUNDING…..1593
      E-6 MACHINE MONITOR DOES NOT NORMALLY DISPLAY GAUGES, CAUTION LAMPS, AND CHARACTER DISPLAY SECTION…..1594
      E-7 DISPLAY OF CHARACTER DISPLAY SECTION CANNOT BE CHANGED…..1595
      E-8 POWER MODE SELECTION FUNTION DOES NOT OPERATE NORMALLY…..1599
      E-9 AISS FUNCTION DOES NOT OPERATE NORMALLY…..1601
      E-10 RIGHT AND LEFT DIFFERENTIAL LOCK FUNCTION DOES NOT OPERATE NORMALLY (DIFFERENTIAL LOCK-UP SPECIFICATION)…..1603
      E-11 INTERAXLE DIFFERENTIAL LOCK-UP FUNCTION DOES NOT OPERATE NORMALLY…..1607
      E-12 DISPLAY OF SEAT BELT CAUTION LAMP IS ABNORMAL…..1609
      E-13 TURN SIGNAL LAMPS AND PILOT LAMPS DO NOT OPERATE NORMALLY…..1611
      E-14 NIGHT LIGHTING IS ABNORMAL…..1616
      E-15 BACKUP LAMP AND BACKUP BUZZER OPERATE ABNORMALLY…..1622
      E-16 EMERGENCY STEERING SYSTEM DOES NOT OPERATE…..1626
    TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…..1632
      INFORMATION IN TROUBLESHOOTING TABLE…..1634
      H-1 MACHINE DOES NTO START…..1635
      H-2 TRAVEL IS NOT SMOOTH (MACHINE HUNTS)…..1637
      H-3 LOCKUP IS NOT RESET…..1637
      H-4 START SHOCK AND GEAR SHIFT SHOCK ARE ABNORMALLY LARGE…..1638
      H-5 GEAR IS NOT SHIFTED UP…..1639
      H-6 TRAVEL SPEED OR POWER IS LOW…..1641
      H-7 START AND GEARSHIFT TIME LAG IS LARGE…..1645
      H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…..1647
      H-9 TORQUE CONVERTER OIL TEMPERATURE IS LOW…..1648
      H-10 FRONT BRAKE DOES NOT WORK FULLY…..1649
      H-11 CENTER BRAKE DOES NOT WORK FULLY…..1650
      H-12 REAR BRAKE DOES NOT WORK FULLY…..1651
      H-13 STEERING WHEEL IS HEAVY…..1652
      H-14 STEERING WHEEL DOES NOT MOVE…..1653
      H-15 STEERING WHEEL WAGGLE…..1654
      H-16 DUMP BODY RAISING SPEED IS LOW…..1655
      H-17 DUMP BODY DOES NOT MOVE…..1656
      H-18 HYDRUALIC DRIFT OF DUMP BODY IS LARGE…..1657
    TROUGLESHOOTING OF ENGINE (S-MODE)…..1660
      METHOD OF USING TROUBLE SHOOTING CHART…..1663
      S-1 STARTING PERFORMANCE OF ENGINE IS POOR…..1667
      S-2 ENGINE DOES NOT START…..1669
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY…..1673
      S-4 ENGINE STOPS DURING OPERATION…..1674
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY…..1675
      S-6 ENGINE LACK OUTPUT (OR LACKS POWER)…..1676
      S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMPUSTION)…..1677
      S-8 OIL CONSUMPTION IS EXCESSIIVE (OR EXHAUST GAS IS BLUE)…..1679
      S-9 OIL BECOMES DIRTY QUICKLY…..1680
      S-10 FUEL CONSUMPTION IS EXCESSIVE…..1681
      S-11 OIL IS IN COOLAND (OR COOLANT SPRAYS BACK OR COOLANT LEVEL GOES DOWN)…..1682
      S-12 OIL PRESSURE DROPS…..1683
      S-13 OIL LEVEL RISES (TRNTY OF COOLANT OR FUEL)…..1685
      S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..1687
      S-15 ABNORMAL NOISE IS MADE…..1688
      S-16 VIBRATION IS EXCESSIVE…..1689
  50 DISASSEMBLY AND ASSEMBLY…..1692
    GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY…..1692
      HOW TO READ THIS MANUAL…..1693
      LIST OF ADHESIVES…..1695
      SPECIAL TOOL LIST…..1698
      SKETCHES OF SPECIAL TOOLS…..1704
    ENGINE AND COOLING SYSTEM…..1718
      REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP…..1719
      REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY…..1722
      REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…..1730
      REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…..1743
      REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…..1748
      REMOVAL AND INSTALLATION OF COOLING ASSEMBLY…..1752
      REMOVAL AND INSTALLATION OF AFTERCOOLER…..1756
      REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…..1759
      REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…..1761
    POWER TRAIN, PART 1…..1766
      REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY…..1767
      DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..1771
      REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..1774
      DISCONNECTION AND COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION…..1782
      DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…..1783
      DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY…..1791
    POWER TRAIN, PART 2…..1836
      DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..1837
      REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…..1856
      DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..1860
      REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…..1876
      DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..1878
    POWER TRAIN, PART 3…..1892
      REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..1893
      DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..1895
      REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..1908
      DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..1910
      REMOVAL AND INSTALLATION OF REAR FINAL DRIVE ASSEMBLY…..1921
      DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..1923
      REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY…..1930
      REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY…..1933
    UNDERCARRIAGE AND FRAME…..1938
      REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY…..1939
      REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY…..1941
      REMOVAL AND INSTALLATION OF EQUILIZER BAR ASSEMBLY…..1942
      REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY…..1944
      REMOVAL AND INSTALLATION OF REAR FRONT WHEEL ASSEMBLY…..1945
      REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY…..1946
      DISASSEMBLY AND ASSEMBLY OF HITCH FRAME…..1952
      REMOVAL AND INSTALLATION OF BODY ASSEMBLY…..1955
    HYDRAULIC SYSTEM…..1958
      DISASSEMBLY AND ASSEMBLY OF STEERING VALVE…..1959
      REMOVAL AND INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY…..1969
      REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY…..1971
      DISASSEMBLY AND ASSEMBLY OF HOIST VALVE ASSEMBLY…..1973
      DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY…..1975
      DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY…..1981
    CAB AND ITS ATTACHMENTS…..1990
      REMOVAL AND INSTALLATION OF OPERATOR&apos;S CAB…..1991
      REMOVAL AND INSTALLATION OF OPERATOR&apos;S CAB GLASS (STUCK GLASS)…..1996
      DISASSEMBLY AND ASSEMBLY OF OPERATOR&apos;S SEAT ASSEMBLY…..2003
      REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…..2013
    ELECTRICAL SYSTEM…..2020
      REMOVAL AND INSTALLATION OF RETARDER CONTROLLER ASSEMBLY…..2021
      REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY…..2023
      REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY…..2025
  90 DIAGRAMS AND DRAWINGS…..2028
    HYDRAULIC DIAGRAMS AND DRAWINGS…..2028
      STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.:  PREVIOUS DESIGN)…..2030
      STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.:  NEW DESIGN)…..2032
      BRAKE HYDRAULIC CIRCUIT DIAGRAM,…..2034
      BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…..2036
      DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM…..2038
    ELECTRICAL DIAGRAMS AND DRAWINGS…..2043
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/4)…..2045
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4)(SERIAL NO.: PREVIOUS DESIGN)…..2047
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4)(SERIAL NO.: NEW DESIGN)…..2049
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: PREVIOUS DESIGN)…..2051
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: NEW DESIGN)…..2053
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (4/4)…..2055
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3)…..2057
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3)…..2059
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3)…..2061
      CONNECTORS TABLE AND ARRANGEMENT DRAWING HM350-2…..2063
EEAM0024900 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..2064
  FOREWORD…..2066
    FOREWORD…..2067
    SAFETY INFORMATION…..2068
      Noise emission levels…..2070
      Vibration levels…..2070
        Guide to Reduce Vibration Levels on Machine…..2071
    INTENDED USE…..2073
      DIRECTIONS OF MACHINE…..2073
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2074
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..2074
      EPA REGULATIONS, ENGINE NUMBER PLATE…..2074
      SERVICE METER POSITION…..2075
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2075
      MACHINE SERIAL NUMBER PLATE…..2076
      FOREWORD…..2077
      SAFETY…..2077
      OPERATION…..2078
      MAINTENANCE…..2080
      SPECIFICATIONS…..2082
      ATTACHMENTS, OPTIONS…..2083
      INDEX…..2083
      COLOPHON…..2083
  SAFETY…..2084
    SAFETY INFORMATION…..2085
    SAFETY LABELS…..2087
      POSITION FOR ATTACHING SAFETY LABELS…..2087
      SAFETY LABELS…..2088
    GENERAL PRECAUTIONS…..2095
    PRECAUTIONS DURING OPERATION…..2104
      STARTING ENGINE…..2104
      OPERATION…..2106
      TRANSPORTATION…..2110
      BATTERY…..2111
      TOWING…..2113
    PRECAUTIONS FOR MAINTENANCE…..2114
    PRECAUTIONS WITH TIRES…..2121
  OPERATION…..2122
    GENERAL VIEW…..2123
      GENERAL VIEW OF MACHINE…..2123
      GENERAL VIEW OF CONTROLS AND GAUGES…..2124
    EXPLANATION OF COMPONENTS…..2126
      MACHINE MONITOR…..2126
        CHARACTER DISPLAY…..2128
        CAUTION ITEMS…..2133
        EMERGENCY STOP ITEM…..2136
        METER DISPLAY PORTION…..2140
        CENTRAL WARNING LAMP…..2146
      OTHER FUNCTIONS OF MACHINE MONITOR…..2147
      SWITCHES…..2150
      CONTROL LEVERS AND PEDALS…..2160
      BODY PIVOT PIN…..2165
      ARTICULATE LOCK…..2165
      LOCATION OF FIRE EXTINGUISHER…..2166
      DUST INDICATOR…..2166
      CIRCUIT BREAKER…..2166
      FUSES…..2167
        FUSE CAPACITY AND CIRCUIT NAME…..2167
      CAR RADIO…..2170
        EXPLANATION OF COMPONENTS…..2170
        METHOD OF OPERATION…..2173
        PRECAUTIONS FOR USE…..2175
      CAR STEREO…..2176
        EXPLANATION OF COMPONENTS…..2176
        METHOD OF OPERATION…..2181
        PRECAUTIONS FOR USE…..2183
      AIR CONDITIONER…..2184
        GENERAL LOCATIONS ON CONTROL PANEL…..2184
        METHOD OF OPERATION…..2187
        PRECAUTIONS WHEN USING AIR CONDITIONER…..2189
        INSPECTION AND MAINTENANCE…..2189
    OPERATION…..2190
      CHECK BEFORE STARTING ENGINE…..2190
        WALK-AROUND CHECK…..2190
        CHECK BEFORE STARTING…..2192
        ADJUSTMENT BEFORE OPERATION…..2198
        OPERATIONS, CHECKS BEFORE STARTING…..2202
      STARTING ENGINE…..2203
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..2205
        BREAKING-IN THE MACHINE…..2205
        WARMING-UP OPERATION…..2205
        CANCELING DUMP BODY HOLD CONDITION…..2206
      STOPPING ENGINE…..2206
      CHECKS AFTER STOPPING ENGINE…..2206
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..2207
        MOVING MACHINE FORWARD…..2207
        MOVING MACHINE IN REVERSE…..2209
        STOPPING MACHINE…..2210
      SHIFTING GEAR…..2212
      TRAVELING DOWNHILL…..2213
        BRAKE PERFORMANCE CURVE…..2215
      STEERING THE MACHINE…..2219
      OPERATION USING DIFFERENTIAL LOCK…..2219
        COMBINATION OF DIFFERENTIAL LOCK…..2220
        WHEN TIRES ARE STUCK IN GROUND…..2221
      LOADING OPERATIONS…..2222
      DUMP OPERATIONS…..2223
      CAB TILT OPERATION…..2225
        WHEN USING CRANE…..2225
        WHEN USING TILT CYLINDER…..2226
      PRECAUTIONS FOR OPERATION…..2226
        PERMISSIBLE WATER DEPTH…..2227
      PARKING MACHINE…..2228
      CHECKS AFTER COMPLETION OF WORK…..2229
      LOCKING…..2229
      HANDLING TIRES…..2230
        PRECAUTIONS WHEN HANDLING TIRES…..2230
        PRECAUTIONS FOR LONG DISTANCE TRAVEL…..2230
    DETERMINING AND MAINTAINING TRAVEL ROAD…..2231
      DETERMINING TRAVEL ROAD…..2231
      MAINTAINING TRAVEL ROAD…..2231
    TRANSPORTATION…..2232
      PRECAUTIONS WHEN TRANSPORTING…..2232
      STEPS FOR TRANSPORTATION…..2232
      METHOD OF SECURING MACHINE…..2233
      METHOD OF LIFTING MACHINE…..2234
        LOCATION OF LIFTING POSITION MARK…..2235
        WEIGHT TABLE…..2235
        LIFTING PROCEDURE…..2236
    COLD WEATHER OPERATION…..2238
      PRECAUTIONS FOR LOW TEMPERATURE…..2238
        FUEL AND LUBRICANTS…..2238
        COOLANT…..2238
        BATTERY…..2239
        INSTALLATION OF RADIATOR CURTAIN…..2239
      PRECAUTIONS AFTER COMPLETION OF WORK…..2240
      AFTER COLD WEATHER…..2240
    LONG-TERM STORAGE…..2241
      BEFORE STORAGE…..2241
      DURING STORAGE…..2241
      AFTER STORAGE…..2242
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..2242
    TROUBLESHOOTING…..2243
      AFTER RUNNING OUT OF FUEL…..2243
      IF TRANSMISSION HAS TROUBLE…..2244
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..2245
      METHOD OF TOWING MACHINE…..2245
        WHEN ENGINE RUNS…..2247
        WHEN ENGINE DOES NOT RUN…..2247
        WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY…..2248
      IF BATTERY IS DISCHARGED…..2249
        REMOVAL AND INSTALLATION OF BATTERY…..2249
        PRECAUTIONS FOR CHARGING BATTERY…..2250
        STARTING ENGINE WITH BOOSTER CABLE…..2251
      OTHER TROUBLE…..2253
        ELECTRICAL SYSTEM…..2253
        CHASSIS…..2254
        ENGINE…..2256
        ACTION CODE…..2258
  MAINTENANCE…..2260
    GUIDES TO MAINTENANCE…..2261
    OUTLINE OF SERVICE…..2263
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2263
        OIL…..2263
        FUEL…..2264
        COOLANT AND WATER FOR DILUTION…..2264
        GREASE…..2265
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…..2266
        STORING OIL AND FUEL…..2267
        FILTERS…..2267
      OUTLINE OF ELECTRIC SYSTEM…..2267
    WEAR PARTS…..2268
      WEAR PARTS LIST…..2268
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..2269
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..2270
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..2272
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..2273
      TORQUE LIST…..2273
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2274
      SAFETY CRITICAL PARTS…..2275
    MAINTENANCE SCHEDULE CHART…..2276
      MAINTENANCE SCHEDULE CHART…..2276
    SERVICE PROCEDURE…..2279
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..2279
      WHEN REQUIRED…..2280
        CHECK, CLEAN OR REPLACE AIR CLEANER…..2280
        CLEAN INSIDE OF COOLING SYSTEM…..2286
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..2289
        CLEAN AIR CONDITIONER AIR FILTER…..2289
        CHECK REFRIGERANT (GAS) LEVEL…..2290
        CHECK DUMP BODY…..2291
        BLEED AIR FROM FRONT BRAKE…..2291
        BLEED AIR FROM CENTER BRAKE…..2292
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..2293
        SELECTION AND INSPECTION OF TIRES…..2294
      CHECK BEFORE STARTING…..2296
      EVERY 50 HOURS SERVICE…..2297
        LUBRICATION…..2297
      EVERY 250 HOURS SERVICE…..2298
        LUBRICATION…..2298
        LUBRICATE DRIVE SHAFT…..2300
        CHECK DRIVE SHAFT…..2300
        CLEAN BREATHERS…..2301
        CLEAN OVERFLOW HOSE…..2302
        CHECK LEVEL OF BATTERY ELECTROLYTE…..2303
        CHECK ALTERNATOR BELT TENSION, ADJUST…..2305
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..2306
        CHECK FRAME, A-ARM…..2307
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..2308
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..2308
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..2309
        CHECK WEAR OF PARKING BRAKE PADS…..2309
        CHECK LENGTH OF SUSPENSION CYLINDER…..2309
        CHECK OF ACCUMULATOR GAS PRESSURE…..2311
      EVERY 500 HOURS SERVICE…..2312
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2312
        REPLACE FUEL PREFILTER CARTRIDGE…..2313
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..2314
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2315
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..2316
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..2317
        CHECK FAN BELT TENSION, ADJUST…..2318
        RECOVER OIL LEAKING FROM FLOATING SEAL…..2319
      EVERY 1000 HOURS SERVICE…..2320
        REPLACE FUEL MAIN FILTER CARTRIDGE…..2320
        REPLACE CORROSION RESISTOR CARTRIDGE…..2321
        REPLACE TRANSMISSION FILTER ELEMENT…..2322
        CHANGE OIL IN TRANSMISSION CASE…..2323
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..2325
        LUBRICATION…..2327
        CHECK WEAR OF BRAKE DISC…..2329
        CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS…..2330
      EVERY 2000 HOURS SERVICE…..2331
        CHANGE OIL IN FINAL DRIVE CASE…..2331
        CHANGE OIL IN DIFFERENTIAL CASE…..2332
        REPLACE HYDRAULIC FILTER ELEMENT…..2334
        CLEAN HYDRAULIC TANK STRAINER…..2335
        CLEAN TRANSMISSION CASE STRAINER…..2335
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..2336
        CLEAN BREATHER…..2337
        CHECK ACCUMULATOR GAS PRESSURE…..2338
        CHECK ALTERNATOR…..2338
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..2338
      EVERY 4000 HOURS SERVICE…..2339
        CHANGE OIL IN HYDRAULIC TANK…..2339
        CHECK STARTING MOTOR…..2339
        CHECK WATER PUMP…..2339
        CHECK AIR COMPRESSOR…..2339
        CHECK FAN PULLEY AND TENSION PULLEY…..2339
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..2340
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..2340
      EVERY 6000 HOURS SERVICE…..2341
        LUBRICATE DRIVE SHAFT…..2341
      EVERY 8000 HOURS SERVICE…..2342
        REPLACE HIGH-PRESSURE PIPING CLAMP…..2342
        REPLACE FUEL SPRAY PREVENTION CAP…..2342
        OVERHAUL STARTING MOTOR AND ALTERNATOR…..2342
  SPECIFICATIONS…..2344
    SPECIFICATIONS…..2345
  ATTACHMENTS, OPTIONS…..2346
    HANDLING TACHOGRAPH (TCO20-90W)…..2347
      EXPLANATION OF COMPONENTS…..2347
      METHOD OF USE…..2350
        OPENING AND CLOSING COVER…..2350
        SETTING TIME…..2351
        REPLACING CHART PAPER…..2352
        REPLACING LAMP…..2353
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..2354
      BASIC PRECAUTIONS…..2354
  INDEX…..2356
    &lt;A&gt;…..2358
    &lt;B&gt;…..2358
    &lt;C&gt;…..2358
    &lt;D&gt;…..2358
    &lt;E&gt;…..2358
    &lt;F&gt;…..2358
    &lt;G&gt;…..2358
    &lt;H&gt;…..2358
    &lt;I&gt;…..2358
    &lt;L&gt;…..2358
    &lt;M&gt;…..2358
    &lt;O&gt;…..2358
    &lt;P&gt;…..2359
    &lt;R&gt;…..2359
    &lt;S&gt;…..2359
    &lt;T&gt;…..2359
    &lt;W&gt;…..2359
  COLOPHON…..2360
EEAM022502 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual…..2362
  FOREWORD…..2364
    FOREWORD…..2365
    SAFETY INFORMATION…..2366
      NOISE…..2368
      Vibration levels…..2369
    INTENDED USE…..2371
      DIRECTIONS OF MACHINE…..2371
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2372
      MACHINE SERIAL NO. PLATE POSITION…..2372
      ENGINE SERIAL NO. PLATE POSITION…..2372
      SERVICE METER POSITION…..2373
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2373
      MACHINE SERIAL NUMBER PLATE…..2374
        REMARKS…..2374
      FOREWORD…..2375
      SAFETY…..2375
      OPERATION…..2376
      MAINTENANCE…..2378
      SPECIFICATIONS…..2380
  SAFETY…..2382
    SAFETY INFORMATION…..2383
    SAFETY LABELS…..2385
      POSITION FOR ATTACHING SAFETY LABELS…..2385
      SAFETY LABELS…..2386
    GENERAL PRECAUTIONS…..2392
    PRECAUTIONS DURING OPERATION…..2399
      STARTING ENGINE…..2399
      OPERATION…..2401
      TRANSPORTATION…..2404
      BATTERY…..2405
      TOWING…..2407
    PRECAUTIONS FOR MAINTENANCE…..2408
    PRECAUTIONS WITH TIRES…..2414
  OPERATION…..2416
    GENERAL VIEW…..2417
      GENERAL VIEW OF MACHINE…..2417
      GENERAL VIEW OF CONTROLS AND GAUGES…..2418
    EXPLANATION OF COMPONENTS…..2420
      MACHINE MONITOR…..2420
        CHARACTER DISPLAY…..2422
        CAUTION ITEMS…..2426
        EMERGENCY STOP ITEM…..2429
        METER DISPLAY PORTION…..2433
        CENTRAL WARNING LAMP…..2439
      OTHER FUNCTIONS OF MACHINE MONITOR…..2440
      SWITCHES…..2443
      CONTROL LEVERS AND PEDALS…..2454
      MECHATRONICS EQUIPMENT CONTROLLER…..2459
      SAFETY PIN…..2460
      ARTICULATE LOCK…..2460
      DUST INDICATOR…..2461
      FUSES…..2461
        FUSE CAPACITY AND CIRCUIT NAME…..2461
      CAR RADIO…..2464
        EXPLANATION OF COMPONENTS…..2464
        METHOD OF OPERATION…..2467
        PRECAUTIONS FOR USE…..2468
      CAR STEREO…..2469
        EXPLANATION OF COMPONENTS…..2469
        METHOD OF OPERATION…..2474
        PRECAUTIONS FOR USE…..2476
      AIR CONDITIONER…..2477
        GENERAL LOCATIONS ON CONTROL PANEL…..2477
        METHOD OF OPERATION…..2479
        PRECAUTIONS WHEN USING AIR CONDITIONER…..2480
        INSPECTION AND MAINTENANCE…..2480
    OPERATION…..2481
      CHECK BEFORE STARTING ENGINE…..2481
        WALK-AROUND CHECK…..2481
        CHECK BEFORE STARTING…..2483
        ADJUSTMENT BEFORE OPERATION…..2489
        OPERATIONS, CHECKS BEFORE STARTING…..2491
      STARTING ENGINE…..2492
        NORMAL STARTING…..2492
        STARTING IN COLD WEATHER…..2493
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..2495
        BREAKING-IN THE MACHINE…..2495
        WARMING-UP OPERATION…..2495
        CANCELING DUMP BODY HOLD CONDITION…..2495
      STOPPING ENGINE…..2496
      CHECKS AFTER STOPPING ENGINE…..2496
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..2497
        MOVING MACHINE FORWARD…..2497
        MOVING MACHINE REVERSE…..2498
        STOPPING THE MACHINE…..2499
      SHIFTING GEAR…..2500
      TRAVELING DOWNHILL…..2502
        BRAKE PERFORMANCE CURVE…..2503
      STEERING THE MACHINE…..2504
      OPERATION USING DIFFERENTIAL LOCK…..2505
        METHOD OF USING INTER-AXLE DIFFERENTIAL LOCK…..2505
        COMBINATION OF DIFFERENTIAL LOCK…..2506
        WHEN TIRES ARE STUCK IN GROUND…..2507
      LOADING OPERATIONS…..2507
      DUMP OPERATIONS…..2508
      CAB TILT OPERATION…..2510
        WHEN USING CRANE…..2510
        WHEN USING TILT CYLINDER…..2511
      PRECAUTIONS FOR OPERATION…..2511
      PARKING MACHINE…..2512
      CHECKS AFTER COMPLETION OF WORK…..2512
      LOCKING…..2513
      HANDLING TIRES…..2514
        PRECAUTIONS WHEN HANDLING TIRES…..2514
        PRECAUTIONS FOR LONG DISTANCE TRAVEL…..2514
    DETERMINING AND MAINTAINING TRAVEL ROAD…..2515
      DETERMINING TRAVEL ROAD…..2515
      MAINTAINING TRAVEL ROAD…..2515
    TRANSPORTATION…..2516
      PRECAUTIONS WHEN TRANSPORTING…..2516
      STEPS FOR TRANSPORTATION…..2516
      PRECAUTIONS WHEN LOADING…..2516
      METHOD OF LIFTING MACHINE…..2517
        LOCATION OF LIFTING POSITION MARK…..2518
        WEIGHT TABLE…..2518
        LIFTING PROCEDURE…..2519
    COLD WEATHER OPERATION…..2520
      PRECAUTIONS FOR LOW TEMPERATURE…..2520
        FUEL AND LUBRICANTS…..2520
        COOLANT…..2520
        BATTERY…..2521
        INSTALLATION OF RADIATOR CURTAIN…..2521
      PRECAUTIONS AFTER COMPLETION OF WORK…..2521
      AFTER COLD WEATHER…..2522
    LONG-TERM STORAGE…..2523
      BEFORE STORAGE…..2523
      DURING STORAGE…..2523
      AFTER STORAGE…..2523
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..2523
    TROUBLESHOOTING…..2524
      AFTER RUNNING OUT OF FUEL…..2524
      TOWING THE MACHINE…..2525
        WHEN ENGINE RUNS…..2526
        WHEN ENGINE DOES NOT RUN…..2526
        WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY…..2526
        WHEN FINAL DRIVE, DIFFERENTIAL, TRANSMISSION, TRANSFER HAVE BROKEN DOWN…..2526
      IF BATTERY IS DISCHARGED…..2527
        REMOVAL AND INSTALLATION OF BATTERY…..2527
        PRECAUTIONS FOR CHARGING BATTERY…..2528
        STARTING ENGINE WITH BOOSTER CABLE…..2528
      OTHER TROUBLE…..2530
        ELECTRICAL SYSTEM…..2530
        CHASSIS…..2531
        ENGINE…..2533
        ACTION CODE…..2535
  MAINTENANCE…..2536
    GUIDES TO MAINTENANCE…..2537
    OUTLINE OF SERVICE…..2539
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2539
        OIL…..2539
        FUEL…..2539
        COOLANT…..2539
        GREASE…..2540
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…..2540
        STORING OIL AND FUEL…..2541
        FILTERS…..2541
      OUTLINE OF ELECTRIC SYSTEM…..2541
    WEAR PARTS…..2542
      WEAR PARTS LIST…..2542
    USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..2543
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..2548
      TORQUE LIST…..2548
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2549
      SAFETY CRITICAL PARTS…..2549
    MAINTENANCE SCHEDULE CHART…..2550
      MAINTENANCE SCHEDULE CHART…..2550
    SERVICE PROCEDURE…..2552
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..2552
      WHEN REQUIRED…..2553
        CHECK, CLEAN OR REPLACE AIR CLEANER…..2553
        CLEAN INSIDE OF COOLING SYSTEM…..2555
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..2557
        CLEAN AIR CONDITIONER AIR FILTER…..2557
        CHECK REFRIGERANT (GAS) LEVEL…..2558
        CHECK DUMP BODY…..2558
        CHECK ELECTRIC INTAKE AIR HEATER…..2558
        CHECK LENGTH OF SUSPENSION CYLINDER…..2559
        BLEED AIR FROM FRONT BRAKE…..2560
        BLEED AIR FROM CENTER BRAKE…..2561
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..2562
        SELECTION AND INSPECTION OF TIRES…..2562
      CHECK BEFORE STARTING…..2565
      EVERY 50 HOURS SERVICE…..2566
        LUBRICATION…..2566
      EVERY 250 HOURS SERVICE…..2567
        LUBRICATION…..2567
        LUBRICATE DRIVE SHAFT…..2568
        CHECK DRIVE SHAFT…..2568
        CHECK LEVEL OF BATTERY ELECTROLYTE…..2569
        CHECK ALTERNATOR BELT TENSION, ADJUST…..2571
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..2572
        CHECK FRAME, A-ARM…..2573
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..2574
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..2574
        CHECK WEAR OF PARKING BRAKE PADS…..2575
      EVERY 500 HOURS SERVICE…..2576
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2576
        REPLACE FUEL FILTER CARTRIDGE…..2577
        CLEAN FUEL TANK STRAINER…..2578
        LUBRICATION…..2579
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2579
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..2580
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..2581
        CHECK FAN BELT TENSION, ADJUST…..2582
      EVERY 1000 HOURS SERVICE…..2583
        REPLACE CORROSION RESISTOR CARTRIDGE…..2583
        REPLACE TRANSMISSION FILTER ELEMENT…..2583
        CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER…..2584
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..2586
        LUBRICATION…..2587
        CHECK WEAR OF BRAKE DISC…..2588
        CHECK TIGHTENING PARTS OF TURBOCHARGER…..2588
      EVERY 2000 HOURS SERVICE…..2589
        CHANGE OIL IN FINAL DRIVE CASE…..2589
        CHANGE OIL IN DIFFERENTIAL CASE…..2590
        REPLACE HYDRAULIC FILTER ELEMENT…..2591
        CLEAN HYDRAULIC TANK STRAINER…..2592
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..2592
        CLEAN BREATHER…..2594
        CLEAN ENGINE BREATHER ELEMENT…..2595
        CHECK ALTERNATOR, STARTING MOTOR…..2595
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..2595
        CLEAN, CHECK TURBOCHARGER…..2595
        CHECK PLAY OF TURBOCHARGER ROTOR…..2595
        CHECK INJECTOR…..2596
      EVERY 4000 HOURS SERVICE…..2597
        CHANGE OIL IN HYDRAULIC TANK…..2597
        CHECK WATER PUMP…..2597
        CHECK AIR COMPRESSOR…..2597
        CHECK FAN PULLEY AND TENSION PULLEY…..2597
        CHECK VIBRATION DAMPER…..2597
        REPLACE INJECTOR ASSEMBLY…..2597
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..2598
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..2598
      EVERY 6000 HOURS SERVICE…..2599
        LUBRICATE DRIVE SHAFT…..2599
      EVERY 8000 HOURS SERVICE…..2600
        REPLACE HIGH-PRESSURE PIPING CLAMP…..2600
        REPLACE FUEL SPRAY PREVENTION CAP…..2600
  SPECIFICATIONS…..2602
    SPECIFICATIONS…..2603
      &lt;A&gt;…..2606
      &lt;C&gt;…..2606
      &lt;D&gt;…..2606
      &lt;E&gt;…..2606
      &lt;F&gt;…..2606
      &lt;G&gt;…..2606
      &lt;H&gt;…..2606
      &lt;I&gt;…..2606
      &lt;L&gt;…..2606
      &lt;M&gt;…..2606
      &lt;O&gt;…..2606
      &lt;P&gt;…..2606
      &lt;S&gt;…..2607
      &lt;T&gt;…..2607
      &lt;U&gt;…..2607
      &lt;W&gt;…..2607
EEAM027403 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..2610
  FOREWORD…..2612
    BEFORE READING THIS MANUAL…..2613
    SAFETY INFORMATION…..2614
      Noise emission levels…..2615
      Vibration levels…..2615
        Guide to Reduce Vibration Levels on Machine…..2616
    INTENDED USE…..2617
      USE OF MACHINE…..2617
      DIRECTIONS OF MACHINE…..2617
      VISIBILITY FROM OPERATOR&apos;S SEAT…..2617
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2618
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..2618
      EPA REGULATIONS, ENGINE NUMBER PLATE…..2618
      SERVICE METER POSITION…..2619
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..2619
      MACHINE SERIAL NUMBER PLATE…..2620
      MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)…..2620
      Declaration of conformity (Directive 2006/42/EC)…..2621
      FOREWORD…..2622
      SAFETY…..2622
      OPERATION…..2623
      MAINTENANCE…..2625
      SPECIFICATIONS…..2628
      ATTACHMENTS, OPTIONS…..2628
      INDEX…..2628
      COLOPHON…..2628
  SAFETY…..2630
    SAFETY…..2631
    SAFETY LABELS…..2634
      POSITION FOR ATTACHING SAFETY LABELS…..2635
      SAFETY LABELS…..2636
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..2644
      PRECAUTIONS BEFORE STARTING OPERATION…..2644
      PREPARATIONS FOR SAFE OPERATION…..2644
      FIRE PREVENTION…..2646
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..2649
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..2651
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..2651
      UNAUTHORIZED MODIFICATION…..2651
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..2652
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..2652
    PRECAUTIONS FOR OPERATION…..2653
      PRECAUTIONS FOR JOBSITE…..2653
      STARTING ENGINE…..2655
      OPERATION…..2658
      TRANSPORTATION…..2662
      TOWING…..2663
    PRECAUTIONS FOR MAINTENANCE…..2664
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..2664
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..2668
      TIRES…..2673
      DISMANTLING THE MACHINE END OF SERVICE LIVE…..2674
  OPERATION…..2676
    GENERAL VIEW…..2677
      GENERAL VIEW OF MACHINE…..2677
      GENERAL VIEW OF CONTROLS AND GAUGES…..2678
    EXPLANATION OF COMPONENTS…..2680
      MACHINE MONITOR…..2680
        CHARACTER DISPLAY…..2682
        CAUTION ITEMS…..2688
        EMERGENCY STOP ITEM…..2691
        METER DISPLAY PORTION…..2695
        CENTRAL WARNING LAMP…..2701
      OTHER FUNCTIONS OF MACHINE MONITOR…..2702
      SWITCHES…..2706
      CONTROL LEVERS AND PEDALS…..2718
      BODY PIVOT PIN…..2723
      ARTICULATE LOCK…..2723
      LOCATION OF FIRE EXTINGUISHER…..2724
      DUST INDICATOR…..2724
      CIRCUIT BREAKER…..2724
      BATTERY DISCONNECT SWITCH (if installed)…..2725
      FUSES…..2726
        FUSE CAPACITY AND CIRCUIT NAME…..2727
      CAR RADIO…..2730
        EXPLANATION OF COMPONENTS…..2730
        METHOD OF OPERATION…..2733
        PRECAUTIONS FOR USE…..2735
      CAR STEREO…..2736
        EXPLANATION OF COMPONENTS…..2736
        METHOD OF OPERATION…..2741
        PRECAUTIONS FOR USE…..2743
      AIR CONDITIONER…..2744
        GENERAL LOCATIONS ON CONTROL PANEL…..2744
        METHOD OF OPERATION…..2747
        PRECAUTIONS WHEN USING AIR CONDITIONER…..2749
        INSPECTION AND MAINTENANCE…..2749
    OPERATION…..2750
      CHECK BEFORE STARTING ENGINE…..2750
        WALK-AROUND CHECK…..2750
        CHECK BEFORE STARTING…..2753
        ADJUSTMENT BEFORE OPERATION…..2760
        OPERATIONS, CHECKS BEFORE STARTING…..2764
      STARTING ENGINE…..2765
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..2767
        BREAKING-IN THE MACHINE…..2767
        WARMING-UP OPERATION…..2767
        CANCELLING DUMP BODY HOLD CONDITION…..2768
      STOPPING ENGINE…..2768
      CHECKS AFTER STOPPING ENGINE…..2768
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..2769
        MOVING MACHINE FORWARD…..2769
        MOVING MACHINE IN REVERSE…..2771
        STOPPING MACHINE…..2772
      SHIFTING GEAR…..2774
      TRAVELLING DOWNHILL…..2776
        BRAKE PERFORMANCE CURVE…..2778
      STEERING THE MACHINE…..2782
      OPERATION USING DIFFERENTIAL LOCK…..2783
        COMBINATION OF DIFFERENTIAL LOCK…..2784
        WHEN TIRES ARE STUCK IN GROUND…..2785
      LOADING OPERATIONS…..2786
        HANDLING TAILGATE…..2786
      DUMP OPERATIONS…..2787
      CAB TILT OPERATION…..2789
        WHEN USING CRANE…..2790
        WHEN USING TILT CYLINDER…..2791
      PRECAUTIONS FOR OPERATION…..2792
        PERMISSIBLE WATER DEPTH…..2792
      PARKING MACHINE…..2793
      CHECKS AFTER COMPLETION OF WORK…..2794
      LOCKING…..2794
      HANDLING TIRES…..2795
        PRECAUTIONS WHEN HANDLING TIRES…..2795
        PRECAUTIONS FOR LONG DISTANCE TRAVEL…..2796
    DETERMINING AND MAINTAINING TRAVEL ROAD…..2797
      DETERMINING TRAVEL ROAD…..2797
      MAINTAINING TRAVEL ROAD…..2797
    TRANSPORTATION…..2798
      PRECAUTIONS WHEN TRANSPORTING…..2798
      STEPS FOR TRANSPORTATION…..2798
      METHOD OF SECURING MACHINE…..2799
      METHOD OF LIFTING MACHINE…..2800
        LOCATION OF LIFTING POSITION MARK…..2801
        WEIGHT TABLE…..2801
        LIFTING PROCEDURE…..2802
    COLD WEATHER OPERATION…..2804
      PRECAUTIONS FOR LOW TEMPERATURE…..2804
        FUEL AND LUBRICANTS…..2804
        COOLANT…..2804
        BATTERY…..2805
        INSTALLATION OF RADIATOR CURTAIN…..2805
      PRECAUTIONS AFTER COMPLETION OF WORK…..2806
      AFTER COLD WEATHER…..2806
    LONG-TERM STORAGE…..2807
      BEFORE STORAGE…..2807
      DURING STORAGE…..2807
      AFTER STORAGE…..2808
      PRECAUTIONS BEFORE TRAVELLING AFTER LONG-TERM STORAGE…..2808
    TROUBLESHOOTING…..2809
      AFTER RUNNING OUT OF FUEL…..2809
      IF TRANSMISSION HAS TROUBLE…..2810
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..2811
      METHOD OF TOWING MACHINE…..2812
        WHEN ENGINE RUNS…..2814
        WHEN ENGINE DOES NOT RUN…..2814
        WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY…..2815
      IF BATTERY IS DISCHARGED…..2816
        REMOVAL AND INSTALLATION OF BATTERY…..2816
        PRECAUTIONS FOR CHARGING BATTERY…..2817
        STARTING ENGINE WITH BOOSTER CABLE…..2818
      OTHER TROUBLE…..2821
        ELECTRICAL SYSTEM…..2821
        CHASSIS…..2822
        ENGINE…..2824
        ACTION CODE…..2826
  MAINTENANCE…..2828
    GUIDES TO MAINTENANCE…..2829
    OUTLINE OF SERVICE…..2832
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2833
        OIL…..2833
        FUEL…..2834
        COOLANT AND WATER FOR DILUTION…..2835
        GREASE…..2835
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…..2836
        STORING OIL AND FUEL…..2837
        FILTERS…..2837
      OUTLINE OF ELECTRIC SYSTEM…..2837
    WEAR PARTS…..2838
      WEAR PARTS LIST…..2838
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..2839
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..2840
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..2842
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..2843
      TORQUE LIST…..2843
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2845
      SAFETY CRITICAL PARTS…..2846
    MAINTENANCE SCHEDULE CHART…..2847
      MAINTENANCE SCHEDULE CHART…..2847
    SERVICE PROCEDURE…..2849
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..2849
      WHEN REQUIRED…..2850
        CHECK, CLEAN OR REPLACE AIR CLEANER…..2850
        CLEAN INSIDE OF COOLING SYSTEM…..2856
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..2859
        CLEAN AIR CONDITIONER AIR FILTER…..2859
        CHECK REFRIGERANT (GAS) LEVEL…..2860
        CHECK DUMP BODY…..2861
        BLEED AIR FROM FRONT BRAKE…..2862
        BLEED AIR FROM CENTRE BRAKE…..2863
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..2864
        SELECTION AND INSPECTION OF TIRES…..2865
      CHECK BEFORE STARTING…..2868
      EVERY 50 HOURS SERVICE…..2869
        LUBRICATION…..2869
      EVERY 250 HOURS SERVICE…..2870
        LUBRICATION…..2870
        LUBRICATE DRIVE SHAFT…..2872
        CHECK DRIVE SHAFT…..2872
        CLEAN BREATHERS…..2873
        CLEAN OVERFLOW HOSE…..2874
        CHECK LEVEL OF BATTERY ELECTROLYTE…..2875
        CHECK ALTERNATOR BELT TENSION, ADJUST…..2876
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..2878
        CHECK FRAME, A-ARM…..2879
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..2880
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..2880
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..2881
        CHECK WEAR OF PARKING BRAKE PADS…..2881
        CHECK LENGTH OF SUSPENSION CYLINDER…..2882
        CHECK OF ACCUMULATOR GAS PRESSURE…..2883
      EVERY 500 HOURS SERVICE…..2884
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2884
        REPLACE FUEL PREFILTER CARTRIDGE…..2886
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..2888
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2888
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..2889
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..2890
        CHECK FAN BELT TENSION, ADJUST…..2891
        RECOVER OIL LEAKING FROM FLOATING SEAL…..2892
      EVERY 1000 HOURS SERVICE…..2893
        REPLACE FUEL MAIN FILTER CARTRIDGE…..2893
        REPLACE FUEL TANK BREATHER ELEMENT…..2894
        REPLACE CORROSION RESISTOR CARTRIDGE…..2895
        REPLACE TRANSMISSION FILTER ELEMENT…..2896
        CHANGE OIL IN TRANSMISSION CASE…..2898
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..2900
        LUBRICATION…..2903
        CHECK WEAR OF BRAKE DISC…..2905
        CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS…..2906
      EVERY 2000 HOURS SERVICE…..2907
        CHANGE OIL IN FINAL DRIVE CASE…..2907
        CHANGE OIL IN DIFFERENTIAL CASE…..2908
        REPLACE HYDRAULIC FILTER ELEMENT…..2910
        CLEAN HYDRAULIC TANK STRAINER…..2911
        CLEAN TRANSMISSION CASE STRAINER…..2911
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..2912
        CLEAN BREATHER…..2913
        CHECK ACCUMULATOR GAS PRESSURE…..2913
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..2913
      EVERY 4000 HOURS SERVICE…..2914
        CHANGE OIL IN HYDRAULIC TANK…..2914
        LUBRICATE FAN PULLEY…..2914
        CHECK ALTERNATOR, STARTING MOTOR…..2914
        CHECK WATER PUMP…..2914
        CHECK AIR COMPRESSOR…..2915
        CHECK FAN PULLEY AND TENSION PULLEY…..2915
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..2915
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..2916
      EVERY 6000 HOURS SERVICE…..2917
        LUBRICATE DRIVE SHAFT…..2917
      EVERY 8000 HOURS SERVICE…..2918
        REPLACE HIGH-PRESSURE PIPING CLAMP…..2918
        REPLACE FUEL SPRAY PREVENTION CAP…..2918
        OVERHAUL STARTING MOTOR AND ALTERNATOR…..2918
  SPECIFICATIONS…..2920
    SPECIFICATIONS…..2921
  ATTACHMENTS, OPTIONS…..2922
    GENERAL PRECAUTIONS…..2923
      AUTHORIZED OPTIONAL EQUIPMENT…..2923
      PRECAUTIONS RELATED TO SAFETY…..2923
      PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…..2924
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)…..2925
      EXPLANATION OF COMPONENTS…..2925
      METHOD OF OPERATION…..2926
        ACTUATION OF ARAC SYSTEM…..2926
    USE OF REAR VIEW MONITOR…..2927
      NAME AND FUNCTION OF EACH PART OF REAR VIEW MONITOR…..2927
      SETTING OF REAR VIEW MONITOR…..2930
      CAUTIONS WHEN USING REAR VIEW MONITOR…..2931
    HANDLING DUMPING COUNTER…..2932
      METHOD OF DISPLAYING, RESETTING DUMPING COUNTER…..2932
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..2933
      BASIC PRECAUTIONS…..2933
  INDEX…..2936
    &lt;A&gt;…..2938
    &lt;B&gt;…..2938
    &lt;C&gt;…..2938
    &lt;D&gt;…..2938
    &lt;E&gt;…..2938
    &lt;F&gt;…..2938
    &lt;G&gt;…..2938
    &lt;H&gt;…..2938
    &lt;I&gt;…..2938
    &lt;L&gt;…..2938
    &lt;M&gt;…..2939
    &lt;O&gt;…..2939
    &lt;P&gt;…..2939
    &lt;R&gt;…..2939
    &lt;S&gt;…..2939
    &lt;T&gt;…..2939
    &lt;U&gt;…..2939
    &lt;W&gt;…..2939
  COLOPHON…..2940
EPAM022502 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual…..2942
  PRÓLOGO…..2944
    PRÓLOGO…..2945
    INFORMAÇÃO SOBRE SEGURANÇA…..2946
      Níveis de emissão de ruído…..2948
      Níveis de vibração…..2948
        Condição de operação:…..2948
        Guia de Redução de Níveis de Vibração na Máquina…..2949
    FINALIDADE…..2950
      DIRECÇÕES DA MÁQUINA…..2950
    LOCALIZAÇÃO DAS CHAPAS, QUADRO PARA INSCREVER O N.º DE SÉRIE E DISTRIBUIDOR…..2951
      LOCALIZAÇÃO DA CHAPA COM O N.º DE SÉRIE DA MÁQUINA…..2951
      LOCALIZAÇÃO DA CHAPA COM O N.º DE SÉRIE DO MOTOR…..2951
      POSIÇÃO DO CONTADOR DE SERVIÇO…..2952
      CHAPA DE METAL PARA INSCREVER O Nº DE SÉRIE E DISTRIBUIDOR…..2952
      PLACA DE SÉRIE DA MÁQUINA…..2953
      PRÓLOGO…..2955
      SEGURANÇA…..2955
      OPERAÇÃO…..2956
      MANUTENÇÃO…..2958
      ESPECIFICAÇÕES…..2960
  SEGURANÇA…..2962
    INFORMAÇÃO SOBRE SEGURANÇA…..2963
    ETIQUETAS DE SEGURANÇA…..2965
      LOCAIS PARA AFIXAÇÃO DE ETIQUETAS DE SEGURANÇA…..2965
      ETIQUETAS DE SEGURANÇA…..2966
    PRECAUÇÕES GERAIS…..2972
    PRECAUÇÕES DURANTE O FUNCIONAMENTO…..2979
      ARRANQUE DO MOTOR…..2979
      OPERAÇÃO…..2981
      TRANSPORTE…..2984
      BATERIA…..2985
      REBOQUE…..2987
    PRECAUÇÕES DE MANUTENÇÃO…..2988
    PRECAUÇÕES COM OS PNEUS…..2994
  OPERAÇÃO…..2996
    VISTA GERAL…..2997
      VISTA GERAL DA MÁQUINA…..2997
      VISTA GERAL DE COMANDOS E INDICADORES…..2998
    EXPLICAÇÃO DOS COMPONENTES…..3000
      MONITOR DA MÁQUINA…..3000
        VISOR DE CARACTERES…..3002
        INDICADORES DE AVISO…..3006
        INDICADORES DE PARAGEM DE EMERGÊNCIA…..3009
        SECÇÃO DO VISOR DE MEDIÇÕES…..3013
        LUZ CENTRAL DE AVISO…..3019
      OUTRAS FUNÇÕES DO MONITOR DA MÁQUINA…..3020
      INTERRUPTORES…..3023
      ALAVANCAS E PEDAIS DE COMANDO…..3034
      CONTROLADOR DO EQUIPAMENTO DA MECATRÓNICA…..3039
      CAVILHA DE SEGURANÇA…..3040
      BLOQUEIO DE ARTICULAÇÃO…..3040
      INDICADOR DE POEIRAS…..3041
      FUSÍVEIS…..3041
        CAPACIDADE DOS FUSÍVEIS E NOME DO CIRCUITO…..3041
      AUTO-RÁDIO…..3044
        EXPLICAÇÃO DOS COMPONENTES…..3044
        MÉTODO DE UTILIZAÇÃO…..3047
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3048
      AUTO-RÁDIO ESTÉREO…..3049
        EXPLICAÇÃO DOS COMPONENTES…..3049
        MÉTODO DE UTILIZAÇÃO…..3054
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3056
      AR CONDICIONADO…..3057
        LOCALIZAÇÕES GERAIS NO PAINEL DE CONTROLO…..3057
        MÉTODO DE UTILIZAÇÃO…..3059
        PRECAUÇÕES AO UTILIZAR O AR CONDICIONADO…..3060
        INSPECÇÃO E MANUTENÇÃO…..3060
    OPERAÇÃO…..3061
      VERIFICAÇÃO ANTES DE PÔR O MOTOR A TRABALHAR…..3061
        VERIFICAÇÃO À VOLTA DA MÁQUINA…..3061
        VERIFICAÇÕES ANTES DE PÔR O MOTOR A FUNCIONAR…..3063
        AJUSTE ANTES DA OPERAÇÃO…..3069
        OPERAÇÕES E VERIFICAÇÕES ANTES DO ARRANQUE…..3071
      ARRANQUE DO MOTOR…..3072
        ARRANQUE NORMAL…..3072
        ARRANQUE COM TEMPO FRIO…..3073
      OPERAÇÕES E VERIFICAÇÕES APÓS O ARRANQUE DO MOTOR…..3075
        RODAGEM DA MÁQUINA…..3075
        OPERAÇÃO DE AQUECIMENTO…..3075
        CANCELAR A FIXAÇÃO DA CARROÇARIA BASCULANTE…..3075
      PARAGEM DO MOTOR…..3076
      VERIFICAÇÕES APÓS A PARAGEM DO MOTOR…..3076
      ANDAMENTO DA MÁQUINA (PARA A FRENTE, PARA TRÁS), PARAGEM…..3077
        ANDAMENTO DA MÁQUINA PARA A FRENTE…..3077
        CIRCULAR EM MARCHA-ATRÁS…..3078
        PARAGEM DA MÁQUINA…..3079
      MUDANÇA DE VELOCIDADES…..3080
      DESLOCAÇÃO EM DESCIDAS…..3082
        GRÁFICO DE DESEMPENHO DO TRAVÃO…..3083
      DIRECÇÃO DA MÁQUINA…..3084
      UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL…..3085
        MÉTODO DE UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL ENTRE EIXOS…..3085
        COMBINAÇÃO DE BLOQUEIO DE DIFERENCIAL…..3086
        QUANDO AS RODAS FICAM ATOLADAS NO SOLO…..3087
      OPERAÇÕES DE CARGA…..3087
      OPERAÇÕES DE DESCARGA…..3088
      OPERAÇÃO DA BASCULAÇÃO DA CABINA…..3090
        AO UTILIZAR A GRUA…..3090
        AO UTILIZAR O CILINDRO DE BASCULAÇÃO…..3091
      PRECAUÇÕES DE OPERAÇÃO…..3091
      ESTACIONAMENTO DA MÁQUINA…..3092
      VERIFICAÇÕES APÓS O TRABALHO…..3092
      BLOQUEIO…..3093
      MANUSEAMENTO DOS PNEUS…..3094
        PRECAUÇÕES AO MANUSEAR OS PNEUS…..3094
        PRECAUÇÕES EM VIAGENS DE LONGA DISTÂNCIA…..3094
    TRAÇADO E MANUTENÇÃO DA ESTRADA DE DESLOCAÇÃO…..3095
      TRAÇADO DA ESTRADA DE DESLOCAÇÃO…..3095
      MANUTENÇÃO DA ESTRADA DE DESLOCAÇÃO…..3095
    TRANSPORTE…..3096
      PRECAUÇÕES DURANTE O TRANSPORTE…..3096
      INSTRUÇÕES DE TRANSPORTE…..3096
      PRECAUÇÕES DURANTE O CARREGAMENTO…..3096
      MÉTODO DE LEVANTAMENTO DA MÁQUINA…..3097
        LOCALIZAÇÃO DA MARCA DA POSIÇÃO DE LEVANTAMENTO…..3098
        TABELA DE PESOS…..3098
        PROCEDIMENTO DE LEVANTAMENTO…..3099
    OPERAÇÃO EM TEMPO FRIO…..3100
      PRECAUÇÕES EM BAIXAS TEMPERATURAS…..3100
        COMBUSTÍVEL E LUBRIFICANTES…..3100
        LÍQUIDO REFRIGERANTE…..3100
        BATERIA…..3101
        INSTALAÇÃO DA CORTINA DO RADIADOR…..3101
      PRECAUÇÕES APÓS A CONCLUSÃO DO TRABALHO…..3101
      DEPOIS DO TEMPO FRIO…..3102
    ESTACIONAMENTO PROLONGADO…..3103
      ANTES DO ESTACIONAMENTO…..3103
      DURANTE O ESTACIONAMENTO PROLONGADO…..3103
      APÓS O ESTACIONAMENTO PROLONGADO…..3103
      PRECAUÇÕES ANTES DE DESLOCAR A MÁQUINA APÓS UM ESTACIONAMENTO PROLONGADO…..3103
    DIAGRAMA DE AVARIAS…..3104
      DEPOIS DE SE ESGOTAR O COMBUSTÍVEL…..3104
      REBOCAR A MÁQUINA…..3105
        QUANDO O MOTOR FUNCIONA…..3106
        QUANDO O MOTOR NÃO FUNCIONA…..3106
        QUANDO O TRAVÃO DE ESTACIONAMENTO FOI ACTIVADO EM SITUAÇÃO DE EMERGÊNCIA…..3106
        QUANDO A CAIXA DE TRANSMISSÃO FINAL, O DIFERENCIAL, A TRANSMISSÃO E O TRANSFERIDOR AVARIAM…..3106
      SE A BATERIA ESTIVER DESCARREGADA…..3107
        REMOÇÃO E INSTALAÇÃO DA BATERIA…..3107
        PRECAUÇÕES AO CARREGAR A BATERIA…..3108
        ARRANQUE DO MOTOR COM CABOS AUXILIARES…..3108
      OUTROS PROBLEMAS…..3110
        SISTEMA ELÉCTRICO…..3110
        CHASSIS…..3111
        MOTOR…..3113
        CÓDIGO DE ACÇÃO…..3115
  MANUTENÇÃO…..3116
    LINHAS DE ORIENTAÇÃO PARA A MANUTENÇÃO…..3117
    LINHAS GERAIS DE ASSISTÊNCIA…..3119
      MANIPULAÇÃO DE ÓLEO, COMBUSTÍVEL, LÍQUIDO REFRIGERANTE E REALIZAÇÃO DO TESTE CLÍNICO DO ÓLEO…..3119
        ÓLEO…..3119
        COMBUSTÍVEL…..3119
        LÍQUIDO REFRIGERANTE…..3119
        LUBRIFICANTES…..3120
        REALIZAÇÃO DA KOWA (Análise de Desgaste do Óleo da Komatsu)…..3120
        ARMAZENAMENTO DE ÓLEO E COMBUSTÍVEL…..3121
        FILTROS…..3121
      LINHAS GERAIS DO SISTEMA ELÉCTRICO…..3121
    PEÇAS DE DESGASTE…..3122
      LISTA DE PEÇAS SUJEITAS A DESGASTE…..3122
    UTILIZAÇÃO DO COMBUSTÍVEL, DO LÍQUIDO REFRIGERANTE E DOS LUBRIFICANTES DE ACORDO COM A TEMPERATURA AMBIENTE…..3123
    BINÁRIOS DE APERTO STANDARD DE PARAFUSOS E PORCAS…..3128
      LISTA DE BINÁRIOS…..3128
    SUBSTITUIÇÃO PERIÓDICA DE PEÇAS ESSENCIAIS À SEGURANÇA…..3129
      PEÇAS ESSENCIAIS À SEGURANÇA…..3129
    PROGRAMA DE MANUTENÇÃO…..3130
      PROGRAMA DE MANUTENÇÃO…..3130
    PROCEDIMENTOS DE MANUTENÇÃO…..3132
      MANUTENÇÃO INICIAL DAS 250 HORAS (SÓ APÓS AS PRIMEIRAS 250 HORAS)…..3132
      QUANDO NECESSÁRIO…..3133
        VERIFIQUE, LIMPE OU SUBSTITUA O FILTRO DE AR…..3133
        LIMPE O INTERIOR DO SISTEMA DE ARREFECIMENTO…..3135
        VERIFICAÇÃO DO NÍVEL DO LÍQUIDO DE LAVAGEM DOS VIDROS, ACRESCENTAR LÍQUIDO…..3138
        LIMPEZA DO FILTRO DO AR CONDICIONADO…..3138
        VERIFIQUE O NÍVEL DO REFRIGERANTE (GÁS)…..3139
        VERIFICAÇÃO DA CARROÇARIA BASCULANTE…..3139
        VERIFIQUE O AQUECEDOR ELÉCTRICO DE ADMISSÃO DE AR…..3139
        VERIFIQUE O COMPRIMENTO DO CILINDRO DE SUSPENSÃO…..3140
        PURGA DO AR DOS TRAVÕES DA FRENTE…..3141
        PURGA DO AR DOS TRAVÕES CENTRAIS…..3142
        VERIFIQUE A FOLGA DO ENCAIXE DE POTÊNCIA DO EIXO DE POTÊNCIA…..3143
        SELECÇÃO E INSPECÇÃO DOS PNEUS…..3143
      VERIFICAÇÕES ANTES DE PÔR O MOTOR A TRABALHAR…..3146
      MANUTENÇÃO CADA 50 HORAS…..3147
        LUBRIFICAÇÃO…..3147
      MANUTENÇÃO CADA 250 HORAS…..3148
        LUBRIFICAÇÃO…..3148
        LUBRIFIQUE O VEIO DA TRANSMISSÃO…..3149
        VERIFIQUE O VEIO DE TRANSMISSÃO…..3149
        VERIFIQUE O NÍVEL DO ELECTRÓLITO DA BATERIA…..3150
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO ALTERNADOR…..3152
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO COMPRESSOR DO CONDICIONADOR DE AR…..3153
        VERIFIQUE A ESTRUTURA, BRAÇO-A…..3154
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO DE PÉ…..3155
        VERIFIQUE A CAPACIDADE DO TRAVÃO DE ESTACIONAMENTO…..3155
        VERIFIQUE O DESGASTE DOS CALÇOS DOS TRAVÕES DE ESTACIONAMENTO…..3156
      MANUTENÇÃO CADA 500 HORAS…..3157
        MUDE O ÓLEO DO CÁRTER DO MOTOR, SUBSTITUA O FILTRO DE ÓLEO DO MOTOR…..3157
        SUBSTITUA O FILTRO DO COMBUSTÍVEL…..3158
        LIMPE O FILTRO DO DEPÓSITO DE COMBUSTÍVEL…..3159
        LUBRIFICAÇÃO…..3160
        VERIFIQUE O NÍVEL DE ÓLEO DA CAIXA DE TRANSMISSÃO FINAL. ADICIONE ÓLEO…..3160
        VERIFIQUE O NÍVEL DO ÓLEO DA CAIXA DO DIFERENCIAL, ADICIONE ÓLEO…..3161
        LIMPE E VERIFIQUE AS PALHETAS DO RADIADOR E AS PALHETAS DO PÓS- ARREFECEDOR…..3162
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DA VENTOINHA…..3163
      MANUTENÇÃO CADA 1000 HORAS…..3164
        SUBSTITUA O CARTUCHO ANTI-CORROSÃO…..3164
        SUBSTITUA O ELEMENTO DO FILTRO DE TRANSMISSÃO…..3164
        MUDE O ÓLEO NA CAIXA DE TRANSMISSÃO, LIMPE O FILTRO DA CAIXA DE TRANSMISSÃO…..3165
        MUDE O ÓLEO DO DEPÓSITO DE ÓLEO DOS TRAVÕES, SUBSTITUA O ELEMENTO DO FILTRO DE ÓLEO…..3167
        LUBRIFICAÇÃO…..3168
        VERIFIQUE O DESGASTE DOS DISCOS DOS TRAVÕES…..3169
        VERIFIQUE AS PEÇAS DE APERTO DO TURBOCOMPRESSOR…..3169
      MANUTENÇÃO CADA 2000 HORAS…..3170
        MUDE O ÓLEO DA CAIXA DA TRANSMISSÃO FINAL…..3170
        MUDE O ÓLEO DA CAIXA DO DIFERENCIAL…..3171
        SUBSTITUA O ELEMENTO DO FILTRO HIDRÁULICO…..3172
        LIMPE O FILTRO DO DEPÓSITO HIDRÁULICO…..3173
        LIMPE O FILTRO DO CIRCUITO HIDRÁULICO DE BLOQUEIO DO DIFERENCIAL…..3173
        LIMPE O RESPIRADOURO…..3175
        LIMPE O ELEMENTO DO RESPIRADOURO DO MOTOR…..3176
        VERIFIQUE O ALTERNADOR E O MOTOR DE ARRANQUE…..3176
        VERIFIQUE E AJUSTE A FOLGA DA VÁLVULA DO MOTOR…..3176
        LIMPE E VERIFIQUE O TURBOCOMPRESSOR…..3176
        VERIFIQUE A FOLGA DO ROTOR DO TURBOCOMPRESSOR…..3176
        VERIFIQUE O INJECTOR…..3177
      MANUTENÇÃO CADA 4000 HORAS…..3178
        MUDE O ÓLEO DO DEPÓSITO HIDRÁULICO…..3178
        VERIFIQUE A BOMBA DE ÁGUA…..3178
        VERIFIQUE O COMPRESSOR DE AR…..3178
        VERIFIQUE A POLIA DA VENTOINHA E A POLIA TENSORA…..3178
        VERIFIQUE O AMORTECEDOR DE VIBRAÇÃO…..3178
        SUBSTITUA O INJECTOR…..3178
        VERIFIQUE SE A BRAÇADEIRA DE ALTA PRESSÃO ESTÁ DESAPERTADA E SE A BORRACHA ENDURECEU…..3179
        VERIFIQUE SE O TAMPÃO DE PREVENÇÃO DA PULVERIZAÇÃO DE COMBUSTÍVEL SE PERDEU E SE A BORRACHA ENDURECEU…..3179
      MANUTENÇÃO CADA 6000 HORAS…..3180
        LUBRIFIQUE O VEIO DA TRANSMISSÃO…..3180
      MANUTENÇÃO CADA 8000 HORAS…..3181
        SUBSTITUA A BRAÇADEIRA DA TUBAGEM DE ALTA PRESSÃO…..3181
        SUBSTITUA A TAMPA DE PREVENÇÃO DE PULVERIZAÇÃO DE COMBUSTÍVEL…..3181
  ESPECIFICAÇÕES…..3182
    ESPECIFICAÇÕES…..3183
      &lt;A&gt;…..3186
      &lt;B&gt;…..3186
      &lt;C&gt;…..3186
      &lt;D&gt;…..3186
      &lt;E&gt;…..3186
      &lt;F&gt;…..3186
      &lt;I&gt;…..3186
      &lt;L&gt;…..3186
      &lt;M&gt;…..3186
      &lt;O&gt;…..3186
      &lt;P&gt;…..3186
      &lt;S&gt;…..3187
      &lt;T&gt;…..3187
      &lt;U&gt;…..3187
      &lt;V&gt;…..3187
EPAM024900 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção…..3190
  PREFÁCIO…..3192
    PREFÁCIO…..3193
    INFORMAÇÃO SOBRE SEGURANÇA…..3194
      Níveis de emissão de ruído…..3196
      Níveis de vibração…..3196
        Guia de Redução de Níveis de Vibração na Máquina…..3197
    FINALIDADE…..3198
      DIRECÇÕES DA MÁQUINA…..3198
    LOCALIZAÇÃO DAS CHAPAS, QUADRO PARA INTRODUZIR O N.º DE SÉRIE E REPRESENTANTE…..3199
      NÚMERO DE IDENTIFICAÇÃO DO PRODUTO (PIN)/CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3199
      REGULAMENTOS DA EPA, CHAPA DO NÚMERO DO MOTOR…..3199
      POSIÇÃO DO CONTADOR DE SERVIÇO…..3200
      QUADRO PARA INTRODUZIR O Nº DE SÉRIE E O REPRESENTANTE…..3200
      CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3201
      PREFÁCIO…..3203
      SEGURANÇA…..3203
      OPERAÇÃO…..3203
      MANUTENÇÃO…..3206
      ESPECIFICAÇÕES…..3208
      ACESSÓRIOS, OPÇÕES…..3209
      ÍNDICE…..3209
      CÓLOFON…..3209
  SEGURANÇA…..3210
    INFORMAÇÃO SOBRE SEGURANÇA…..3211
    ETIQUETAS DE SEGURANÇA…..3213
      LOCAIS PARA AFIXAÇÃO DE ETIQUETAS DE SEGURANÇA…..3213
      ETIQUETAS DE SEGURANÇA…..3214
    PRECAUÇÕES GERAIS…..3221
    PRECAUÇÕES DURANTE A OPERAÇÃO…..3230
      ARRANQUE DO MOTOR…..3230
      OPERAÇÃO…..3232
      TRANSPORTE…..3236
      BATERIA…..3237
      REBOCAR…..3239
    PRECAUÇÕES COM A MANUTENÇÃO…..3240
    PRECAUÇÕES COM OS PNEUS…..3247
  OPERAÇÃO…..3248
    VISÃO GERAL…..3249
      VISÃO GERAL DA MÁQUINA…..3249
      VISÃO GERAL DE CONTROLOS E INDICADORES…..3250
    EXPLICAÇÃO DOS COMPONENTES…..3252
      MONITOR DA MÁQUINA…..3252
        VISOR DE CARACTERES…..3254
        ITENS DE AVISO…..3259
        ITEM DE PARAGEM DE EMERGÊNCIA…..3262
        PARTE DO VISOR DE MEDIÇÃO…..3266
        LUZ DE AVISO CENTRAL…..3272
      OUTRAS FUNÇÕES DO MONITOR DA MÁQUINA…..3273
      INTERRUPTORES…..3276
      PEDAIS E ALAVANCAS DE CONTROLO…..3286
      CAVILHA PIVÔ DA CARROÇARIA…..3291
      BLOQUEIO DA ARTICULAÇÃO…..3291
      LOCALIZAÇÃO DO EXTINTOR…..3292
      INDICADOR DE POEIRAS…..3292
      DISJUNTOR…..3292
      FUSÍVEIS…..3293
        CAPACIDADE DOS FUSÍVEIS E NOME DO CIRCUITO…..3293
      AUTO-RÁDIO…..3296
        EXPLICAÇÃO DOS COMPONENTES…..3296
        MÉTODO DE OPERAÇÃO…..3299
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3301
      AUTO-RÁDIO ESTÉREO…..3302
        EXPLICAÇÃO DOS COMPONENTES…..3302
        MÉTODO DE OPERAÇÃO…..3307
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3309
      AR CONDICIONADO…..3310
        LOCALIZAÇÕES GERAIS NO PAINEL DE CONTROLO…..3310
        MÉTODO DE OPERAÇÃO…..3313
        PRECAUÇÕES AO UTILIZAR O AR CONDICIONADO…..3315
        INSPECÇÃO E MANUTENÇÃO…..3315
    OPERAÇÃO…..3316
      VERIFICAÇÕES ANTES DO ARRANQUE DO MOTOR…..3316
        VERIFICAÇÃO À VOLTA DA MÁQUINA…..3316
        VERIFICAÇÕES ANTES DO ARRANQUE…..3318
        REGULAÇÕES ANTES DA OPERAÇÃO…..3324
        OPERAÇÕES E VERIFICAÇÕES ANTES DO ARRANQUE…..3328
      ARRANQUE DO MOTOR…..3329
      OPERAÇÕES E VERIFICAÇÕES APÓS O ARRANQUE DO MOTOR…..3331
        RODAGEM DA MÁQUINA…..3331
        OPERAÇÃO DE AQUECIMENTO…..3331
        CANCELAMENTO DA FIXAÇÃO DA CARROÇARIA BASCULANTE…..3332
      PARAR O MOTOR…..3333
      VERIFICAÇÕES APÓS A PARAGEM DO MOTOR…..3333
      ANDAMENTO DA MÁQUINA (AVANÇO, MARCHA-ATRÁS), PARAGEM…..3334
        DESLOCAR A MÁQUINA PARA A FRENTE…..3334
        ANDAMENTO DA MÁQUINA EM MARCHA-ATRÁS…..3336
        PARAR A MÁQUINA…..3337
      MUDANÇA DE VELOCIDADES…..3339
      DESLOCAÇÃO EM DESCIDAS…..3340
        GRÁFICO DE DESEMPENHO DOS TRAVÕES…..3342
      DIRECÇÃO DA MÁQUINA…..3346
      UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL…..3346
        COMBINAÇÃO DO BLOQUEIO DO DIFERENCIAL…..3347
        QUANDO OS PNEUS FICAM ATOLADOS NO SOLO…..3348
      OPERAÇÕES DE CARGA…..3349
      OPERAÇÕES DE DESCARGA…..3350
      OPERAÇÃO DE INCLINAÇÃO DA CABINE…..3352
        QUANDO SE UTILIZA UM GUINDASTE…..3352
        QUANDO USAR O CILINDRO DE INCLINAÇÃO…..3353
      PRECAUÇÕES DE OPERAÇÃO…..3353
        PROFUNDIDADE DE ÁGUA PERMITIDA…..3354
      ESTACIONAR A MÁQUINA…..3355
      VERIFICAÇÕES APÓS O TRABALHO…..3356
      FECHAR…..3356
      MANUSEAMENTO DOS PNEUS…..3357
        PRECAUÇÕES QUANDO MANUSEAR OS PNEUS…..3357
        PRECAUÇÕES EM VIAGENS LONGAS…..3357
    DETERMINAR E MANTER AS VIAS DE DESLOCAÇÃO…..3358
      DETERMINAR AS VIAS DE DESLOCAÇÃO…..3358
      MANTER AS VIAS DE DESLOCAÇÃO…..3358
    TRANSPORTE…..3359
      PRECAUÇÕES PARA O TRANSPORTE…..3359
      PROCEDIMENTOS PARA O TRANSPORTE…..3359
      MÉTODO PARA PRENDER A MÁQUINA…..3360
      MÉTODO DE ELEVAÇÃO DA MÁQUINA…..3361
        LOCALIZAÇÃO DA MARCA DA POSIÇÃO DE ELEVAÇÃO…..3362
        TABELA DE PESOS…..3362
        PROCEDIMENTO DE ELEVAÇÃO…..3363
    OPERAÇÃO EM TEMPO FRIO…..3365
      PRECAUÇÕES PARA BAIXAS TEMPERATURAS…..3365
        COMBUSTÍVEL E LUBRIFICANTES…..3365
        LÍQUIDO DE REFRIGERAÇÃO…..3365
        BATERIA…..3366
        INSTALAÇÃO DA CORTINA DO RADIADOR…..3366
      PRECAUÇÕES DEPOIS DE TERMINAR O TRABALHO…..3367
      DEPOIS DO TEMPO FRIO…..3367
    ARMAZENAMENTO PROLONGADO…..3368
      ANTES DE ARMAZENAR…..3368
      DURANTE O ARMAZENAMENTO…..3368
      DEPOIS DO ARMAZENAMENTO…..3369
      PRECAUÇÕES ANTES DO ANDAMENTO APÓS ARMAZENAMENTO PROLONGADO…..3369
    RESOLUÇÃO DE PROBLEMAS…..3370
      DEPOIS DE FICAR SEM COMBUSTÍVEL…..3370
      SE A TRANSMISSÃO TIVER PROBLEMAS…..3371
      MÉTODO DE BAIXAR A CARROÇARIA BASCULANTE NUMA EMERGÊNCIA…..3372
      MÉTODO DE REBOQUE DA MÁQUINA…..3373
        QUANDO O MOTOR FUNCIONA…..3374
        QUANDO O MOTOR NÃO FUNCIONA…..3375
        QUANDO O TRAVÃO DE ESTACIONAMENTO FOI ACTIVADO EM SITUAÇÃO DE EMERGÊNCIA…..3375
      SE A BATERIA ESTIVER DESCARREGADA…..3376
        REMOÇÃO E INSTALAÇÃO DA BATERIA…..3376
        PRECAUÇÕES AO CARREGAR A BATERIA…..3377
        ARRANQUE DO MOTOR COM CABOS AUXILIARES…..3378
      OUTROS PROBLEMAS…..3380
        SISTEMA ELÉCTRICO…..3380
        CHASSIS…..3381
        MOTOR…..3383
        CÓDIGO DE ACÇÃO…..3385
  MANUTENÇÃO…..3386
    LINHAS DE ORIENTAÇÃO PARA A MANUTENÇÃO…..3387
    LINHAS GERAIS DE ASSISTÊNCIA…..3389
      MANUSEAMENTO DE ÓLEO, COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E REALIZAÇÃO DO TESTE CLÍNICO DO ÓLEO…..3389
        ÓLEO…..3389
        COMBUSTÍVEL…..3390
        LÍQUIDO DE REFRIGERAÇÃO E ÁGUA PARA DILUIÇÃO…..3390
        MASSA LUBRIFICANTE…..3391
        REALIZAÇÃO DA KOWA (Análise ao Desgaste do Óleo da Komatsu)…..3392
        ARMAZENAMENTO DE ÓLEO E COMBUSTÍVEL…..3393
        FILTROS…..3393
      LINHAS GERAIS DO SISTEMA ELÉCTRICO…..3393
    PEÇAS SUJEITAS A DESGASTE…..3394
      LISTA DE PEÇAS SUJEITAS A DESGASTE…..3394
    COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E LUBRIFICANTE RECOMENDADOS…..3395
      UTILIZAÇÃO DO COMBUSTÍVEL, DO LÍQUIDO DE REFRIGERAÇÃO E DOS LUBRIFICANTES DE ACORDO COM A TEMPERATURA AMBIENTE…..3396
      MARCAS RECOMENDADAS, QUALIDADE RECOMENDADA PARA PRODUTOS QUE NÃO SEJAM ÓLEO DE ORIGEM DA KOMATSU…..3398
    BINÁRIOS DE APERTO STANDARD PARA PARAFUSOS E PORCAS…..3399
      LISTA DE BINÁRIOS…..3399
    SUBSTITUIÇÃO PERIÓDICA DE PEÇAS ESSENCIAIS À SEGURANÇA…..3400
      PEÇAS ESSENCIAIS À SEGURANÇA…..3401
    ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..3402
      ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..3402
    PROCEDIMENTOS DE MANUTENÇÃO…..3405
      MANUTENÇÃO DAS 250 HORAS DE SERVIÇO INICIAIS (SÓ APÓS AS PRIMEIRAS 250 HORAS)…..3405
      QUANDO NECESSÁRIO…..3406
        VERIFIQUE, LIMPE OU SUBSTITUA O FILTRO DE AR…..3406
        LIMPAR O INTERIOR DO SISTEMA DE REFRIGERAÇÃO…..3412
        VERIFICAÇÃO DO NÍVEL DO LÍQUIDO DO LIMPA-VIDROS, ADICIONE LÍQUIDO…..3415
        LIMPEZA DO FILTRO DE AR DO AR CONDICIONADO…..3415
        VERIFIQUE O NÍVEL DO REFRIGERANTE (GÁS)…..3416
        VERIFICAÇÃO DA CARROÇARIA BASCULANTE…..3417
        PURGA DO AR DOS TRAVÕES DA FRENTE…..3417
        PURGA DO AR DOS TRAVÕES CENTRAIS…..3418
        VERIFIQUE A FOLGA DA JUNÇÃO DE POTÊNCIA DO EIXO DE POTÊNCIA…..3419
        SELECÇÃO E INSPECÇÃO DOS PNEUS…..3419
      VERIFICAÇÕES ANTES DO ARRANQUE…..3422
      CADA 50 HORAS DE SERVIÇO…..3423
        LUBRIFICAÇÃO…..3423
      CADA 250 HORAS DE SERVIÇO…..3424
        LUBRIFICAÇÃO…..3424
        LUBRIFIQUE O VEIO DE TRANSMISSÃO…..3426
        VERIFIQUE O VEIO DE TRANSMISSÃO…..3426
        LIMPE OS RESPIRADORES…..3427
        LIMPE A MANGUEIRA DE EXCESSO DE FLUXO…..3428
        VERIFIQUE O NÍVEL DO ELECTRÓLITO DA BATERIA…..3429
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO ALTERNADOR…..3431
        VERIFIQUE A TENSÃO DA CORREIA DO COMPRESSOR DO AR CONDICIONADO, AJUSTE…..3432
        VERIFIQUE A ESTRUTURA, BRAÇO-A…..3433
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO DE PÉ…..3434
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO RETARDADOR…..3434
        VERIFIQUE A CAPACIDADE DO TRAVÃO DE ESTACIONAMENTO…..3435
        VERIFIQUE O DESGASTE DOS CALÇOS DOS TRAVÕES DE ESTACIONAMENTO…..3435
        VERIFIQUE O COMPRIMENTO DO CILINDRO DA SUSPENSÃO…..3436
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..3437
      CADA 500 HORAS DE SERVIÇO…..3438
        MUDE O ÓLEO DO CÁRTER DE ÓLEO DO MOTOR, SUBSTITUA O CARTUCHO DO FILTRO DE ÓLEO DO MOTOR…..3438
        SUBSTITUA O CARTUCHO DO PRÉ-FILTRO DE COMBUSTÍVEL…..3439
        LUBRIFIQUE A CAVILHA DE MONTAGEM DA CABINE (ESQUERDA E DIREITA: 1 PONTO CADA)…..3440
        VERIFIQUE O NÍVEL DE ÓLEO DA CAIXA DE TRANSMISSÃO FINAL, ADICIONE ÓLEO…..3441
        VERIFIQUE O NÍVEL DO ÓLEO DA CAIXA DO DIFERENCIAL, ADICIONE ÓLEO…..3442
        LIMPE E VERIFIQUE AS ALETAS DO RADIADOR E AS ALETAS DO REFRIGERADOR POSTERIOR…..3443
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DA VENTOINHA…..3444
        RECOLHA O ÓLEO QUE VERTE DA VEDAÇÃO FLUTUANTE…..3445
      CADA 1000 HORAS DE SERVIÇO…..3446
        SUBSTITUA O CARTUCHO DO FILTRO PRINCIPAL DE COMBUSTÍVEL…..3446
        SUBSTITUA O CARTUCHO DO AGENTE ANTI-CORROSÃO…..3448
        SUBSTITUA O ELEMENTO DO FILTRO DE TRANSMISSÃO…..3449
        MUDE O ÓLEO DA CAIXA DA TRANSMISSÃO…..3450
        MUDE O ÓLEO DO DEPÓSITO DE ÓLEO DOS TRAVÕES, SUBSTITUA O ELEMENTO DO FILTRO DE ÓLEO…..3452
        LUBRIFICAÇÃO…..3454
        VERIFIQUE O DESGASTE DOS DISCOS DOS TRAVÕES…..3456
        VERIFIQUE SE AS BRAÇADEIRAS DA TUBAGEM DE ADMISSÃO DE AR DO MOTOR ESTÃO SOLTAS…..3457
      CADA 2000 HORAS DE SERVIÇO…..3458
        MUDE O ÓLEO DA CAIXA DA TRANSMISSÃO FINAL…..3458
        MUDE O ÓLEO DA CAIXA DO DIFERENCIAL…..3459
        SUBSTITUIR O ELEMENTO DO FILTRO HIDRÁULICO…..3461
        LIMPE O FILTRO DO DEPÓSITO HIDRÁULICO…..3462
        LIMPE O FILTRO DA CAIXA DE TRANSMISSÃO…..3462
        LIMPE O FILTRO DO CIRCUITO HIDRÁULICO DE BLOQUEIO DO DIFERENCIAL…..3463
        LIMPE O RESPIRADOR…..3464
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..3465
        VERIFIQUE O ALTERNADOR…..3465
        VERIFIQUE E AJUSTE A FOLGA DA VÁLVULA DO MOTOR…..3465
      CADA 4000 HORAS DE SERVIÇO…..3466
        MUDE O ÓLEO DO DEPÓSITO HIDRÁULICO…..3466
        VERIFIQUE O MOTOR DE ARRANQUE…..3466
        VERIFIQUE A BOMBA DE ÁGUA…..3466
        VERIFIQUE O COMPRESSOR DE AR…..3466
        VERIFIQUE A POLIA DA VENTOINHA E A POLIA DE TENSÃO…..3466
        VERIFIQUE SE A BRAÇADEIRA DE ALTA PRESSÃO ESTÁ DESAPERTADA E SE A BORRACHA ENDURECEU…..3467
        VERIFIQUE SE O TAMPÃO DE PREVENÇÃO DA PULVERIZAÇÃO DE COMBUSTÍVEL SE PERDEU E SE A BORRACHA ENDURECEU…..3467
      CADA 6000 HORAS DE SERVIÇO…..3468
        LUBRIFIQUE O VEIO DE TRANSMISSÃO…..3468
      CADA 8000 HORAS DE SERVIÇO…..3469
        SUBSTITUA A BRAÇADEIRA DA TUBAGEM DE ALTA PRESSÃO…..3469
        SUBSTITUA O TAMPÃO DE PREVENÇÃO DE PULVERIZAÇÃO DE COMBUSTÍVEL…..3469
        INSPECCIONE O ALTERNADOR E O MOTOR DE ARRANQUE…..3469
  ESPECIFICAÇÕES…..3470
    ESPECIFICAÇÕES…..3471
  ACESSÓRIOS, OPÇÕES…..3472
    MANUSEAMENTO DO TACÓGRAFO (TCO20-90W)…..3473
      EXPLICAÇÃO DOS COMPONENTES…..3473
      MÉTODO DE UTILIZAÇÃO…..3476
        ABRIR E FECHAR A TAMPA…..3476
        REGULAÇÃO DA HORA…..3477
        SUBSTITUIR O PAPEL DO MAPA…..3478
        SUBSTITUIR A LÂMPADA…..3479
    MANUSEAMENTO DE MÁQUINAS EQUIPADAS COM KOMTRAX…..3480
      PRECAUÇÕES BÁSICAS…..3480
  ÍNDICE…..3482
    &lt;A&gt;…..3484
    &lt;B&gt;…..3484
    &lt;C&gt;…..3484
    &lt;D&gt;…..3484
    &lt;E&gt;…..3484
    &lt;F&gt;…..3484
    &lt;I&gt;…..3484
    &lt;L&gt;…..3484
    &lt;M&gt;…..3484
    &lt;O&gt;…..3484
    &lt;P&gt;…..3485
    &lt;R&gt;…..3485
    &lt;S&gt;…..3485
    &lt;T&gt;…..3485
    &lt;U&gt;…..3485
    &lt;V&gt;…..3485
  CÓLOFON…..3486
EPAM027403 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção…..3488
  PREFÁCIO…..3490
    ANTES DE LER ESTE MANUAL…..3491
    INFORMAÇÃO SOBRE SEGURANÇA…..3492
      Níveis de emissão de ruído…..3493
      Níveis de vibração…..3493
        Guia de Redução de Níveis de Vibração na Máquina…..3494
    FINALIDADE…..3495
      UTILIZAÇÃO DA MÁQUINA…..3495
      DIRECÇÕES DA MÁQUINA…..3495
      VISIBILIDADE A PARTIR DO ASSENTO DO OPERADOR…..3495
    LOCALIZAÇÃO DAS CHAPAS, QUADRO PARA INTRODUZIR O N.º DE SÉRIE E REPRESENTANTE…..3496
      NÚMERO DE IDENTIFICAÇÃO DO PRODUTO (PIN)/CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3496
      REGULAMENTOS DA EPA, CHAPA DO NÚMERO DO MOTOR…..3496
      POSIÇÃO DO CONTADOR DE SERVIÇO…..3497
      QUADRO PARA INTRODUZIR O N.º DE SÉRIE E O REPRESENTANTE…..3497
      CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3498
      CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA (em conformidade com a Directiva 2006/42/CE)…..3498
      Declaração de conformidade (Directiva 2006/42/EC)…..3499
      PREFÁCIO…..3500
      SEGURANÇA…..3500
      OPERAÇÃO…..3501
      MANUTENÇÃO…..3504
      ESPECIFICAÇÕES…..3506
      ACESSÓRIOS, OPÇÕES…..3506
      ÍNDICE REMISSIVO…..3507
      CÓLOFON…..3507
  SEGURANÇA…..3508
    SEGURANÇA…..3509
    ETIQUETAS DE SEGURANÇA…..3512
      LOCAIS PARA AFIXAÇÃO DE ETIQUETAS DE SEGURANÇA…..3513
      ETIQUETAS DE SEGURANÇA…..3514
    PRECAUÇÕES GERAIS HABITUAIS PARA OPERAÇÃO E MANUTENÇÃO…..3523
      PRECAUÇÕES ANTES DE INICIAR AS OPERAÇÕES…..3523
      PREPARAÇÕES PARA OPERAÇÃO SEGURA…..3523
      PREVENÇÃO DE INCÊNDIO…..3525
      PRECAUÇÕES QUANDO ENTRAR OU SAIR DA MÁQUINA…..3528
      NÃO SE DEIXE APANHAR PELAS PEÇAS ARTICULADAS DA CARROÇARIA BASCULANTE…..3530
      PRECAUÇÕES RELATIVAS ÀS ESTRUTURAS DE PROTECÇÃO…..3530
      MODIFICAÇÕES NÃO AUTORIZADAS…..3531
      PRECAUÇÕES RELACIONADAS COM OS ACESSÓRIOS E OPÇÕES…..3531
      PRECAUÇÕES QUANDO COLOCAR O MOTOR A TRABALHAR DENTRO DE UM EDIFÍCIO…..3531
    PRECAUÇÕES DE OPERAÇÃO…..3532
      PRECAUÇÕES NO LOCAL DE TRABALHO…..3532
      ARRANQUE DO MOTOR…..3535
      OPERAÇÃO…..3538
      TRANSPORTE…..3543
      REBOCAR…..3544
    PRECAUÇÕES DURANTE A MANUTENÇÃO…..3545
      PRECAUÇÕES ANTES DE INICIAR A INSPECÇÃO E A MANUTENÇÃO…..3545
      PRECAUÇÕES DURANTE A INSPECÇÃO E A MANUTENÇÃO…..3549
      PNEUS…..3555
      DESMONTAGEM DA MÁQUINA NO FIM DA SUA VIDA ÚTIL…..3556
  OPERAÇÃO…..3558
    VISÃO GERAL…..3559
      VISÃO GERAL DA MÁQUINA…..3559
      VISÃO GERAL DE CONTROLOS E INDICADORES…..3560
    EXPLICAÇÃO DOS COMPONENTES…..3562
      MONITOR DA MÁQUINA…..3562
        VISOR DE CARACTERES…..3564
        ITENS DE AVISO…..3570
        ITEM DE PARAGEM DE EMERGÊNCIA…..3573
        PARTE DO VISOR DE MEDIÇÃO…..3577
        LUZ CENTRAL DE AVISO…..3583
      OUTRAS FUNÇÕES DO MONITOR DA MÁQUINA…..3584
      INTERRUPTORES…..3588
      PEDAIS E ALAVANCAS DE CONTROLO…..3600
      CAVILHA PIVÔ DA CARROÇARIA…..3605
      BLOQUEIO DA ARTICULAÇÃO…..3606
      LOCALIZAÇÃO DO EXTINTOR…..3606
      INDICADOR DE POEIRAS…..3606
      DISJUNTOR…..3607
      INTERRUPTOR DE DESCONEXÃO DA BATERIA (se instalado)…..3608
      FUSÍVEIS…..3609
        CAPACIDADE DOS FUSÍVEIS E NOME DO CIRCUITO…..3610
      AUTO-RÁDIO…..3613
        EXPLICAÇÃO DOS COMPONENTES…..3613
        MÉTODO DE OPERAÇÃO…..3616
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3618
      AUTO-RÁDIO ESTÉREO…..3619
        EXPLICAÇÃO DOS COMPONENTES…..3619
        MÉTODO DE OPERAÇÃO…..3624
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3626
      AR CONDICIONADO…..3628
        LOCALIZAÇÕES GERAIS NO PAINEL DE CONTROLO…..3628
        MÉTODO DE OPERAÇÃO…..3631
        PRECAUÇÕES AO UTILIZAR O AR CONDICIONADO…..3633
        INSPECÇÃO E MANUTENÇÃO…..3633
    OPERAÇÃO…..3634
      VERIFICAÇÕES ANTES DO ARRANQUE DO MOTOR…..3634
        VERIFICAÇÃO GERAL DA MÁQUINA…..3634
        VERIFICAÇÕES ANTES DO ARRANQUE…..3637
        REGULAÇÕES ANTES DA OPERAÇÃO…..3644
        OPERAÇÕES E VERIFICAÇÕES ANTES DO ARRANQUE…..3648
      ARRANQUE DO MOTOR…..3649
      OPERAÇÕES E VERIFICAÇÕES APÓS O ARRANQUE DO MOTOR…..3651
        RODAGEM DA MÁQUINA…..3651
        OPERAÇÃO DE AQUECIMENTO…..3651
        CANCELAMENTO DA RETENÇÃO DA CARROÇARIA BASCULANTE…..3652
      PARAR O MOTOR…..3652
      VERIFICAÇÕES APÓS A PARAGEM DO MOTOR…..3653
      ANDAMENTO DA MÁQUINA (AVANÇAR, MARCHA-ATRÁS), PARAGEM…..3653
        DESLOCAR A MÁQUINA PARA A FRENTE…..3653
        ANDAMENTO DA MÁQUINA EM MARCHA-ATRÁS…..3655
        PARAR A MÁQUINA…..3656
      MUDANÇA DE VELOCIDADES…..3658
      DESLOCAÇÃO EM DESCIDAS…..3660
        GRÁFICO DE DESEMPENHO DO TRAVÃO…..3662
      DIRECÇÃO DA MÁQUINA…..3666
      UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL…..3667
        COMBINAÇÃO DO BLOQUEIO DO DIFERENCIAL…..3668
        QUANDO OS PNEUS FICAM ATOLADOS NO SOLO…..3669
      OPERAÇÕES DE CARGA…..3670
        MANUSEAMENTO DA TAMPA TRASEIRA…..3670
      OPERAÇÕES DE DESCARGA…..3671
      OPERAÇÃO DE INCLINAÇÃO DA CABINA…..3673
        QUANDO SE UTILIZA UM GUINDASTE…..3674
        QUANDO USAR O CILINDRO DE BASCULAÇÃO…..3675
      PRECAUÇÕES DE OPERAÇÃO…..3676
        PROFUNDIDADE DE ÁGUA PERMITIDA…..3676
      ESTACIONAR A MÁQUINA…..3677
      VERIFICAÇÕES DEPOIS DE TERMINAR O TRABALHO…..3678
      FECHAR…..3678
      MANUSEAMENTO DOS PNEUS…..3679
        PRECAUÇÕES QUANDO MANUSEAR OS PNEUS…..3679
        PRECAUÇÕES EM VIAGENS DE LONGA DISTÂNCIA…..3680
    DETERMINAR E MANTER AS VIAS DE DESLOCAÇÃO…..3681
      DETERMINAR AS VIAS DE DESLOCAÇÃO…..3681
      MANTER AS VIAS DE DESLOCAÇÃO…..3681
    TRANSPORTE…..3682
      PRECAUÇÕES DURANTE O TRANSPORTE…..3682
      PROCEDIMENTOS PARA O TRANSPORTE…..3682
      MÉTODO PARA PRENDER A MÁQUINA…..3683
      MÉTODO DE ELEVAÇÃO DA MÁQUINA…..3684
        LOCALIZAÇÃO DA MARCA DA POSIÇÃO DE ELEVAÇÃO…..3685
        TABELA DE PESOS…..3685
        PROCEDIMENTO DE ELEVAÇÃO…..3686
    OPERAÇÃO EM TEMPO FRIO…..3688
      PRECAUÇÕES PARA BAIXAS TEMPERATURAS…..3688
        COMBUSTÍVEL E LUBRIFICANTES…..3688
        LÍQUIDO DE REFRIGERAÇÃO…..3688
        BATERIA…..3689
        INSTALAÇÃO DA CORTINA DO RADIADOR…..3689
      PRECAUÇÕES DEPOIS DE TERMINAR O TRABALHO…..3690
      DEPOIS DO TEMPO FRIO…..3690
    ARMAZENAMENTO PROLONGADO…..3691
      ANTES DE ARMAZENAR…..3691
      DURANTE O ARMAZENAMENTO…..3691
      DEPOIS DO ARMAZENAMENTO…..3692
      PRECAUÇÕES ANTES DO ANDAMENTO APÓS ARMAZENAMENTO PROLONGADO…..3692
    RESOLUÇÃO DE PROBLEMAS…..3693
      DEPOIS DE FICAR SEM COMBUSTÍVEL…..3693
      SE A TRANSMISSÃO TIVER PROBLEMAS…..3694
      MÉTODO DE BAIXAR A CARROÇARIA BASCULANTE NUMA EMERGÊNCIA…..3695
      MÉTODO DE REBOQUE DA MÁQUINA…..3696
        QUANDO O MOTOR FUNCIONA…..3698
        QUANDO O MOTOR NÃO FUNCIONA…..3698
        QUANDO O TRAVÃO DE ESTACIONAMENTO FOI ACTIVADO EM SITUAÇÃO DE EMERGÊNCIA…..3699
      SE A BATERIA ESTIVER DESCARREGADA…..3700
        REMOÇÃO E INSTALAÇÃO DA BATERIA…..3700
        PRECAUÇÕES AO CARREGAR A BATERIA…..3701
        ARRANQUE DO MOTOR COM CABOS AUXILIARES…..3702
      OUTROS PROBLEMAS…..3705
        SISTEMA ELÉCTRICO…..3705
        CHASSI…..3706
        MOTOR…..3708
        CÓDIGO DE ACÇÃO…..3710
  MANUTENÇÃO…..3712
    LINHAS DE ORIENTAÇÃO PARA A MANUTENÇÃO…..3713
    LINHAS GERAIS DE ASSISTÊNCIA…..3716
      MANUSEAMENTO DE ÓLEO, COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E REALIZAÇÃO DO TESTE CLÍNICO DO ÓLEO…..3717
        ÓLEO…..3717
        COMBUSTÍVEL…..3718
        LÍQUIDO DE REFRIGERAÇÃO E ÁGUA PARA DILUIÇÃO…..3719
        LUBRIFICANTES…..3719
        REALIZAÇÃO DA KOWA (Análise ao Desgaste do Óleo da Komatsu)…..3720
        ARMAZENAMENTO DE ÓLEO E COMBUSTÍVEL…..3721
        FILTROS…..3721
      LINHAS GERAIS DO SISTEMA ELÉCTRICO…..3721
    PEÇAS SUJEITAS A DESGASTE…..3722
      LISTA DE PEÇAS SUJEITAS A DESGASTE…..3722
    COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E LUBRIFICANTE RECOMENDADOS…..3723
      UTILIZAÇÃO DO COMBUSTÍVEL, DO LÍQUIDO REFRIGERANTE E DOS LUBRIFICANTES DE ACORDO COM A TEMPERATURA AMBIENTE…..3724
      MARCAS RECOMENDADAS, QUALIDADE RECOMENDADA PARA PRODUTOS QUE NÃO SEJAM ÓLEO DE ORIGEM DA KOMATSU…..3726
    BINÁRIOS DE APERTO PADRÃO PARA PARAFUSOS E PORCAS…..3727
      LISTA DE BINÁRIOS…..3727
    SUBSTITUIÇÃO PERIÓDICA DE PEÇAS ESSENCIAIS À SEGURANÇA…..3729
      PEÇAS ESSENCIAIS À SEGURANÇA…..3730
    ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..3731
      ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..3731
    PROCEDIMENTOS DE MANUTENÇÃO…..3733
      MANUTENÇÃO DAS 250 HORAS DE SERVIÇO INICIAIS (SÓ APÓS AS PRIMEIRAS 250 HORAS)…..3733
      QUANDO NECESSÁRIO…..3734
        VERIFIQUE, LIMPE OU SUBSTITUA O FILTRO DE AR…..3734
        LIMPE O INTERIOR DO SISTEMA DE REFRIGERAÇÃO…..3740
        VERIFIQUE O NÍVEL DO LÍQUIDO LIMPA-VIDROS, ADICIONE LÍQUIDO…..3744
        LIMPEZA DO FILTRO DE AR DO AR CONDICIONADO…..3744
        VERIFIQUE O NÍVEL DO REFRIGERANTE (GÁS)…..3745
        VERIFICAÇÃO DA CARROÇARIA BASCULANTE…..3746
        PURGUE O AR DOS TRAVÕES DIANTEIROS…..3747
        PURGAR O AR DOS TRAVÕES CENTRAIS…..3748
        VERIFIQUE A FOLGA DO ENCAIXE DE SAÍDA DO EIXO DE SAÍDA…..3749
        SELECÇÃO E INSPECÇÃO DOS PNEUS…..3750
      VERIFICAÇÕES ANTES DO ARRANQUE…..3753
      CADA 50 HORAS DE SERVIÇO…..3754
        LUBRIFICAÇÃO…..3754
      CADA 250 HORAS DE SERVIÇO…..3755
        LUBRIFICAÇÃO…..3755
        LUBRIFIQUE O VEIO DE TRANSMISSÃO…..3757
        VERIFIQUE O VEIO DE TRANSMISSÃO…..3757
        LIMPE OS RESPIRADORES…..3758
        LIMPE A MANGUEIRA DE EXCESSO DE FLUXO…..3759
        VERIFIQUE O NÍVEL DO ELECTRÓLITO DA BATERIA…..3760
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO ALTERNADOR…..3761
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO COMPRESSOR DO AR CONDICIONADO…..3763
        VERIFIQUE A ESTRUTURA, O BRAÇO A…..3764
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO DE PÉ…..3765
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO RETARDADOR…..3765
        VERIFIQUE A CAPACIDADE DO TRAVÃO DE ESTACIONAMENTO…..3766
        VERIFIQUE O DESGASTE DOS CALÇOS DO TRAVÃO DE ESTACIONAMENTO…..3766
        VERIFIQUE O COMPRIMENTO DO CILINDRO DA SUSPENSÃO…..3767
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..3768
      CADA 500 HORAS DE SERVIÇO…..3769
        MUDE O ÓLEO DO CÁRTER DE ÓLEO DO MOTOR, SUBSTITUA O CARTUCHO DO FILTRO DE ÓLEO DO MOTOR…..3769
        SUBSTITUA O CARTUCHO DO PRÉ-FILTRO DE COMBUSTÍVEL…..3771
        LUBRIFIQUE A CAVILHA DE MONTAGEM DA CABINA (ESQUERDA E DIREITA: 1 PONTO CADA)…..3773
        VERIFIQUE O NÍVEL DE ÓLEO DA CAIXA DE TRANSMISSÃO FINAL, ADICIONE ÓLEO…..3773
        VERIFIQUE O NÍVEL DO ÓLEO DA CAIXA DO DIFERENCIAL, ADICIONE ÓLEO…..3774
        LIMPE E VERIFIQUE AS ALETAS DO RADIADOR E AS ALETAS DO REFRIGERADOR POSTERIOR…..3775
        VERIFIQUE A TENSÃO DA CORREIA DA VENTOINHA, AJUSTE…..3776
        RECOLHA O ÓLEO QUE VERTE DA VEDAÇÃO FLUTUANTE…..3777
      CADA 1000 HORAS DE SERVIÇO…..3778
        SUBSTITUA O CARTUCHO DO FILTRO PRINCIPAL DE COMBUSTÍVEL…..3778
        SUBSTITUA O ELEMENTO DO RESPIRADOR DO DEPÓSITO DE COMBUSTÍVEL…..3780
        SUBSTITUA O CARTUCHO DO AGENTE ANTICORROSÃO…..3781
        SUBSTITUA O ELEMENTO DO FILTRO DE TRANSMISSÃO…..3782
        MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO…..3784
        MUDE O ÓLEO DO DEPÓSITO DE ÓLEO DOS TRAVÕES, SUBSTITUA O ELEMENTO DO FILTRO DE ÓLEO…..3786
        LUBRIFICAÇÃO…..3789
        VERIFIQUE O DESGASTE DOS DISCOS DOS TRAVÕES…..3791
        VERIFIQUE SE AS BRAÇADEIRAS DA TUBAGEM DE ADMISSÃO DE AR DO MOTOR ESTÃO SOLTAS…..3792
      CADA 2000 HORAS DE SERVIÇO…..3793
        MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO FINAL…..3793
        MUDE O ÓLEO DA CAIXA DO DIFERENCIAL…..3794
        SUBSTITUA O ELEMENTO DO FILTRO HIDRÁULICO…..3796
        LIMPE O FILTRO DO DEPÓSITO HIDRÁULICO…..3797
        LIMPE O FILTRO DA CAIXA DE TRANSMISSÃO…..3797
        LIMPE O FILTRO DO CIRCUITO HIDRÁULICO DE BLOQUEIO DO DIFERENCIAL…..3798
        LIMPE O RESPIRADOR…..3799
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..3799
        VERIFIQUE E AJUSTE A FOLGA DA VÁLVULA DO MOTOR…..3799
      CADA 4000 HORAS DE SERVIÇO…..3800
        MUDE O ÓLEO DO DEPÓSITO HIDRÁULICO…..3800
        LUBRIFIQUE A POLIA DA VENTOINHA…..3800
        VERIFIQUE O ALTERNADOR E O MOTOR DE ARRANQUE…..3800
        VERIFIQUE A BOMBA DE ÁGUA…..3801
        VERIFIQUE O COMPRESSOR DE AR…..3801
        VERIFIQUE A POLIA DA VENTOINHA E A POLIA DE TENSÃO…..3801
        VERIFIQUE SE A BRAÇADEIRA DE ALTA PRESSÃO ESTÁ DESAPERTADA E SE A BORRACHA ENDURECEU…..3801
        VERIFIQUE SE O TAMPÃO DE PREVENÇÃO DA PULVERIZAÇÃO DE COMBUSTÍVEL SE PERDEU E SE A BORRACHA ENDURECEU…..3802
      CADA 6000 HORAS DE SERVIÇO…..3803
        LUBRIFIQUE O VEIO DE TRANSMISSÃO…..3803
      CADA 8000 HORAS DE SERVIÇO…..3804
        SUBSTITUA A BRAÇADEIRA DA TUBAGEM DE ALTA PRESSÃO…..3804
        SUBSTITUA O TAMPÃO DE PREVENÇÃO DE PULVERIZAÇÃO DE COMBUSTÍVEL…..3804
        INSPECCIONE O ALTERNADOR E O MOTOR DE ARRANQUE…..3804
  ESPECIFICAÇÕES…..3806
    ESPECIFICAÇÕES…..3807
  ACESSÓRIOS, OPÇÕES…..3808
    PRECAUÇÕES GERAIS…..3809
      EQUIPAMENTO OPCIONAL AUTORIZADO…..3809
      PRECAUÇÕES RELACIONADAS COM A SEGURANÇA…..3809
      PRECAUÇÕES RELATIVAS À INSTALAÇÃO DO EQUIPAMENTO…..3810
    MANUSEAR O RETARDADOR AUTOMÁTICO, CONTROLO DO ACELERADOR (ARAC)…..3811
      EXPLICAÇÃO DOS COMPONENTES…..3811
      MÉTODO DE OPERAÇÃO…..3812
        ACTIVAÇÃO DO SISTEMA ARAC…..3812
    UTILIZAR O MONITOR DE VISÃO TRASEIRA…..3813
      NOME E FUNÇÃO DE CADA PARTE DO MONITOR DE VISÃO TRASEIRA…..3813
      AJUSTAR O MONITOR DE VISÃO TRASEIRA…..3816
      CUIDADOS QUANDO UTILIZAR O MONITOR DE VISÃO TRASEIRA…..3817
    MANUSEAMENTO DO CONTADOR DE DESCARGA…..3818
      MÉTODO DE VISUALIZAÇÃO, REDEFINIR O CONTADOR DE DESCARGA…..3818
    MANUSEAMENTO DE MÁQUINAS EQUIPADAS COM KOMTRAX…..3819
      PRECAUÇÕES BÁSICAS…..3819
  ÍNDICE REMISSIVO…..3822
    &lt;A&gt;…..3824
    &lt;B&gt;…..3824
    &lt;C&gt;…..3824
    &lt;D&gt;…..3824
    &lt;E&gt;…..3824
    &lt;F&gt;…..3824
    &lt;I&gt;…..3824
    &lt;L&gt;…..3824
    &lt;M&gt;…..3824
    &lt;O&gt;…..3825
    &lt;P&gt;…..3825
    &lt;R&gt;…..3825
    &lt;S&gt;…..3825
    &lt;T&gt;…..3825
    &lt;U&gt;…..3825
    &lt;V&gt;…..3825
  CÓLOFON…..3826
EPAM027602 – Camião Basculante Articulado HM350-2 Manual de Operação e Manutenção…..3828
  PREFÁCIO…..3830
    ANTES DE LER ESTE MANUAL…..3831
    INFORMAÇÃO SOBRE SEGURANÇA…..3832
      Níveis de emissão de ruído…..3833
      Níveis de vibração…..3833
        Guia de Redução de Níveis de Vibração na Máquina…..3834
    FINALIDADE…..3835
      UTILIZAÇÃO DA MÁQUINA…..3835
      DIRECÇÕES DA MÁQUINA…..3835
      VISIBILIDADE A PARTIR DO ASSENTO DO OPERADOR…..3835
    LOCALIZAÇÃO DAS CHAPAS, QUADRO PARA INTRODUZIR O N.º DE SÉRIE E REPRESENTANTE…..3836
      NÚMERO DE IDENTIFICAÇÃO DO PRODUTO (PIN)/CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3836
      REGULAMENTOS DA EPA, CHAPA DO NÚMERO DO MOTOR…..3836
      POSIÇÃO DO CONTADOR DE SERVIÇO…..3837
      QUADRO PARA INTRODUZIR O N.º DE SÉRIE E O REPRESENTANTE…..3837
      CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA…..3838
      CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA (em conformidade com a Directiva 2006/42/CE)…..3838
      Declaração de conformidade (Directiva 2006/42/EC)…..3839
      PREFÁCIO…..3840
      SEGURANÇA…..3840
      OPERAÇÃO…..3841
      MANUTENÇÃO…..3843
      ESPECIFICAÇÕES…..3846
      ACESSÓRIOS, OPÇÕES…..3846
      ÍNDICE…..3846
      CÓLOFON…..3846
  SEGURANÇA…..3848
    SEGURANÇA…..3849
    ETIQUETAS DE SEGURANÇA…..3852
      LOCAIS PARA AFIXAÇÃO DE ETIQUETAS DE SEGURANÇA…..3853
      ETIQUETAS DE SEGURANÇA…..3854
    PRECAUÇÕES GERAIS HABITUAIS PARA OPERAÇÃO E MANUTENÇÃO…..3863
      PRECAUÇÕES ANTES DE INICIAR AS OPERAÇÕES…..3863
      PREPARAÇÕES PARA OPERAÇÃO SEGURA…..3863
      PREVENÇÃO DE INCÊNDIO…..3866
      PRECAUÇÕES QUANDO ENTRAR OU SAIR DA MÁQUINA…..3868
      NÃO SE DEIXE APANHAR PELAS PEÇAS ARTICULADAS DA CARROÇARIA BASCULANTE…..3870
      PRECAUÇÕES RELATIVAS ÀS ESTRUTURAS DE PROTECÇÃO…..3870
      MODIFICAÇÕES NÃO AUTORIZADAS…..3871
      PRECAUÇÕES RELACIONADAS COM OS ACESSÓRIOS E OPÇÕES…..3871
      PRECAUÇÕES QUANDO COLOCAR O MOTOR A TRABALHAR DENTRO DE UM EDIFÍCIO…..3871
    PRECAUÇÕES DE OPERAÇÃO…..3872
      PRECAUÇÕES NO LOCAL DE TRABALHO…..3872
      ARRANQUE DO MOTOR…..3875
      OPERAÇÃO…..3878
      TRANSPORTE…..3882
      REBOCAR…..3883
    PRECAUÇÕES DURANTE A MANUTENÇÃO…..3884
      PRECAUÇÕES ANTES DE INICIAR A INSPECÇÃO E A MANUTENÇÃO…..3884
      PRECAUÇÕES DURANTE A INSPECÇÃO E A MANUTENÇÃO…..3889
      PNEUS…..3894
      DESMONTAGEM DA MÁQUINA NO FIM DA SUA VIDA ÚTIL…..3895
  OPERAÇÃO…..3896
    VISÃO GERAL…..3897
      VISÃO GERAL DA MÁQUINA…..3897
      VISÃO GERAL DE CONTROLOS E INDICADORES…..3898
    EXPLICAÇÃO DOS COMPONENTES…..3900
      MONITOR DA MÁQUINA…..3900
        VISOR DE CARACTERES…..3902
        ITENS DE AVISO…..3908
        ITEM DE PARAGEM DE EMERGÊNCIA…..3911
        PARTE DO VISOR DE MEDIÇÃO…..3915
        LUZ CENTRAL DE AVISO…..3921
      OUTRAS FUNÇÕES DO MONITOR DA MÁQUINA…..3922
      INTERRUPTORES…..3926
      PEDAIS E ALAVANCAS DE CONTROLO…..3938
      CAVILHA PIVÔ DA CARROÇARIA…..3943
      BLOQUEIO DA ARTICULAÇÃO…..3944
      LOCALIZAÇÃO DO EXTINTOR…..3944
      INDICADOR DE POEIRAS…..3944
    MANUSEAR O INTERRUPTOR DISJUNTOR DA BATERIA…..3945
      DISJUNTOR…..3946
      FUSÍVEIS…..3947
        CAPACIDADE DOS FUSÍVEIS E NOME DO CIRCUITO…..3948
      AUTO-RÁDIO…..3951
        EXPLICAÇÃO DOS COMPONENTES…..3951
        MÉTODO DE OPERAÇÃO…..3954
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3956
      AUTO-RÁDIO ESTÉREO…..3957
        EXPLICAÇÃO DOS COMPONENTES…..3957
        MÉTODO DE OPERAÇÃO…..3962
        PRECAUÇÕES DURANTE A UTILIZAÇÃO…..3964
      AR CONDICIONADO…..3966
        LOCALIZAÇÕES GERAIS NO PAINEL DE CONTROLO…..3966
        MÉTODO DE OPERAÇÃO…..3969
        PRECAUÇÕES AO UTILIZAR O AR CONDICIONADO…..3971
        INSPECÇÃO E MANUTENÇÃO…..3971
    OPERAÇÃO…..3972
      VERIFICAÇÕES ANTES DO ARRANQUE DO MOTOR…..3972
        VERIFICAÇÃO GERAL DA MÁQUINA…..3972
        VERIFICAÇÕES ANTES DO ARRANQUE…..3975
        REGULAÇÕES ANTES DA OPERAÇÃO…..3983
        OPERAÇÕES E VERIFICAÇÕES ANTES DO ARRANQUE…..3988
      ARRANQUE DO MOTOR…..3989
      OPERAÇÕES E VERIFICAÇÕES APÓS O ARRANQUE DO MOTOR…..3991
        RODAGEM DA MÁQUINA…..3991
        OPERAÇÃO DE AQUECIMENTO…..3991
        CANCELAMENTO DA RETENÇÃO DA CARROÇARIA BASCULANTE…..3992
      PARAR O MOTOR…..3992
      VERIFICAÇÕES APÓS A PARAGEM DO MOTOR…..3993
      ANDAMENTO DA MÁQUINA (AVANÇAR, MARCHA-ATRÁS), PARAGEM…..3993
        DESLOCAR A MÁQUINA PARA A FRENTE…..3993
        ANDAMENTO DA MÁQUINA EM MARCHA-ATRÁS…..3995
        PARAR A MÁQUINA…..3996
      MUDANÇA DE VELOCIDADES…..3998
      DESLOCAÇÃO EM DESCIDAS…..4000
        GRÁFICO DE DESEMPENHO DO TRAVÃO…..4002
      DIRECÇÃO DA MÁQUINA…..4006
      UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL…..4007
        MÉTODO DE UTILIZAÇÃO DO BLOQUEIO DO DIFERENCIAL ENTRE OS EIXOS…..4007
        QUANDO OS PNEUS FICAM ATOLADOS NO SOLO…..4008
      OPERAÇÕES DE CARGA…..4008
        MANUSEAMENTO DA TAMPA TRASEIRA…..4009
      OPERAÇÕES DE DESCARGA…..4010
      OPERAÇÃO DE INCLINAÇÃO DA CABINA…..4012
        QUANDO SE UTILIZA UM GUINDASTE…..4013
        QUANDO USAR O CILINDRO DE BASCULAÇÃO…..4014
      PRECAUÇÕES DE OPERAÇÃO…..4015
        PROFUNDIDADE DE ÁGUA PERMITIDA…..4015
      ESTACIONAR A MÁQUINA…..4016
      VERIFICAÇÕES DEPOIS DE TERMINAR O TRABALHO…..4017
      FECHAR…..4017
      MANUSEAMENTO DOS PNEUS…..4018
        PRECAUÇÕES QUANDO MANUSEAR OS PNEUS…..4018
        PRECAUÇÕES EM VIAGENS DE LONGA DISTÂNCIA…..4019
    DETERMINAR E MANTER AS VIAS DE DESLOCAÇÃO…..4020
      DETERMINAR AS VIAS DE DESLOCAÇÃO…..4020
      MANTER AS VIAS DE DESLOCAÇÃO…..4020
    TRANSPORTE…..4021
      PRECAUÇÕES DURANTE O TRANSPORTE…..4021
      PROCEDIMENTOS PARA O TRANSPORTE…..4021
      MÉTODO PARA PRENDER A MÁQUINA…..4022
      MÉTODO DE ELEVAÇÃO DA MÁQUINA…..4023
        LOCALIZAÇÃO DA MARCA DA POSIÇÃO DE ELEVAÇÃO…..4024
        TABELA DE PESOS…..4024
        PROCEDIMENTO DE ELEVAÇÃO…..4025
    OPERAÇÃO EM TEMPO FRIO…..4027
      PRECAUÇÕES PARA BAIXAS TEMPERATURAS…..4027
        COMBUSTÍVEL E LUBRIFICANTES…..4027
        LÍQUIDO DE REFRIGERAÇÃO…..4027
        BATERIA…..4028
        INSTALAÇÃO DA CORTINA DO RADIADOR…..4028
      PRECAUÇÕES DEPOIS DE TERMINAR O TRABALHO…..4029
      DEPOIS DO TEMPO FRIO…..4029
    ARMAZENAMENTO PROLONGADO…..4030
      ANTES DE ARMAZENAR…..4030
      DURANTE O ARMAZENAMENTO…..4030
      DEPOIS DO ARMAZENAMENTO…..4031
      PRECAUÇÕES ANTES DO ANDAMENTO APÓS ARMAZENAMENTO PROLONGADO…..4031
    RESOLUÇÃO DE PROBLEMAS…..4032
      DEPOIS DE FICAR SEM COMBUSTÍVEL…..4032
      SE A TRANSMISSÃO TIVER PROBLEMAS…..4033
      MÉTODO DE BAIXAR A CARROÇARIA BASCULANTE NUMA EMERGÊNCIA…..4033
      MÉTODO DE REBOQUE DA MÁQUINA…..4034
        QUANDO O MOTOR FUNCIONA…..4036
        QUANDO O MOTOR NÃO FUNCIONA…..4036
        QUANDO O TRAVÃO DE ESTACIONAMENTO FOI ACTIVADO EM SITUAÇÃO DE EMERGÊNCIA…..4037
      SE A BATERIA ESTIVER DESCARREGADA…..4038
        REMOÇÃO E INSTALAÇÃO DA BATERIA…..4038
        PRECAUÇÕES AO CARREGAR A BATERIA…..4039
        ARRANQUE DO MOTOR COM CABOS AUXILIARES…..4040
      OUTROS PROBLEMAS…..4042
        SISTEMA ELÉCTRICO…..4042
        CHASSI…..4043
        MOTOR…..4045
        CÓDIGO DE ACÇÃO…..4047
  MANUTENÇÃO…..4048
    LINHAS DE ORIENTAÇÃO PARA A MANUTENÇÃO…..4049
    LINHAS GERAIS DE ASSISTÊNCIA…..4052
      MANUSEAMENTO DE ÓLEO, COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E REALIZAÇÃO DO TESTE CLÍNICO DO ÓLEO…..4053
        ÓLEO…..4053
        COMBUSTÍVEL…..4054
        LÍQUIDO DE REFRIGERAÇÃO E ÁGUA PARA DILUIÇÃO…..4055
        LUBRIFICANTES…..4055
        REALIZAÇÃO DA KOWA (Análise ao Desgaste do Óleo da Komatsu)…..4056
        ARMAZENAMENTO DE ÓLEO E COMBUSTÍVEL…..4057
        FILTROS…..4057
      LINHAS GERAIS DO SISTEMA ELÉCTRICO…..4057
    PEÇAS SUJEITAS A DESGASTE…..4058
      LISTA DE PEÇAS SUJEITAS A DESGASTE…..4058
    COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E LUBRIFICANTE RECOMENDADOS…..4059
      UTILIZAÇÃO DO COMBUSTÍVEL, DO LÍQUIDO REFRIGERANTE E DOS LUBRIFICANTES DE ACORDO COM A TEMPERATURA AMBIENTE…..4060
      MARCAS RECOMENDADAS, QUALIDADE RECOMENDADA PARA PRODUTOS QUE NÃO SEJAM ÓLEO DE ORIGEM DA KOMATSU…..4062
    BINÁRIOS DE APERTO STANDARD PARA PARAFUSOS E PORCAS…..4063
      LISTA DE BINÁRIOS…..4063
    SUBSTITUIÇÃO PERIÓDICA DE PEÇAS ESSENCIAIS À SEGURANÇA…..4065
      PEÇAS ESSENCIAIS À SEGURANÇA…..4066
    ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..4067
      ESQUEMA DO PROGRAMA DE MANUTENÇÃO…..4067
    PROCEDIMENTOS DE MANUTENÇÃO…..4069
      MANUTENÇÃO DAS 250 HORAS DE SERVIÇO INICIAIS (SÓ APÓS AS PRIMEIRAS 250 HORAS)…..4069
      QUANDO NECESSÁRIO…..4070
        VERIFIQUE, LIMPE OU SUBSTITUA O FILTRO DE AR…..4070
        LIMPE O INTERIOR DO SISTEMA DE REFRIGERAÇÃO…..4076
        VERIFIQUE O NÍVEL DO LÍQUIDO LIMPA-VIDROS, ADICIONE LÍQUIDO…..4080
        LIMPEZA DO FILTRO DE AR DO AR CONDICIONADO…..4080
        VERIFIQUE O NÍVEL DO REFRIGERANTE (GÁS)…..4081
        VERIFICAÇÃO DA CARROÇARIA BASCULANTE…..4082
        VERIFIQUE O COMPRIMENTO DO CILINDRO DA SUSPENSÃO…..4082
        PURGUE O AR DOS TRAVÕES DIANTEIROS…..4083
        PURGAR O AR DOS TRAVÕES CENTRAIS…..4084
        VERIFIQUE A FOLGA DO ENCAIXE DE SAÍDA DO EIXO DE SAÍDA…..4085
        SELECÇÃO E INSPECÇÃO DOS PNEUS…..4086
        AFINAR O TRAVÃO DE ESTACIONAMENTO…..4088
        LIMPE O FILTRO DO DEPÓSITO HIDRÁULICO…..4089
      VERIFICAÇÕES ANTES DO ARRANQUE…..4090
      CADA 50 HORAS DE SERVIÇO…..4091
        LUBRIFICAÇÃO…..4091
      CADA 250 HORAS DE SERVIÇO…..4092
        LUBRIFICAÇÃO…..4092
        VERIFIQUE O VEIO DE TRANSMISSÃO…..4093
        LIMPE A MANGUEIRA DE EXCESSO DE FLUXO…..4094
        VERIFIQUE O NÍVEL DO ELECTRÓLITO DA BATERIA…..4095
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DA VENTOINHA E DO ALTERNADOR…..4097
        VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO COMPRESSOR DO AR CONDICIONADO…..4098
        VERIFIQUE A ESTRUTURA, O BRAÇO A…..4099
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO DE PÉ…..4100
        VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO RETARDADOR…..4100
        VERIFIQUE A CAPACIDADE DO TRAVÃO DE ESTACIONAMENTO…..4101
        VERIFIQUE O DESGASTE DOS CALÇOS DO TRAVÃO DE ESTACIONAMENTO…..4101
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..4102
      CADA 500 HORAS DE SERVIÇO…..4103
        MUDE O ÓLEO DO CÁRTER DE ÓLEO DO MOTOR, SUBSTITUA O CARTUCHO DO FILTRO DE ÓLEO DO MOTOR…..4103
        SUBSTITUA O CARTUCHO DO PRÉ-FILTRO DE COMBUSTÍVEL…..4105
        LUBRIFIQUE A CAVILHA DE MONTAGEM DA CABINA (ESQUERDA E DIREITA: 1 PONTO CADA)…..4106
        VERIFIQUE O NÍVEL DE ÓLEO DA CAIXA DE TRANSMISSÃO FINAL, ADICIONE ÓLEO…..4107
        VERIFIQUE O NÍVEL DO ÓLEO DA CAIXA DO DIFERENCIAL, ADICIONE ÓLEO…..4108
        LIMPE E VERIFIQUE AS ALETAS DO RADIADOR E AS ALETAS DO REFRIGERADOR POSTERIOR…..4109
        RECOLHA O ÓLEO QUE VERTE DA VEDAÇÃO FLUTUANTE…..4110
      CADA 1000 HORAS DE SERVIÇO…..4112
        SUBSTITUA O CARTUCHO DO FILTRO PRINCIPAL DE COMBUSTÍVEL…..4112
        SUBSTITUA O ELEMENTO DO RESPIRADOR DO DEPÓSITO DE COMBUSTÍVEL…..4114
        SUBSTITUA O CARTUCHO DO AGENTE ANTICORROSÃO…..4115
        SUBSTITUA O ELEMENTO DO FILTRO DE TRANSMISSÃO…..4116
        MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO…..4118
        MUDE O ÓLEO DO DEPÓSITO DE ÓLEO DOS TRAVÕES, SUBSTITUA O ELEMENTO DO FILTRO DE ÓLEO…..4120
        LUBRIFICAÇÃO…..4123
        VERIFIQUE O DESGASTE DOS DISCOS DOS TRAVÕES…..4124
        VERIFIQUE SE AS BRAÇADEIRAS DA TUBAGEM DE ADMISSÃO DE AR DO MOTOR ESTÃO SOLTAS…..4125
      CADA 2000 HORAS DE SERVIÇO…..4126
        MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO FINAL…..4126
        MUDE O ÓLEO DA CAIXA DO DIFERENCIAL…..4127
        SUBSTITUA O ELEMENTO DO FILTRO HIDRÁULICO…..4128
        LIMPE O FILTRO DA CAIXA DE TRANSMISSÃO…..4129
        LIMPE O RESPIRADOR…..4130
        VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR…..4132
        VERIFIQUE O ALTERNADOR…..4132
        VERIFIQUE E AJUSTE A FOLGA DA VÁLVULA DO MOTOR…..4132
        VERIFIQUE O AMORTECEDOR DE VIBRAÇÃO…..4132
      CADA 4000 HORAS DE SERVIÇO…..4133
        MUDE O ÓLEO DO DEPÓSITO HIDRÁULICO…..4133
        VERIFIQUE O MOTOR DE ARRANQUE…..4133
        VERIFIQUE A BOMBA DE ÁGUA…..4133
        VERIFIQUE O COMPRESSOR DE AR…..4133
        VERIFIQUE A POLIA DA VENTOINHA E A POLIA DE TENSÃO…..4133
        VERIFIQUE SE A BRAÇADEIRA DE ALTA PRESSÃO ESTÁ DESAPERTADA E SE A BORRACHA ENDURECEU…..4134
        VERIFIQUE SE O TAMPÃO DE PREVENÇÃO DA PULVERIZAÇÃO DE COMBUSTÍVEL SE PERDEU E SE A BORRACHA ENDURECEU…..4134
      CADA 6000 HORAS DE SERVIÇO…..4135
        LUBRIFIQUE O VEIO DE TRANSMISSÃO…..4135
      CADA 8000 HORAS DE SERVIÇO…..4136
        SUBSTITUA A BRAÇADEIRA DA TUBAGEM DE ALTA PRESSÃO…..4136
        SUBSTITUA O TAMPÃO DE PREVENÇÃO DE PULVERIZAÇÃO DE COMBUSTÍVEL…..4136
        INSPECCIONE O ALTERNADOR E O MOTOR DE ARRANQUE…..4136
  ESPECIFICAÇÕES…..4138
    ESPECIFICAÇÕES…..4139
  ACESSÓRIOS, OPÇÕES…..4140
    PRECAUÇÕES GERAIS…..4141
      EQUIPAMENTO OPCIONAL AUTORIZADO…..4141
      PRECAUÇÕES RELACIONADAS COM A SEGURANÇA…..4141
      PRECAUÇÕES RELATIVAS À INSTALAÇÃO DO EQUIPAMENTO…..4142
    MANUSEAR O RETARDADOR AUTOMÁTICO, CONTROLO DO ACELERADOR (ARAC)…..4143
      EXPLICAÇÃO DOS COMPONENTES…..4143
      MÉTODO DE OPERAÇÃO…..4144
        ACTIVAÇÃO DO SISTEMA ARAC…..4144
    UTILIZAR O MONITOR DE VISÃO TRASEIRA…..4145
      NOME E FUNÇÃO DE CADA PARTE DO MONITOR DE VISÃO TRASEIRA…..4145
      UTILIZAR O MONITOR DE VISÃO TRASEIRA…..4148
      CUIDADOS QUANDO UTILIZAR O MONITOR DE VISÃO TRASEIRA…..4149
    MANUSEAMENTO DO CONTADOR DE DESCARGA…..4150
      MÉTODO DE VISUALIZAÇÃO, REDEFINIR O CONTADOR DE DESCARGA…..4150
    MANUSEAMENTO DE MÁQUINAS EQUIPADAS COM KOMTRAX…..4151
      PRECAUÇÕES BÁSICAS…..4151
  ÍNDICE…..4154
    &lt;A&gt;…..4156
    &lt;B&gt;…..4156
    &lt;C&gt;…..4156
    &lt;D&gt;…..4156
    &lt;E&gt;…..4156
    &lt;F&gt;…..4156
    &lt;I&gt;…..4156
    &lt;L&gt;…..4156
    &lt;M&gt;…..4156
    &lt;O&gt;…..4157
    &lt;P&gt;…..4157
    &lt;R&gt;…..4157
    &lt;S&gt;…..4157
    &lt;T&gt;…..4157
    &lt;U&gt;…..4157
    &lt;V&gt;…..4157
  CÓLOFON…..4158
GEN00021-00 – Articulated Dump Truck GALEO HM350-1 Field Assembly Instruction…..4160
  COVER…..4160
  CONTENTS…..4161
  1 DRAWING OF REMOVED UNITS…..4162
  2 DIMENSIONS OF REMOVED UNITS…..4162
  3 ASSEMBLY PROCEDURE, NECESSARY EQUIPMENTS, AND SCHEDULE…..4163
  4 NECESSARY TOOLS AND EQUIPMENTS…..4164
  5 ASSEMBLY PROCEDURE…..4165
    A-1 POSITIONING BARE MACHINE…..4165
    A-2 INSTALLING TIRE AND WHEEL ASSEMBLY…..4166
    A-3 INSTALLING ENGINE HOOD MIRROR…..4167
    A-4 INSTALLING FRONT COVER…..4168
    A-5 ADJUSTING N2 GAS OF FRONT AND REAR SUSPENSIONS…..4169
  SLINGING PROCEDURE…..4170
    PREPARATION FOR SLINGING…..4171
    HOW TO INSTALL SLING…..4172
    PRECAUTIONS …..4173
    RELATED SPECIFICATIONS…..4174
  TAIL GATE SPECIFICTION (IF EQUIPPED)…..4175
    1 DRAWING OF REMOVED UNITS…..4176
    2 DIMENSIONS OF REMOVED UNITS…..4176
    3 ASSEMBLY PROCEDURE, NECESSARY EQUIPMENTS, AND SCHEDULE…..4177
    4 NECESSARY TOOLS AND EQUIPMENTS…..4178
    5 ASSEMBLY PROCEDURE NO…..4179
      A-1 ASSEMBLING TAIL GATE…..4179
      A-2 POSITIONING TAIL GATE BRACKET…..4180
      A-3 WELDING TAIL GATE BRACKET…..4181
      A-4 TOUCHING UP TAIL GATE…..4182
      A-5 INSTALLING TAIL GATE…..4183
      A-6 INSTALLING ENGINE HOOD MIRROR…..4184
      A-7 INSTALLING FRONT COVER…..4185
  DETAIL OF COMPONENTS DIVIDED FOR DELIVERY…..4186
    M351-00-000…..4186
    M351-01-010…..4187
    M351-02-010…..4188
    M351-05-010…..4189
    M351-05-020…..4190
    M351-05-030…..4191
    M351-05-040…..4193
    M351-05-041…..4194
    M351-05-050…..4195
    M351-09-010…..4196
GEN00041-03 – Articulated Dump Truck HM350-2 Field Assembly Instruction…..4197
  Cover…..4197
  Contents…..4198
  1 Drawings of removed units…..4200
  2 Dimensions of removed units…..4200
  3 Assembly procedure, necessary equipments, and schedule…..4201
  4 Necessary tools and equipments…..4201
  5 Assembly procedure No…..0
    No. 0100  Positioning bare machine…..4202
    No. 0200  Installation of right and left mudgurds…..4203
    No. 0300  Installation of rear monitor…..4204
    No. 0400  Installation engine hood mirrors…..4205
    No. 0500  Adjusting N2 gas of front and rear suspensions…..4206
    No. A0100  Installation of antenna…..4207
    Attached sheet Mirror adjustment procedure…..4208
  Appendix: Field assembly inspection report…..4210
PEN00045-01 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual…..4216
  COVER…..4216
  FOREWORD…..4217
    FOREWORD…..4218
    SAFETY INFORMATION…..4221
    INTENDED USE…..4223
      DIRECTIONS OF MACHINE…..4223
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4224
      PRODUCT IDENTIFICATION NUMBER (PIN) / MACHINE SERIAL NO. PLATE…..4224
      ENGINE SERIAL NO. PLATE POSITION…..4224
      SERVICE METER POSITION…..4225
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4225
  CONTENTS…..4226
  SAFETY…..4229
    SAFETY INFORMATION…..4230
    SAFETY LABELS…..4232
      POSITION FOR ATTACHING SAFETY LABELS…..4233
      SAFETY LABELS…..4234
    GENERAL PRECAUTIONS…..4240
      SAFETY RULES…..4240
      IF ABNORMALITIES ARE FOUND…..4240
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..4240
      FIRE EXTINGUISHER AND FIRST AID KIT…..4240
      SAFETY FEATURES…..4241
      KEEP MACHINE CLEAN…..4241
      INSIDE OPERATOR&apos;S COMPARTMENT…..4241
      ALWAYS APPLY LOCK LEAVING OPERATOR&apos;S SEAT…..4241
      HANDRAILS AND STEPS…..4242
      MOUNTING AND DISMOUNTING…..4242
      CRUSHING OR CUTTING PREVENTION…..4242
      PREVENTION OF BURNS…..4243
      FIRE PREVENTION…..4243
      ACTION IF FIRE OCCURS…..4244
      WINDOW WASHER LIQUID…..4244
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..4245
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..4245
      UNAUTHORIZED MODIFICATION…..4245
      SAFETY AT WORKSITE…..4245
      WORKING ON LOOSE GROUND…..4246
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..4246
      ENSURE GOOD VISIBILITY…..4246
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..4247
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..4247
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..4247
      ASBESTOS DUST HAZARD PREVENTION…..4247
    PRECAUTIONS DURING OPERATION…..4248
      STARTING ENGINE …..4248
        CHECKS BEFORE STARTING ENGINE, ADJUST…..4248
        PRECAUTIONS WHEN STARTING…..4248
        PRECAUTIONS IN COLD AREAS…..4249
      OPERATION…..4250
        CHECKS BEFORE STARTING OPERATION…..4250
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..4250
        PRECAUTIONS WHEN TRAVELING …..4251
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..4251
        PRECAUTIONS WHEN OPERATING DUMP BODY…..4251
        PRECAUTIONS WHEN OPERATING…..4251
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..4252
        PARKING MACHINE…..4252
      TRANSPORTATION…..4253
        LOADING AND UNLOADING…..4253
        SHIPPING…..4253
      BATTERY…..4254
        BATTERY HAZARD PREVENTION…..4254
        STARTING WITH BOOSTER CABLES…..4255
      TOWING…..4256
        WHEN TOWING…..4256
    PRECAUTIONS FOR MAINTENANCE…..4257
      WARNING TAG…..4257
      KEEP WORK PLACE CLEAN AND TIDY…..4257
      APPOINT LEADER WHEN WORKING WITH OTHERS…..4257
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..4258
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..4259
      PROPER TOOLS…..4260
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..4260
      PERSONNEL…..4260
      WORK UNDER THE MACHINE…..4260
      NOISE…..4260
      PRECAUTIONS WHEN USING HAMMER…..4261
      REPAIR WELDING…..4261
      REMOVING BATTERY TERMINAL…..4261
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..4261
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..4261
      HANDLING HIGH-PRESSURE HOSES, PIPING…..4262
      PRECAUTIONS FOR HIGH VOLTAGE…..4262
      WASTE MATERIALS…..4262
      MAINTENANCE OF AIR CONDITIONER…..4262
      COMPRESSED AIR…..4262
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..4263
    PRECAUTIONS WITH TIRES…..4264
      HANDLING TIRES…..4264
      PRECAUTIONS WHEN STORING TIRE…..4264
  OPERATION…..4265
    GENERAL VIEW…..4266
      GENERAL VIEW OF MACHINE…..4266
      GENERAL VIEW OF CONTROLS AND GAUGES…..4267
    EXPLANATION OF COMPONENTS…..4269
      MACHINE MONITOR…..4269
      OTHER FUNCTIONS OF MACHINE MONITOR…..4290
      SWITCHES…..4293
      CONTROL LEVERS AND PEDALS…..4304
      MECHATRONICS EQUIPMENT CONTROLLER…..4309
      SAFETY PIN…..4310
      ARTICULATE LOCK…..4310
      DUST INDICATOR…..4311
      FUSES…..4311
      CAR RADIO…..4314
      CAR STEREO…..4320
      AIR CONDITIONER…..4328
    OPERATION…..4333
      CHECK BEFORE STARTING ENGINE…..4333
      STARTING ENGINE…..4345
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..4348
      STOPPING ENGINE…..4349
      CHECKS AFTER STOPPING ENGINE…..4349
      MOVING MACHINE OFF (FORWARD,REVERSE), STOPPING…..4350
      SHIFTING GEAR…..4355
      TRAVELING DOWNHILL…..4357
      STEERING THE MACHINE…..4365
      OPERATION USING DIFFERENTIAL LOCK…..4365
      LOADING OPERATIONS…..4367
      DUMP OPERATIONS…..4368
      CAB TILT OPERATION…..4370
      PRECAUTIONS FOR OPERATION…..4371
      PARKING MACHINE…..4372
      CHECKS AFTER COMPLETION OF WORK…..4373
      LOCKING…..4373
      HANDLING TIRES…..4374
    DETERMINING AND MAINTAINING TRAVEL ROAD…..4375
      DETERMINING TRAVEL ROAD…..4375
      MAINTAINING TRAVEL ROAD…..4375
    TRANSPORTATION…..4376
      PRECAUTIONS WHEN TRANSPORTING…..4376
      STEPS FOR TRANSPORTATION…..4376
      METHOD OF SECURING MACHINE…..4377
      METHOD OF LIFTING MACHINE…..4378
    COLD WEATHER OPERATION…..4382
      PRECAUTIONS FOR LOW TEMPERATURE…..4382
      PRECAUTIONS AFTER COMPLETION OF WORK…..4383
      AFTER COLD WEATHER…..4384
    LONG-TERM STORAGE…..4385
      BEFORE STORAGE…..4385
      DURING STORAGE…..4385
      AFTER STORAGE…..4385
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..4385
    TROUBLESHOOTING…..4386
      AFTER RUNNING OUT OF FUEL…..4386
      METHOD OF TOWING MACHINE…..4387
      IF BATTERY IS DISCHARGED…..4391
      OTHER TROUBLE…..4395
  MAINTENANCE…..4401
    GUIDES TO MAINTENANCE…..4402
    OUTLINE OF SERVICE…..4404
      HANDLING OIL, FUEL, COOLANT, AND PREFORMING OIL CLINIC…..4404
      OUTLINE OF ELECTRIC SYSTEM…..4407
    WEAR PARTS…..4408
      WEAR PARTS LIST…..4408
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..4409
      USE OF FUEL, COOLANT AND LUBRICANTS ACCOFDING TO AMBIENT TEMPERATURE…..4410
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..4412
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..4413
      TORQUE LIST…..4413
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..4415
      SAFETY CRITICAL PARTS…..4415
    MAINTENANCE SCHEDULE CHART…..4416
      MAINTENANCE SCHEDULE CHART…..4416
      ADJEST INJECTOR…..4419
    SERVICE PROCEDURE…..4420
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..4420
      WHEN REQUIRED…..4421
        CHECK, CLEAN AND REPLACE AIR CLEANER …..4421
        CLEAN INSIDE OF COOLING SYSTEM…..4424
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..4426
        CLEAN AIR CONDITIONER AIR FILTER…..4427
        CHECK REFRIGERANT (GAS) LEVEL…..4427
        CHECK DUMP BODY…..4428
        CHECK ELECTRIC INTAKE AIR HEATER…..4428
        BLEED AIR FROM FRONT BRAKE…..4429
        BLEED AIR FROM CENTER BRAKE…..4430
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..4431
        SELECTION AND INSPECTION OF TIRES…..4432
      CHECK BEFORE STARTING…..4435
      EVERY 50 HOURS SERVICE…..4436
        LUBRICATION…..4436
      EVERY 250 HOURS SERVICE…..4437
        LUBRICATION…..4437
        LUBRICATE DRIVE SHAFT…..4438
        CHECK DRIVE SHAFT…..4439
        CHECK LEVEL OF BATTERY ELECTROLYTE…..4440
        CHECK ALTERNATOR BELT TENSION, ADJUST…..4442
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..4443
        CHECK FRAME, A-ARM…..4444
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..4445
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..4445
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..4446
        CHECK WEAR OF PARKING BRAKE PADS…..4446
        CHECK LENGTH OF SUSPENSION CYLINDER…..4447
      EVERY 500 HOURS SERVICE…..4448
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..4448
        REPLACE ADDITIONAL FUEL FILTER CARTRIDGE…..4449
        CLEAN FUEL TANK STRAINER…..4450
        LUBRICATION CAB MOUNT PIN (LEFT AND RIGHT:1 PLACE EACH)…..4451
        CHECK OIL LEVEL IN FINAL FRIVE CASE, ADD OIL…..4451
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..4452
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..4453
        CHECK FAN BELT TENSION, ADJUST…..4454
      EVERY 1000 HOURS SERVICE…..4455
        REPLACE FUEL FILTER CARTRIDGE…..4455
        REPLACE CORROSION RESISTOR CARTRIDGE…..4456
        REPLACE TRANSMISSION FILTER ELEMENT…..4457
        CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER…..4458
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..4460
        LUBRICATION…..4461
        CHECK WEAR OF BRAKE DISC…..4463
        CHECK TIGHTENING PARTS OF TURBOCHARGER…..4463
      EVERY 2000 HOURS SERVICE…..4464
        CHANGE OIL IN FINAL DRIVE CASE…..4464
        CHANGE OIL IN DIFFERENTIAL CASE…..4465
        REPLACE HYDRAULIC FILTER ELEMENT…..4466
        CLEAN HYDRAULIC TANK STRAINER…..4467
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..4468
        CLEAN BREATHER…..4469
        CLEAN ENGINE BREATHER ELEMENT…..4471
        CHECK ALTERNATOR, STARTING MOTOR …..4471
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..4471
        CHECK INJECTOR…..4471
        CLEAN, CHECK TURBOCHARGER…..4471
        CHECK PLAY OF TURBOCHARGER ROTOR…..4471
      EVERY 4000 HOURS SERVICE…..4472
        CHANGE OIL IN HYDRAULIC TANK…..4472
        CHECK WATER PUMP…..4472
        CHECK AIR COMPRESSOR …..4472
        CHECK FAN PULLEY AND TENSION PULLEY…..4472
        CHECK VIBRATION DAMPER…..4472
        CHECK INJECTOR…..4472
        REPLACE INJECTOR ASSEMBLY…..4472
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..4473
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..4473
      EVERY 6000 HOURS SERVICE…..4474
        LUBRICATE DRIVE SHAFT…..4474
      EVERY 8000 HOURS SERVICE…..4475
        REPLACE INJUCRTOR NOZZLE TIP…..4475
        REPLACE HIGH-PRESSURE PIPING CLAMP…..4475
        REPLACE FUEL SPRAY PREVENTION CAP…..4475
  SPECIFICATIONS…..4476
    SPECIFICATIONS…..4477
  ATTACHMENTS, OPTIONS…..4478
    HANDLING TACHOGRAPH (TCO20-90W)…..4479
      EXPLANATION OF COMPONENTS…..4479
      METHOD OF USE…..4482
  INDEX…..4486
PEN00045-10 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual…..4489
  COVER…..4489
  FOREWORD…..4490
    FOREWORD…..4491
    SAFETY INFORMATION…..4492
    INTENDED USE…..4494
      DIRECTIONS OF MACHINE…..4494
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4495
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..4495
      ENGINE SERIAL NO. PLATE POSITION…..4495
      SERVICE METER POSITION…..4496
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4496
    CONTENTS…..4497
  SAFETY…..4500
    SAFETY…..4501
    SAFETY LABELS…..4503
      POSITION FOR ATTACHING SAFETY LABELS…..4503
      SAFETY LABELS…..4504
    PRECAUTIONS DURING OPERATION…..4519
      STARTING ENGINE…..4519
      OPERATION…..4521
      TRANSPORTATION…..4524
      BATTERY…..4525
      TOWING…..4527
    GENERAL PRECAUTIONS…..4510
    PRECAUTIONS FOR MAINTENANCE…..4528
    PRECAUTIONS WITH TIRES…..4535
  OPERATION…..4536
    GENERAL VIEW…..4537
      GENERAL VIEW OF MACHINE…..4537
      GENERAL VIEW OF CONTROLS AND GAUGES…..4538
    EXPLANATION OF COMPONENTS…..4540
      MACHINE MONITOR…..4540
      OTHER FUNCTIONS OF MACHINE MONITOR…..4561
      SWITCHES…..4565
      CONTROL LEVERS AND PEDALS…..4576
      MECHATRONICS EQUIPMENT CONTROLLER…..4581
      BODY PIVOT PIN…..4582
      ARTICULATE LOCK…..4582
      DUST INDICATOR…..4583
      FUSES…..4584
      CAR RADIO…..4587
      CAR STEREO…..4593
      AIR CONDITIONER…..4601
    OPERATION…..4606
      CHECK BEFORE STARTING ENGINE…..4606
      STARTING ENGINE…..4619
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..4622
      STOPPING ENGINE…..4623
      CHECKS AFTER STOPPING ENGINE…..4623
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..4624
      SHIFTING GEAR…..4629
      TRAVELING DOWNHILL…..4630
      STEERING THE MACHINE…..4638
      OPERATION USING DIFFERENTIAL LOCK…..4639
      LOADING OPERATIONS…..4642
      DUMP OPERATIONS…..4643
      CAB TILT OPERATION…..4645
      PRECAUTIONS FOR OPERATION…..4647
      PARKING MACHINE…..4648
      CHECKS AFTER COMPLETION OF WORK…..4649
      LOCKING…..4649
      HANDLING TIRES…..4650
    DETERMINING AND MAINTAINING TRAVEL ROAD…..4651
      DETERMINING TRAVEL ROAD…..4651
      MAINTAINING TRAVEL ROAD…..4651
    TRANSPORTATION…..4652
      PRECAUTIONS WHEN TRANSPORTING…..4652
      STEPS FOR TRANSPORTATION…..4652
      METHOD OF SECURING MACHINE…..4653
      METHOD OF LIFTING MACHINE…..4654
    COLD WEATHER OPERATION…..4658
      PRECAUTIONS FOR LOW TEMPERATURE…..4658
      PRECAUTIONS AFTER COMPLETION OF WORK…..4659
      AFTER COLD WEATHER…..4660
    LONG-TERM STORAGE…..4661
      BEFORE STORAGE…..4661
      DURING STORAGE…..4661
      AFTER STORAGE…..4661
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..4661
    TROUBLESHOOTING…..4662
      AFTER RUNNING OUT OF FUEL…..4662
      IF TRANSMISSION HAS TROUBLE…..4663
      METHOD OF TOWING MACHINE…..4664
      IF BATTERY IS DISCHARGED…..4668
      OTHER TROUBLE…..4672
  MAINTENANCE…..4678
    GUIDES TO MAINTENANCE…..4679
    OUTLINE OF SERVICE…..4681
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..4681
      OUTLINE OF ELECTRIC SYSTEM…..4685
    WEAR PARTS…..4686
      WEAR PARTS LIST…..4686
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..4687
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..4688
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..4690
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..4691
      TORQUE LIST…..4691
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..4693
      SAFETY CRITICAL PARTS…..4693
    MAINTENANCE SCHEDULE CHART…..4694
      MAINTENANCE SCHEDULE CHART…..4694
      ADJUST INJECTOR…..4697
    SERVICE PROCEDURE…..4698
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..4698
      WHEN REQUIRED…..4699
      CHECK BEFORE STARTING…..4714
      EVERY 50 HOURS SERVICE…..4715
      EVERY 250 HOURS SERVICE…..4716
      EVERY 500 HOURS SERVICE…..4726
      EVERY 1000 HOURS SERVICE…..4733
      EVERY 2000 HOURS SERVICE…..4749
      EVERY 4000 HOURS SERVICE…..4757
      EVERY 6000 HOURS SERVICE…..4760
      EVERY 8000 HOURS SERVICE…..4761
  SPECIFICATIONS…..4762
    SPECIFICATIONS…..4763
  ATTACHMENTS, OPTIONS…..4764
    HANDLING TACHOGRAPH (TCO20-90W)…..4765
    EXPLANATION OF COMPONENTS…..4765
    METHOD OF USE…..4768
  INDEX…..4772
PEN00119-01 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual…..4776
  COVER…..4776
  FOREWORD…..4777
    FOREWORD…..4778
    SAFETY INFORMATION…..4781
    INTENDED USE…..4783
      DIRECTIONS OF MACHINE…..4783
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4784
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..4784
      EPA REGULATIONS, ENGINE NUMBER PLATE…..4784
      SERVICE METER POSITION…..4785
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..4785
  CONTENTS…..4786
  SAFETY…..4789
    SAFETY INFORMATION…..4790
    SAFETY LABELS…..4792
      POSITION FOR ATTACHING SAFETY LABELS…..4793
      SAFETY LABELS…..4794
    GENERAL PRECAUTIONS…..4799
      SAFETY RULES…..4799
      IF PROBLEMS ARE FOUND…..4799
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..4799
      FIRE EXTINGUISHER AND FIRST AID KIT…..4799
      SAFETY FEATURES…..4800
      KEEP MACHINE CLEAN…..4800
      INSIDE OPERATOR&apos;S COMPARTMENT…..4800
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR&apos;S SEAT…..4800
      HANDRAILS AND STEPS…..4801
      MOUNTING AND DISMOUNTING…..4801
      CRUSHING OR CUTTING PREVENTION…..4801
      PREVENTION OF BURNS…..4802
      FIRE PREVENTION…..4802
      ACTION IF FIRE OCCURS…..4803
      WINDOW WASHER LIQUID…..4803
      PRECAUTIONS WHEN USING ROPS (ROLL VOER PROTECTIVE STRUCTURE)…..4804
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..4804
      UNAUTHORIZED MODIFICATION…..4804
      SAFETY AT WORKSITE…..4804
      WORKING ON LOOSE GROUND…..4805
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..4805
      ENSURE GOOD VISIBILITY…..4806
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..4806
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..4806
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..4806
      ASBESTOS DUST HAZARD PREVENTION…..4807
    PRECAUTIONS DURING OPERATION…..4808
      STARTING ENGINE…..4808
        CHECKS BEFORE STARTING ENGINE, ADJUST…..4808
        PRECAUTIONS WHEN STARTING…..4808
        PRECAUTIONS IN COLD AREAS…..4809
      OPERATION…..4810
        CHECKS BEFORE STARTING OPERATION…..4810
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..4810
        PRECAUTIONS WHEN TRAVELING…..4811
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..4811
        PRECAUTIONS WHEN OPERATING DUMP BODY…..4812
        PRECAUTIONS WHEN OPERATING…..4812
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..4813
        PARKING MACHINE…..4813
      TRANSPORTATION…..4814
        LOADING AND UNLOADING…..4814
        SHIPPING…..4814
      BATTERY…..4815
        BATTERY HAZARD PREVENTION…..4815
        STARTING WITH BOOSTER CABLES…..4816
      TOWING…..4817
        WHEN TOWING…..4817
    PRECAUTIONS FOR MAINTENANCE…..4818
      WARNING TAG…..4818
      KEEP WORK PLACE CLEAN AND TIDY…..4818
      APPOINT LEADER WHEN WORKING WITH OTHERS…..4818
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..4819
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..4820
      PROPER TOOLS…..4821
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..4821
      PERSONNEL…..4821
      WORK UNDER THE MACHINE…..4821
      NOISE…..4821
      PRECAUTIONS WHEN USING HAMMER…..4822
      REPAIR WELDING…..4822
      REMOVING BATTERY TERMINAL…..4822
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..4822
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..4822
      HANDLING HIGH-PRESSURE HOSES, PIPING…..4823
      PRECAUTIONS FOR HIGH VOLTAGE…..4823
      WASTE MATERIALS…..4823
      MAINTENANCE OF AIR CONDITIONER…..4823
      COMPRESSED AIR…..4823
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..4824
    PRECAUTIONS WITH TIRES…..4825
      HANDLING TIRES…..4825
      PRECAUTIONS WHEN STORING TIRE…..4825
  OPERATION…..4826
    GENERAL VIEW…..4827
      GENERAL VIEW OF MACHINE…..4827
      GENERAL VIEW OF CONTROLS AND GAUGES…..4828
    EXPLANATION OF COMPONENTS…..4830
      MACHINE MONITOR…..4830
      OTHER FUNCTIONS OF MACHINE MONITOR…..4851
      SWITCHES…..4854
      CONTROL LEVERS AND PEDALS…..4864
      BODY PIVOT PIN…..4869
      ARTICULATE LOCK…..4869
      LOCATION OF FIRE EXTINGUISHER…..4870
      DUST INDICATOR…..4870
      CIRCUIT BREAKER…..4870
      FUSES…..4871
      CAR RADIO…..4874
      CAR STEREO…..4880
      AIR CONDITIONER…..4888
    OPERATION…..4894
      CHECK BEFORE STARTING ENGINE…..4894
      STARTING ENGINE…..4907
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..4909
      STOPPING ENGINE…..4910
      CHECKS AFTER STOPPING ENGINE…..4910
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..4911
      SHIFTING GEAR…..4916
      TRAVELING DOWNHILL…..4918
      STEERING THE MACHINE…..4924
      OPERATION USING DIFFERENTIAL LOCK…..4924
      LOADING OPERATIONS…..4926
      DUMP OPERATIONS…..4927
      CAB TILT OPERATION…..4929
      PRECAUTIONS FOR OPERATION…..4930
      PARKING MACHINE…..4932
      CHECKS AFTER COMPLETION OF WORK…..4933
      LOCKING…..4933
      HANDLING TIRES…..4934
    DETERMINING AND MAINTAINING TRAVEL ROAD…..4935
      DETERMINING TRAVEL ROAD…..4935
      MAINTAINING TRAVEL ROAD…..4935
    TRANSPORTATION…..4936
      PRECAUTIONS WHEN TRANSPORTING…..4936
      STEPS FOR TRANSPORTATION…..4936
      METHOD OF SECURING MACHINE…..4937
      METHOD OF LIFTING MACHINE…..4938
    COLD WEATHER OPERATION…..4942
      PRECAUTIONS FOR LOW TEMPERATURE…..4942
      PRECAUTIONS AFTER COMPLETION OF WORK…..4943
      AFTER COLD WEATHER…..4944
    LONG-TERM STORAGE…..4945
      BEFORE STORAGE…..4945
      DURING STORAGE…..4945
      AFTER STORAGE…..4945
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..4945
    TROUBLESHOOTING…..4946
      AFTER RUNNING OUT OF FUEL…..4946
      IF TRANSMISSION HAS TROUBLE…..4947
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..4947
      METHOD OF TOWING MACHINE…..4948
      IF BATTERY IS DISCHARGED…..4952
      OTHER TROUBLE…..4955
  MAINTENANCE…..4961
    GUIDES TO MAINTENANCE…..4962
    OUTLINE OF SERVICE…..4964
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..4964
      OUTLINE OF ELECTRIC SYSTEM…..4967
    WEAR PARTS…..4968
      WEAR PARTS LIST…..4968
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..4969
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..4970
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..4972
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..4973
      TORQUE LIST…..4973
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..4975
      SAFETY CRITICAL PARTS…..4976
    MAINTENANCE SCHEDULE CHART…..4977
      MAINTENANCE SCHEDULE CHART…..4977
    SERVICE PROCEDURE…..4980
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..4980
      WHEN REQUIRED…..4981
        CHECK, CLEAN OR REPLACE AIR CLEANER…..4981
        CLEAN INSIDE OF COOLING SYSTEM…..4987
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..4990
        CLEAN AIR CONDITIONER AIR FILTER…..4990
        CHECK REFRIGERANT (GAS) LEVEL…..4991
        CHECK DUMP BODY…..4992
        BLEED AIR FROM FRONT BRAKE…..4993
        BLEED AIR FROM CENTER BRAKE…..4994
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..4995
        SELECTION AND INSPECTION OF TIRES…..4996
      CHECK BEFORE STARTING…..4999
      EVERY 50 HOURS SERVICE…..5000
        LUBRICATION…..5000
      EVERY 250 HOURS SERVICE…..5001
        LUBRICATION…..5001
        LUBRICATE DRIVE SHAFT…..5003
        CHECK DRIVE SHAFT…..5003
        CLEAN BREATHERS…..5004
        CLEAN OVERFLOW HOSE…..5006
        CHECK LEVEL OF BATTERY ELECTROLYTE…..5007
        CHECK ALTERNATOR BELT TENSION, ADJUST…..5009
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..5010
        CHECK FRAME, A-ARM…..5011
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..5012
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..5012
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..5013
        CHECK WEAR OF PARKING BRAKE PADS…..5013
        CHECK LENGTH OF SUSPENSION CYLINDER…..5014
        CHECK OF ACCUMULATOR GAS PRESSURE…..5015
      EVERY 500 HOURS SERVICE…..5016
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..5016
        REPLACE FUEL PREFILTER CARTRIDGE…..5017
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..5019
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..5019
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..5020
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..5022
        CHECK FAN BELT TENSION, ADJUST…..5023
        RECOVER OIL LEAKING FROM FLOATING SEAL…..5024
      EVERY 1000 HOURS SERVICE…..5025
        REPLACE FUEL MAIN FILTER CARTRIDGE…..5025
        REPLACE CORROSION RESISTOR CARTRIDGE…..5026
        REPLACE TRANSMISSION FILTER ELEMENT…..5027
        CHANGE OIL IN TRANSMISSION CASE…..5028
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..5030
        LUBRICATION…..5032
        CHECK WEAR OF BRAKE DISC…..5034
        CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS…..5035
      EVERY 2000 HOURS SERVICE…..5036
        CHANGE OIL IN FINAL DRIVE CASE…..5036
        CHANGE OIL IN DIFFERENTIAL CASE…..5037
        REPLACE HYDRAULIC FILTER ELEMENT…..5039
        CLEAN HYDRAULIC TANK STRAINER…..5040
        CLEAN TRANSMISSION CASE STRAINER…..5040
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..5041
        CLEAN BREATHER…..5042
        CHECK ACCUMULATOR GAS PRESSURE…..5043
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..5043
      EVERY 4000 HOURS SERVICE…..5044
        CHANGE OIL IN HYDRAULIC TANK…..5044
        LUBRICATE FAN PULLEY…..5044
        CHECK ALTERNATOR, STARTING MOTOR…..5044
        CHECK WATER PUMP…..5044
        CHECK AIR COMPRESSOR…..5044
        CHECK FAN PULLEY AND TENSION PULLEY…..5045
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..5045
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..5046
      EVERY 6000 HOURS SERVICE…..5047
        LUBRICATE DRIVE SHAFT…..5047
      EVERY 8000 HOURS SERVICE…..5048
        REPLACE HIGH-PRESSURE PIPING CLAMP…..5048
        REPLACE FUEL SPRAY PREVENTION CAP…..5048
        OVERHAUL STARTING MOTOR AND ALTERNATOR…..5048
  SPECIFICATIONS…..5049
    SPECIFICATIONS…..5050
  ATTACHMENTS, OPTIONS…..5051
    HANDLING TACHOGRAPH (TCO20-90W)…..5052
      EXPLANATION OF COMPONENTS…..5052
      METHOD OF USE…..5055
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..5059
      EXPLANATION OF COMPONENTS…..5059
      METHOD OF OPERATION…..5060
    HANDLING DUMPING COUNTER…..5061
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..5062
      BASIC PRECAUTIONS…..5062
  INDEX…..5063
PEN00119-04 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual…..5066
  COVER…..5066
  FOREWORD…..5067
    FOREWORD…..5068
    SAFETY INFORMATION…..5071
    INTENDED USE…..5073
      DIRECTIONS OF MACHINE…..5073
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5074
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..5074
      EPA REGULATIONS, ENGINE NUMBER PLATE…..5074
      SERVICE METER POSITION…..5075
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5075
  CONTENTS…..5076
  SAFETY…..5079
    SAFETY…..5080
    SAFETY LABELS…..5082
      POSITION FOR ATTACHING SAFETY LABELS…..5082
      SAFETY LABELS…..5083
    GENERAL PRECAUTIONS…..5088
      SAFETY RULES…..5088
      IF PROBLEMS ARE FOUND…..5088
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..5088
      FIRE EXTINGUISHER AND FIRST AID KIT…..5088
      SAFETY FEATURES…..5089
      KEEP MACHINE CLEAN…..5089
      INSIDE OPERATOR&apos;S COMPARTMENT…..5089
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR&apos;S SEAT…..5089
      HANDRAILS AND STEPS…..5090
      MOUNTING AND DISMOUNTING…..5090
      CRUSHING OR CUTTING PREVENTION…..5090
      PREVENTION OF BURNS…..5091
      FIRE PREVENTION…..5092
      ACTION IF FIRE OCCURS…..5092
      WINDOW WASHER LIQUID…..5093
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..5093
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..5093
      UNAUTHORIZED MODIFICATION…..5093
      SAFETY AT WORKSITE…..5093
      WORKING ON LOOSE GROUND…..5094
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..5094
      ENSURE GOOD VISIBILITY…..5095
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..5095
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..5095
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..5095
      ASBESTOS DUST HAZARD PREVENTION…..5096
    PRECAUTIONS DURING OPERATION…..5097
      STARTING ENGINE…..5097
        CHECKS BEFORE STARTING ENGINE, ADJUST…..5097
        PRECAUTIONS WHEN STARTING…..5097
        PRECAUTIONS IN COLD AREAS…..5098
      OPERATION…..5099
        CHECKS BEFORE STARTING OPERATION…..5099
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..5099
        PRECAUTIONS WHEN TRAVELING…..5100
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..5100
        PRECAUTIONS WHEN OPERATING DUMP BODY…..5101
        PRECAUTIONS WHEN OPERATING…..5101
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..5101
        PARKING MACHINE…..5102
      TRANSPORTATION…..5103
        LOADING AND UNLOADING…..5103
        SHIPPING…..5103
      BATTERY…..5104
        BATTERY HAZARD PREVENTION…..5104
        STARTING WITH BOOSTER CABLES…..5105
      TOWING…..5106
        WHEN TOWING…..5106
    PRECAUTIONS FOR MAINTENANCE…..5107
      WARNING TAG…..5107
      KEEP WORK PLACE CLEAN AND TIDY…..5107
      APPOINT LEADER WHEN WORKING WITH OTHERS…..5107
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..5108
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..5109
      PROPER TOOLS…..5110
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..5110
      PERSONNEL…..5110
      WORK UNDER THE MACHINE…..5110
      NOISE…..5110
      PRECAUTIONS WHEN USING HAMMER…..5111
      REPAIR WELDING…..5111
      REMOVING BATTERY TERMINAL…..5111
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..5111
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..5111
      HANDLING HIGH-PRESSURE HOSES, PIPING…..5112
      PRECAUTIONS FOR HIGH VOLTAGE…..5112
      WASTE MATERIALS…..5112
      MAINTENANCE OF AIR CONDITIONER…..5112
      COMPRESSED AIR…..5112
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..5113
    PRECAUTIONS WITH TIRES…..5114
      HANDLING TIRES…..5114
      PRECAUTIONS WHEN STORING TIRE…..5114
  OPERATION…..5115
    GENERAL VIEW…..5116
      GENERAL VIEW OF MACHINE…..5116
      GENERAL VIEW OF CONTROLS AND GAUGES…..5117
    EXPLANATION OF COMPONENTS…..5119
      MACHINE MONITOR…..5119
      OTHER FUNCTIONS OF MACHINE MONITOR…..5140
      SWITCHES…..5144
      CONTROL LEVERS AND PEDALS…..5155
      BODY PIVOT PIN…..5160
      ARTICULATE LOCK…..5160
      LOCATION OF FIRE EXTINGUISHER…..5161
      DUST INDICATOR…..5161
      CIRCUIT BREAKER…..5161
      FUSES…..5162
      CAR RADIO…..5165
      CAR STEREO…..5171
      AIR CONDITIONER…..5179
    OPERATION…..5185
      CHECK BEFORE STARTING ENGINE…..5185
      STARTING ENGINE…..5199
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..5201
      STOPPING ENGINE…..5202
      CHECKS AFTER STOPPING ENGINE…..5202
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..5203
      SHIFTING GEAR…..5208
      TRAVELING DOWNHILL…..5210
      STEERING THE MACHINE…..5216
      OPERATION USING DIFFERENTIAL LOCK…..5216
      LOADING OPERATIONS…..5218
      DUMP OPERATIONS…..5219
      CAB TILT OPERATION…..5221
      PRECAUTIONS FOR OPERATION…..5224
      PARKING MACHINE…..5225
      CHECKS AFTER COMPLETION OF WORK…..5226
      LOCKING…..5226
      HANDLING TIRES…..5227
    DETERMINING AND MAINTAINING TRAVEL ROAD…..5228
      DETERMINING TRAVEL ROAD…..5228
      MAINTAINING TRAVEL ROAD…..5228
    TRANSPORTATION…..5229
      PRECAUTIONS WHEN TRANSPORTING…..5229
      STEPS FOR TRANSPORTATION…..5229
      METHOD OF SECURING MACHINE…..5230
      METHOD OF LIFTING MACHINE…..5231
    COLD WEATHER OPERATION…..5235
      PRECAUTIONS FOR LOW TEMPERATURE…..5235
      PRECAUTIONS AFTER COMPLETION OF WORK…..5236
      AFTER COLD WEATHER…..5237
    LONG-TERM STORAGE…..5238
      BEFORE STORAGE…..5238
      DURING STORAGE…..5238
      AFTER STORAGE…..5238
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..5238
    TROUBLESHOOTING…..5239
      AFTER RUNNING OUT OF FUEL…..5239
      IF TRANSMISSION HAS TROUBLE…..5240
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..5240
      METHOD OF TOWING MACHINE…..5241
      IF BATTERY IS DISCHARGED…..5245
      OTHER TROUBLE…..5249
  MAINTENANCE…..5255
    GUIDES TO MAINTENANCE…..5256
    OUTLINE OF SERVICE…..5258
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..5258
      OUTLINE OF ELECTRIC SYSTEM…..5262
    WEAR PARTS…..5263
      WEAR PARTS LIST…..5263
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..5264
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..5265
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..5266
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..5267
      TORQUE LIST…..5267
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..5269
      SAFETY CRITICAL PARTS…..5270
    MAINTENANCE SCHEDULE CHART…..5271
      MAINTENANCE SCHEDULE CHART…..5271
    SERVICE PROCEDURE…..5274
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..5274
      WHEN REQUIRED…..5275
        CHECK, CLEAN OR REPLACE AIR CLEANER…..5275
        CLEAN INSIDE OF COOLING SYSTEM…..5281
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..5284
        CLEAN AIR CONDITIONER AIR FILTER…..5284
        CHECK REFRIGERANT (GAS) LEVEL…..5285
        CHECK DUMP BODY…..5286
        BLEED AIR FROM FRONT BRAKE…..5287
        BLEED AIR FROM CENTER BRAKE…..5288
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..5289
        SELECTION AND INSPECTION OF TIRES…..5290
      CHECK BEFORE STARTING…..5293
      EVERY 50 HOURS SERVICE…..5294
        LUBRICATION…..5294
      EVERY 250 HOURS SERVICE…..5295
        LUBRICATION…..5295
        LUBRICATE DRIVE SHAFT…..5297
        CHECK DRIVE SHAFT…..5297
        CLEAN BREATHERS…..5298
        CLEAN OVERFLOW HOSE…..5300
        CHECK LEVEL OF BATTERY ELECTROLYTE…..5301
        CHECK ALTERNATOR BELT TENSION, ADJUST…..5303
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..5304
        CHECK FRAME, A-ARM…..5305
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..5306
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..5306
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..5307
        CHECK WEAR OF PARKING BRAKE PADS…..5307
        CHECK LENGTH OF SUSPENSION CYLINDER…..5308
        CHECK OF ACCUMULATOR GAS PRESSURE…..5309
      EVERY 500 HOURS SERVICE…..5310
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..5310
        REPLACE FUEL PREFILTER CARTRIDGE…..5311
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..5312
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..5312
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..5313
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..5315
        CHECK FAN BELT TENSION, ADJUST…..5316
        RECOVER OIL LEAKING FROM FLOATING SEAL…..5317
      EVERY 1000 HOURS SERVICE…..5318
        REPLACE FUEL MAIN FILTER CARTRIDGE…..5318
        REPLACE CORROSION RESISTOR CARTRIDGE…..5319
        REPLACE TRANSMISSION FILTER ELEMENT…..5320
        CHANGE OIL IN TRANSMISSION CASE…..5321
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..5323
        LUBRICATION…..5326
        CHECK WEAR OF BRAKE DISC…..5328
        CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS…..5329
      EVERY 2000 HOURS SERVICE…..5330
        CHANGE OIL IN FINAL DRIVE CASE…..5330
        CHANGE OIL IN DIFFERENTIAL CASE…..5331
        REPLACE HYDRAULIC FILTER ELEMENT…..5333
        CLEAN HYDRAULIC TANK STRAINER…..5334
        CLEAN TRANSMISSION CASE STRAINER…..5334
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..5335
        CLEAN BREATHER…..5336
        CHECK ACCUMULATOR GAS PRESSURE…..5336
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..5336
      EVERY 4000 HOURS SERVICE…..5337
        CHANGE OIL IN HYDRAULIC TANK…..5337
        LUBRICATE FAN PULLEY…..5337
        CHECK ALTERNATOR, STARTING MOTOR…..5337
        CHECK WATER PUMP…..5337
        CHECK AIR COMPRESSOR…..5337
        CHECK FAN PULLEY AND TENSION PULLEY…..5337
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..5338
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..5338
      EVERY 6000 HOURS SERVICE…..5339
        LUBRICATE DRIVE SHAFT…..5339
      EVERY 8000 HOURS SERVICE…..5340
        REPLACE HIGH-PRESSURE PIPING CLAMP…..5340
        REPLACE FUEL SPRAY PREVENTION CAP…..5340
        OVERHAUL STARTING MOTOR AND ALTERNATOR…..5340
  SPECIFICATIONS…..5341
    SPECIFICATIONS…..5342
  ATTACHMENTS, OPTIONS…..5343
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..5344
      EXPLANATION OF COMPONENTS…..5344
      METHOD OF OPERATION…..5345
    USE OF REAR VIEW MONITOR…..5346
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..5346
      SETTING OF REAR VIEW MONITOR…..5349
      CAUTIONS WHEN USING REAR VIEW MONITOR…..5349
    HANDLING DUMPING COUNTER…..5350
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..5351
      BASIC PRECAUTIONS…..5351
  INDEX…..5353
PEN00177-06 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual…..5357
  COVER…..5357
  FOREWORD…..5358
    FOREWORD…..5359
    SAFETY INFORMATION…..5360
    INTENDED USE…..5362
      DIRECTIONS OF MACHINE…..5362
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5363
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..5363
      ENGINE SERIAL NO. PLATE POSITION…..5363
      SERVICE METER POSITION…..5364
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5364
    CONTENTS…..5365
  SAFETY…..5368
    SAFETY…..5369
    SAFETY LABELS…..5371
      POSITION FOR ATTACHING SAFETY LABELS…..5371
      SAFETY LABELS…..5372
    GENERAL PRECAUTIONS…..5378
    PRECAUTIONS DURING OPERATION…..5387
      STARTING ENGINE…..5387
      OPERATION…..5389
      TRANSPORTATION…..5392
      BATTERY…..5393
      TOWING…..5395
    PRECAUTIONS FOR MAINTENANCE…..5396
    PRECAUTIONS WITH TIRES…..5403
  OPERATION…..5404
    GENERAL VIEW…..5405
      GENERAL VIEW OF MACHINE…..5405
      GENERAL VIEW OF CONTROLS AND GAUGES…..5406
    EXPLANATION OF COMPONENTS…..5408
      MACHINE MONITOR…..5408
      OTHER FUNCTIONS OF MACHINE MONITOR…..5429
      SWITCHES…..5432
      CONTROL LEVERS AND PEDALS…..5442
      MECHATRONICS EQUIPMENT CONTROLLER…..5447
      BODY PIVOT PIN…..5448
      ARTICULATE LOCK…..5448
      EXTERNAL ELECTRIC HEATER…..5449
      SOCKET FOR ENGINE HEATER…..5449
      SOCKET FOR TRANSMISSION, HYDRAULIC OIL TANK, BRAKE SUB-TANK HEATER…..5449
      FUSES…..5450
      CAR RADIO…..5453
      CAR STEREO…..5459
      AIR CONDITIONER…..5467
    OPERATION…..5472
      CHECK BEFORE STARTING ENGINE…..5472
      STARTING ENGINE…..5486
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..5489
      STOPPING ENGINE…..5490
      CHECKS AFTER STOPPING ENGINE…..5490
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..5491
      SHIFTING GEAR…..5496
      TRAVELING DOWNHILL…..5497
      STEERING THE MACHINE…..5503
      OPERATION USING DIFFERENTIAL LOCK…..5504
      LOADING OPERATIONS…..5505
      DUMP OPERATIONS…..5506
      CAB TILT OPERATION…..5508
      PRECAUTIONS FOR OPERATION…..5514
      PARKING MACHINE…..5515
      CHECKS AFTER COMPLETION OF WORK…..5516
      LOCKING…..5516
      HANDLING TIRES…..5517
    DETERMINING AND MAINTAINING TRAVEL ROAD…..5518
      DETERMINING TRAVEL ROAD…..5518
      MAINTAINING TRAVEL ROAD…..5518
    TRANSPORTATION…..5519
      PRECAUTIONS WHEN TRANSPORTING…..5519
      STEPS FOR TRANSPORTATION…..5519
      METHOD OF SECURING MACHINE…..5520
      METHOD OF LIFTING MACHINE…..5521
    COLD WEATHER OPERATION…..5525
      PRECAUTIONS FOR LOW TEMPERATURE…..5525
      HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…..5527
      PRECAUTIONS AFTER COMPLETION OF WORK…..5533
      AFTER COLD WEATHER…..5533
    LONG-TERM STORAGE…..5534
      BEFORE STORAGE…..5534
      DURING STORAGE…..5534
      AFTER STORAGE…..5534
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..5534
    TROUBLESHOOTING…..5535
      AFTER RUNNING OUT OF FUEL…..5535
      IF TRANSMISSION HAS TROUBLE…..5537
      METHOD OF TOWING MACHINE…..5538
      IF BATTERY IS DISCHARGED…..5542
      OTHER TROUBLE…..5547
  MAINTENANCE…..5554
    GUIDES TO MAINTENANCE…..5555
    OUTLINE OF SERVICE…..5557
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..5557
      OUTLINE OF ELECTRIC SYSTEM…..5561
    WEAR PARTS…..5562
      WEAR PARTS LIST…..5562
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..5563
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..5564
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..5566
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..5567
      TORQUE LIST…..5567
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..5569
      SAFETY CRITICAL PARTS…..5569
    MAINTENANCE SCHEDULE CHART…..5570
      MAINTENANCE SCHEDULE CHART…..5570
      ADJUST INJECTOR…..5573
    SERVICE PROCEDURE…..5574
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..5574
      WHEN REQUIRED…..5575
      CHECK BEFORE STARTING…..5590
      EVERY 50 HOURS SERVICE…..5591
      EVERY 250 HOURS SERVICE…..5592
      EVERY 500 HOURS SERVICE…..5602
      EVERY 1000 HOURS SERVICE…..5609
      EVERY 2000 HOURS SERVICE…..5618
      EVERY 4000 HOURS SERVICE…..5625
      EVERY 6000 HOURS SERVICE…..5628
      EVERY 8000 HOURS SERVICE…..5629
  SPECIFICATIONS…..5630
    SPECIFICATIONS…..5631
  ATTACHMENTS, OPTIONS…..5632
    HANDLING TACHOGRAPH (TCO20-90W)…..5633
      EXPLANATION OF COMPONENTS…..5633
      METHOD OF USE…..5636
  INDEX…..5640
PEN00232-06 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..5644
  COVER…..5644
  FOREWORD…..5645
    BEFORE READING THIS MANUAL…..5646
    SAFETY INFORMATION…..5647
    INTENDED USE…..5648
      USE OF MACHINE…..5648
      DIRECTIONS OF MACHINE…..5648
      VISIBILITY FROM OPERATOR&apos;S SEAT…..5648
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5649
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..5649
      EPA REGULATIONS, ENGINE NUMBER PLATE…..5649
      SERVICE METER POSITION…..5650
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5650
    CONTENTS…..5651
  SAFETY…..5655
    SAFETY…..5656
    SAFETY LABELS…..5659
      POSITION FOR ATTACHING SAFETY LABELS…..5660
      SAFETY LABELS…..5661
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..5666
      PRECAUTIONS BEFORE STARTING OPERATION…..5666
      PREPARATIONS FOR SAFE OPERATION…..5666
      FIRE PREVENTION…..5668
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..5669
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..5671
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..5671
      UNAUTHORIZED MODIFICATION…..5671
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..5672
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..5672
    PRECAUTIONS FOR OPERATION…..5673
      PRECAUTIONS FOR JOBSITE…..5673
      STARTING ENGINE…..5675
      OPERATION…..5678
      TRANSPORTATION…..5682
      TOWING…..5683
    PRECAUTIONS FOR MAINTENANCE…..5684
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..5684
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..5689
      TIRES…..5694
  OPERATION…..5697
    GENERAL VIEW…..5698
      GENERAL VIEW OF MACHINE…..5698
      GENERAL VIEW OF CONTROLS AND GAUGES…..5699
    EXPLANATION OF COMPONENTS…..5701
      MACHINE MONITOR…..5701
      OTHER FUNCTIONS OF MACHINE MONITOR…..5722
      SWITCHES…..5726
      CONTROL LEVERS AND PEDALS…..5737
      BODY PIVOT PIN…..5742
      ARTICULATE LOCK…..5742
      LOCATION OF FIRE EXTINGUISHER…..5743
      DUST INDICATOR…..5743
      CIRCUIT BREAKER…..5743
      FUSES…..5744
      CAR RADIO…..5747
      CAR STEREO…..5753
      AIR CONDITIONER…..5761
    OPERATION…..5766
      CHECK BEFORE STARTING ENGINE…..5766
      STARTING ENGINE…..5780
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..5782
      STOPPING ENGINE…..5783
      CHECKS AFTER STOPPING ENGINE…..5783
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..5784
      SHIFTING GEAR…..5789
      TRAVELING DOWNHILL…..5791
      STEERING THE MACHINE…..5797
      OPERATION USING DIFFERENTIAL LOCK…..5797
      LOADING OPERATIONS…..5800
      DUMP OPERATIONS…..5801
      CAB TILT OPERATION…..5803
      PRECAUTIONS FOR OPERATION…..5806
      PARKING MACHINE…..5807
      CHECKS AFTER COMPLETION OF WORK…..5808
      LOCKING…..5808
      HANDLING TIRES…..5809
    DETERMINING AND MAINTAINING TRAVEL ROAD…..5810
      DETERMINING TRAVEL ROAD…..5810
      MAINTAINING TRAVEL ROAD…..5810
    TRANSPORTATION…..5811
      PRECAUTIONS WHEN TRANSPORTING…..5811
      STEPS FOR TRANSPORTATION…..5811
      METHOD OF SECURING MACHINE…..5812
      METHOD OF LIFTING MACHINE…..5813
    COLD WEATHER OPERATION…..5817
      PRECAUTIONS FOR LOW TEMPERATURE…..5817
      PRECAUTIONS AFTER COMPLETION OF WORK…..5818
      AFTER COLD WEATHER…..5819
    LONG-TERM STORAGE…..5820
      BEFORE STORAGE…..5820
      DURING STORAGE…..5820
      AFTER STORAGE…..5820
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..5820
    TROUBLESHOOTING…..5821
      AFTER RUNNING OUT OF FUEL…..5821
      IF TRANSMISSION HAS TROUBLE…..5822
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..5822
      METHOD OF TOWING MACHINE…..5823
      IF BATTERY IS DISCHARGED…..5827
      OTHER TROUBLE…..5830
  MAINTENANCE…..5837
    GUIDES TO MAINTENANCE…..5838
    OUTLINE OF SERVICE…..5840
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..5840
      OUTLINE OF ELECTRIC SYSTEM…..5844
    WEAR PARTS…..5845
      WEAR PARTS LIST…..5845
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..5846
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..5847
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..5848
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..5849
      TORQUE LIST…..5849
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..5851
      SAFETY CRITICAL PARTS…..5852
    MAINTENANCE SCHEDULE CHART…..5853
      MAINTENANCE SCHEDULE CHART…..5853
    SERVICE PROCEDURE…..5856
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..5856
      WHEN REQUIRED…..5857
      CHECK BEFORE STARTING…..5874
      EVERY 50 HOURS SERVICE…..5875
      EVERY 250 HOURS SERVICE…..5876
      EVERY 500 HOURS SERVICE…..5890
      EVERY 1000 HOURS SERVICE…..5897
      EVERY 2000 HOURS SERVICE…..5909
      EVERY 4000 HOURS SERVICE…..5916
      EVERY 6000 HOURS SERVICE…..5919
      EVERY 8000 HOURS SERVICE…..5920
  SPECIFICATIONS…..5921
    SPECIFICATIONS…..5922
  ATTACHMENTS, OPTIONS…..5923
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..5924
      EXPLANATION OF COMPONENTS…..5924
      METHOD OF OPERATION…..5925
    USE OF REAR VIEW MONITOR…..5926
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..5926
      SETTING OF REAR VIEW MONITOR…..5929
      CAUTIONS WHEN USING REAR VIEW MONITOR…..5929
    HANDLING DUMPING COUNTER…..5930
    HANDLING BATTERY DISCONNECTOR SWITCH…..5931
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..5933
      BASIC PRECAUTIONS…..5933
  INDEX…..5935
PEN00240-00 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual…..5939
  COVER…..5939
  FOREWORD…..5940
    FOREWORD…..5941
    SAFETY INFORMATION…..5944
    INTENDED USE…..5946
      DIRECTIONS OF MACHINE…..5946
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5947
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..5947
      ENGINE SERIAL NO. PLATE POSITION…..5947
      SERVICE METER POSITION…..5948
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..5948
  CONTENTS…..5949
  SAFETY…..5952
    SAFETY…..5953
    SAFETY LABELS…..5955
      POSITION FOR ATTACHING SAFETY LABELS…..5955
      SAFETY LABELS…..5956
    GENERAL PRECAUTIONS…..5962
      SAFETY RULES…..5962
      IF PROBLEMS ARE FOUND…..5962
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..5962
      FIRE EXTINGUISHER AND FIRST AID KIT…..5962
      SAFETY FEATURES…..5963
      KEEP MACHINE CLEAN…..5963
      INSIDE OPERATOR&apos;S COMPARTMENT…..5963
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR&apos;S SEAT…..5963
      HANDRAILS AND STEPS…..5964
      MOUNTING AND DISMOUNTING…..5964
      CRUSHING OR CUTTING PREVENTION…..5964
      PREVENTION OF BURNS…..5965
      FIRE PREVENTION…..5966
      ACTION IF FIRE OCCURS…..5966
      WINDOW WASHER LIQUID…..5967
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..5967
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..5967
      UNAUTHORIZED MODIFICATION…..5967
      SAFETY AT WORKSITE…..5967
      WORKING ON LOOSE GROUND…..5968
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..5968
      ENSURE GOOD VISIBILITY…..5969
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..5969
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..5969
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..5969
      ASBESTOS DUST HAZARD PREVENTION…..5970
    PRECAUTIONS DURING OPERATION…..5971
      STARTING ENGINE…..5971
        CHECKS BEFORE STARTING ENGINE, ADJUST…..5971
        PRECAUTIONS WHEN STARTING…..5971
        PRECAUTIONS IN COLD AREAS…..5972
      OPERATION…..5973
        CHECKS BEFORE STARTING OPERATION…..5973
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..5973
        PRECAUTIONS WHEN TRAVELING…..5974
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..5974
        PRECAUTIONS WHEN OPERATING DUMP BODY…..5974
        PRECAUTIONS WHEN OPERATING…..5974
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..5975
        PARKING MACHINE…..5975
      TRANSPORTATION…..5976
        LOADING AND UNLOADING…..5976
        SHIPPING…..5976
      BATTERY…..5977
        BATTERY HAZARD PREVENTION…..5977
        STARTING WITH BOOSTER CABLES…..5978
      TOWING…..5979
        WHEN TOWING…..5979
    PRECAUTIONS FOR MAINTENANCE…..5980
      WARNING TAG…..5980
      KEEP WORK PLACE CLEAN AND TIDY…..5980
      APPOINT LEADER WHEN WORKING WITH OTHERS…..5980
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..5981
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..5982
      PROPER TOOLS…..5983
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..5983
      PERSONNEL…..5983
      WORK UNDER THE MACHINE…..5983
      NOISE…..5983
      PRECAUTIONS WHEN USING HAMMER…..5984
      REPAIR WELDING…..5984
      REMOVING BATTERY TERMINAL…..5984
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..5984
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..5984
      HANDLING HIGH-PRESSURE HOSES, PIPING…..5985
      PRECAUTIONS FOR HIGH VOLTAGE…..5985
      WASTE MATERIALS…..5985
      MAINTENANCE OF AIR CONDITIONER…..5985
      COMPRESSED AIR…..5985
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..5986
    PRECAUTIONS WITH TIRES…..5987
      HANDLING TIRES…..5987
      PRECAUTIONS WHEN STORING TIRE…..5987
  OPERATION…..5988
    GENERAL VIEW…..5989
      GENERAL VIEW OF MACHINE…..5989
      GENERAL VIEW OF CONTROLS AND GAUGES…..5990
    EXPLANATION OF COMPONENTS…..5992
      MACHINE MONITOR…..5992
      OTHER FUNCTIONS OF MACHINE MONITOR…..6013
      SWITCHES…..6017
      CONTROL LEVERS AND PEDALS…..6028
      MECHATRONICS EQUIPMENT CONTROLLER…..6033
      BODY PIVOT PIN…..6034
      ARTICULATE LOCK…..6034
      DUST INDICATOR…..6035
      FUSES…..6036
      CAR RADIO…..6039
      CAR STEREO…..6045
      AIR CONDITIONER…..6053
    OPERATION…..6058
      CHECK BEFORE STARTING ENGINE…..6058
      STARTING ENGINE…..6071
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..6074
      STOPPING ENGINE…..6075
      CHECKS AFTER STOPPING ENGINE…..6075
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..6076
      SHIFTING GEAR…..6081
      TRAVELING DOWNHILL…..6082
      STEERING THE MACHINE…..6090
      OPERATION USING DIFFERENTIAL LOCK…..6090
      LOADING OPERATIONS…..6092
      DUMP OPERATIONS…..6093
      CAB TILT OPERATION…..6095
      PRECAUTIONS FOR OPERATION…..6097
      PARKING MACHINE…..6098
      CHECKS AFTER COMPLETION OF WORK…..6099
      LOCKING…..6099
      HANDLING TIRES…..6100
    DETERMINING AND MAINTAINING TRAVEL ROAD…..6101
      DETERMINING TRAVEL ROAD…..6101
      MAINTAINING TRAVEL ROAD…..6101
    TRANSPORTATION…..6102
      PRECAUTIONS WHEN TRANSPORTING…..6102
      STEPS FOR TRANSPORTATION…..6102
      METHOD OF SECURING MACHINE…..6103
      METHOD OF LIFTING MACHINE…..6104
    COLD WEATHER OPERATION…..6108
      PRECAUTIONS FOR LOW TEMPERATURE…..6108
      PRECAUTIONS AFTER COMPLETION OF WORK…..6109
      AFTER COLD WEATHER…..6110
    LONG-TERM STORAGE…..6111
      BEFORE STORAGE…..6111
      DURING STORAGE…..6111
      AFTER STORAGE…..6111
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..6111
    TROUBLESHOOTING…..6112
      AFTER RUNNING OUT OF FUEL…..6112
      METHOD OF TOWING MACHINE…..6113
      IF BATTERY IS DISCHARGED…..6117
      OTHER TROUBLE…..6121
  MAINTENANCE…..6128
    GUIDES TO MAINTENANCE…..6129
    OUTLINE OF SERVICE…..6131
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..6131
      OUTLINE OF ELECTRIC SYSTEM…..6135
    WEAR PARTS…..6136
      WEAR PARTS LIST…..6136
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..6137
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..6138
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..6140
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..6141
      TORQUE LIST…..6141
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..6143
      SAFETY CRITICAL PARTS…..6144
    MAINTENANCE SCHEDULE CHART…..6145
      MAINTENANCE SCHEDULE CHART…..6145
      ADJUST INJECTOR…..6148
    SERVICE PROCEDURE…..6149
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..6149
      WHEN REQUIRED…..6150
        CHECK, CLEAN OR REPLACE AIR CLEANER…..6150
        CLEAN INSIDE OF COOLING SYSTEM…..6153
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..6155
        CLEAN AIR CONDITIONER AIR FILTER…..6156
        CHECK REFRIGERANT (GAS) LEVEL…..6156
        CHECK DUMP BODY…..6157
        CHECK ELECTRIC INTAKE AIR HEATER…..6157
        BLEED AIR FROM FRONT BRAKE…..6157
        BLEED AIR FROM CENTER BRAKE…..6158
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..6159
        SELECTION AND INSPECTION OF TIRES…..6160
      CHECK BEFORE STARTING…..6163
      EVERY 50 HOURS SERVICE…..6164
        LUBRICATION…..6164
      EVERY 250 HOURS SERVICE…..6165
        LUBRICATION…..6165
        LUBRICATE DRIVE SHAFT…..6166
        CHECK DRIVE SHAFT…..6167
        CHECK LEVEL OF BATTERY ELECTROLYTE…..6168
        CHECK ALTERNATOR BELT TENSION, ADJUST…..6170
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..6171
        CHECK FRAME, A-ARM…..6172
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..6173
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..6173
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..6174
        CHECK WEAR OF PARKING BRAKE PADS…..6174
        CHECK LENGTH OF SUSPENSION CYLINDER…..6175
      EVERY 500 HOURS SERVICE…..6176
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..6176
        REPLACE FUEL FILTER CARTRIDGE…..6177
        CLEAN FUEL TANK STRAINER…..6178
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..6178
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..6179
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..6180
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..6181
        CHECK FAN BELT TENSION, ADJUST…..6182
      EVERY 1000 HOURS SERVICE…..6183
        REPLACE CORROSION RESISTOR CARTRIDGE…..6183
        REPLACE TRANSMISSION FILTER ELEMENT…..6184
        CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER…..6185
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..6187
        LUBRICATION…..6189
        CHECK WEAR OF BRAKE DISC…..6190
        CHECK TIGHTENING PARTS OF TURBOCHARGER…..6190
      EVERY 2000 HOURS SERVICE…..6191
        CHANGE OIL IN FINAL DRIVE CASE…..6191
        CHANGE OIL IN DIFFERENTIAL CASE…..6192
        REPLACE HYDRAULIC FILTER ELEMENT…..6193
        CLEAN HYDRAULIC TANK STRAINER…..6194
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..6195
        CLEAN BREATHER…..6196
        CLEAN ENGINE BREATHER ELEMENT…..6198
        CHECK ALTERNATOR, STARTING MOTOR…..6198
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..6198
        CHECK INJECTOR (EPA EXHAUST GAS REGULATION AREAS ONLY)…..6198
        CLEAN, CHECK TURBOCHARGER…..6198
        CHECK PLAY OF TURBOCHARGER ROTOR…..6198
      EVERY 4000 HOURS SERVICE…..6199
        CHANGE OIL IN HYDRAULIC TANK…..6199
        CHECK WATER PUMP…..6199
        CHECK AIR COMPRESSOR…..6199
        CHECK FAN PULLEY AND TENSION PULLEY…..6199
        CHECK VIBRATION DAMPER…..6199
        CHECK INJECTOR (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)…..6199
        REPLACE INJECTOR ASSEMBLY (EPA EXHAUST GAS REGULATION AREAS ONLY)…..6199
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..6200
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..6200
      EVERY 6000 HOURS SERVICE…..6201
        LUBRICATE DRIVE SHAFT…..6201
      EVERY 8000 HOURS SERVICE…..6202
        REPLACE INJECTOR NOZZLE TIP (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)…..6202
        REPLACE HIGH-PRESSURE PIPING CLAMP…..6202
        REPLACE FUEL SPRAY PREVENTION CAP…..6202
  SPECIFICATIONS…..6204
    SPECIFICATIONS…..6205
  ATTACHMENTS, OPTIONS…..6206
    HANDLING TACHOGRAPH (TCO20-90W)…..6207
      EXPLANATION OF COMPONENTS…..6207
      METHOD OF USE…..6210
  INDEX…..6214
PEN00379-00 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..6218
  COVER…..6218
  FOREWORD…..6219
    BEFORE READING THIS MANUAL…..6220
    SAFETY INFORMATION…..6221
    INTENDED USE…..6222
      USE OF MACHINE…..6222
      DIRECTIONS OF MACHINE…..6222
      VISIBILITY FROM OPERATOR&apos;S SEAT…..6222
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..6223
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..6223
      EPA REGULATIONS, ENGINE NUMBER PLATE…..6223
      SERVICE METER POSITION…..6224
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..6224
    CONTENTS…..6225
  SAFETY…..6229
    SAFETY…..6230
    SAFETY LABELS…..6233
      POSITION FOR ATTACHING SAFETY LABELS…..6234
      SAFETY LABELS…..6235
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..6240
      PRECAUTIONS BEFORE STARTING OPERATION…..6240
      PREPARATIONS FOR SAFE OPERATION…..6240
      FIRE PREVENTION…..6242
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..6243
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..6245
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..6245
      UNAUTHORIZED MODIFICATION…..6245
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..6246
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..6246
    PRECAUTIONS FOR OPERATION…..6247
      PRECAUTIONS FOR JOBSITE…..6247
      STARTING ENGINE…..6249
      OPERATION…..6252
      TRANSPORTATION…..6256
      TOWING…..6257
    PRECAUTIONS FOR MAINTENANCE…..6258
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..6258
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..6263
      TIRES…..6268
  OPERATION…..6271
    GENERAL VIEW…..6272
      GENERAL VIEW OF MACHINE…..6272
      GENERAL VIEW OF CONTROLS AND GAUGES…..6273
    EXPLANATION OF COMPONENTS…..6275
      MACHINE MONITOR…..6275
      OTHER FUNCTIONS OF MACHINE MONITOR…..6296
      SWITCHES…..6300
      CONTROL LEVERS AND PEDALS…..6311
      BODY PIVOT PIN…..6316
      ARTICULATE LOCK…..6316
      LOCATION OF FIRE EXTINGUISHER…..6317
      DUST INDICATOR…..6317
      CIRCUIT BREAKER…..6317
      FUSES…..6318
      CAR RADIO…..6321
      CAR STEREO…..6327
      AIR CONDITIONER…..6335
    OPERATION…..6340
      CHECK BEFORE STARTING ENGINE…..6340
      STARTING ENGINE…..6354
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..6356
      STOPPING ENGINE…..6357
      CHECKS AFTER STOPPING ENGINE…..6357
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..6358
      SHIFTING GEAR…..6363
      TRAVELING DOWNHILL…..6365
      STEERING THE MACHINE…..6371
      OPERATION USING DIFFERENTIAL LOCK…..6371
      LOADING OPERATIONS…..6374
      DUMP OPERATIONS…..6375
      CAB TILT OPERATION…..6377
      PRECAUTIONS FOR OPERATION…..6380
      PARKING MACHINE…..6381
      CHECKS AFTER COMPLETION OF WORK…..6382
      LOCKING…..6382
      HANDLING TIRES…..6383
    DETERMINING AND MAINTAINING TRAVEL ROAD…..6384
      DETERMINING TRAVEL ROAD…..6384
      MAINTAINING TRAVEL ROAD…..6384
    TRANSPORTATION…..6385
      PRECAUTIONS WHEN TRANSPORTING…..6385
      STEPS FOR TRANSPORTATION…..6385
      METHOD OF SECURING MACHINE…..6386
      METHOD OF LIFTING MACHINE…..6387
    COLD WEATHER OPERATION…..6391
      PRECAUTIONS FOR LOW TEMPERATURE…..6391
      PRECAUTIONS AFTER COMPLETION OF WORK…..6392
      AFTER COLD WEATHER…..6393
    LONG-TERM STORAGE…..6394
      BEFORE STORAGE…..6394
      DURING STORAGE…..6394
      AFTER STORAGE…..6394
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..6394
    TROUBLESHOOTING…..6395
      AFTER RUNNING OUT OF FUEL…..6395
      IF TRANSMISSION HAS TROUBLE…..6396
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..6396
      METHOD OF TOWING MACHINE…..6397
      IF BATTERY IS DISCHARGED…..6401
      OTHER TROUBLE…..6405
  MAINTENANCE…..6411
    GUIDES TO MAINTENANCE…..6412
    OUTLINE OF SERVICE…..6414
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..6414
      OUTLINE OF ELECTRIC SYSTEM…..6418
    WEAR PARTS…..6419
      WEAR PARTS LIST…..6419
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..6420
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..6421
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..6422
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..6423
      TORQUE LIST…..6423
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..6425
      SAFETY CRITICAL PARTS…..6426
    MAINTENANCE SCHEDULE CHART…..6427
      MAINTENANCE SCHEDULE CHART…..6427
    SERVICE PROCEDURE…..6430
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..6430
      WHEN REQUIRED…..6431
      CHECK BEFORE STARTING…..6447
      EVERY 50 HOURS SERVICE…..6448
      EVERY 250 HOURS SERVICE…..6449
      EVERY 500 HOURS SERVICE…..6463
      EVERY 1000 HOURS SERVICE…..6470
      EVERY 2000 HOURS SERVICE…..6481
      EVERY 4000 HOURS SERVICE…..6488
      EVERY 6000 HOURS SERVICE…..6491
      EVERY 8000 HOURS SERVICE…..6492
  SPECIFICATIONS…..6493
    SPECIFICATIONS…..6494
  ATTACHMENTS, OPTIONS…..6495
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..6496
      EXPLANATION OF COMPONENTS…..6496
      METHOD OF OPERATION…..6497
    USE OF REAR VIEW MONITOR…..6498
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..6498
      SETTING OF REAR VIEW MONITOR…..6501
      CAUTIONS WHEN USING REAR VIEW MONITOR…..6501
    HANDLING DUMPING COUNTER…..6502
    HANDLING BATTERY DISCONNECTOR SWITCH…..6503
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..6505
      BASIC PRECAUTIONS…..6505
  INDEX…..6507
PEN00475-11 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..6511
  COVER…..6511
  FOREWORD…..6512
    BEFORE READING THIS MANUAL…..6513
    SAFETY INFORMATION…..6514
    INTENDED USE…..6515
      USE OF MACHINE…..6515
      DIRECTIONS OF MACHINE…..6515
      VISIBILITY FROM OPERATOR&apos;S SEAT…..6516
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..6517
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..6517
      EPA REGULATIONS, ENGINE NUMBER PLATE…..6517
      SERVICE METER POSITION…..6518
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..6518
    CONTENTS…..6519
  SAFETY…..6522
    SAFETY…..6523
    SAFETY LABELS…..6526
      POSITION FOR ATTACHING SAFETY LABELS…..6527
      SAFETY LABELS…..6528
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..6534
      PRECAUTIONS BEFORE STARTING OPERATION…..6534
      PREPARATIONS FOR SAFE OPERATION…..6534
      FIRE PREVENTION…..6536
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..6537
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..6539
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..6539
      UNAUTHORIZED MODIFICATION…..6539
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..6540
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..6540
    PRECAUTIONS FOR OPERATION…..6541
      PRECAUTIONS FOR JOBSITE…..6541
      STARTING ENGINE…..6543
      OPERATION…..6546
      TRANSPORTATION…..6550
      TOWING…..6551
    PRECAUTIONS FOR MAINTENANCE…..6552
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..6552
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..6557
      TIRES…..6562
  OPERATION…..6564
    GENERAL VIEW…..6565
      GENERAL VIEW OF MACHINE…..6565
      GENERAL VIEW OF CONTROLS AND GAUGES…..6566
    EXPLANATION OF COMPONENTS…..6568
      MACHINE MONITOR…..6568
      OTHER FUNCTIONS OF MACHINE MONITOR…..6589
      SWITCHES…..6593
      CONTROL LEVERS AND PEDALS…..6604
      BODY PIVOT PIN…..6609
      ARTICULATE LOCK…..6609
      LOCATION OF FIRE EXTINGUISHER…..6610
      DUST INDICATOR…..6610
      CIRCUIT BREAKER…..6610
      FUSES…..6611
      CAR RADIO…..6614
      CAR STEREO…..6620
      AIR CONDITIONER…..6628
    OPERATION…..6633
      CHECK BEFORE STARTING ENGINE…..6633
      STARTING ENGINE…..6648
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..6650
      STOPPING ENGINE…..6651
      CHECKS AFTER STOPPING ENGINE…..6651
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..6652
      SHIFTING GEAR…..6657
      TRAVELING DOWNHILL…..6659
      STEERING THE MACHINE…..6665
      OPERATION USING DIFFERENTIAL LOCK…..6666
      LOADING OPERATIONS…..6669
      DUMP OPERATIONS…..6670
      CAB TILT OPERATION…..6672
      PRECAUTIONS FOR OPERATION…..6675
      PARKING MACHINE…..6676
      CHECKS AFTER COMPLETION OF WORK…..6677
      LOCKING…..6677
      HANDLING TIRES…..6678
    DETERMINING AND MAINTAINING TRAVEL ROAD…..6679
      DETERMINING TRAVEL ROAD…..6679
      MAINTAINING TRAVEL ROAD…..6679
    TRANSPORTATION…..6680
      PRECAUTIONS WHEN TRANSPORTING…..6680
      STEPS FOR TRANSPORTATION…..6680
      METHOD OF SECURING MACHINE…..6681
      METHOD OF LIFTING MACHINE…..6682
    COLD WEATHER OPERATION…..6686
      PRECAUTIONS FOR LOW TEMPERATURE…..6686
      PRECAUTIONS AFTER COMPLETION OF WORK…..6687
      AFTER COLD WEATHER…..6688
    LONG-TERM STORAGE…..6689
      BEFORE STORAGE…..6689
      DURING STORAGE…..6689
      AFTER STORAGE…..6689
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..6689
    TROUBLESHOOTING…..6690
      AFTER RUNNING OUT OF FUEL…..6690
      IF TRANSMISSION HAS TROUBLE…..6691
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..6691
      METHOD OF TOWING MACHINE…..6692
      IF BATTERY IS DISCHARGED…..6696
      OTHER TROUBLE…..6700
  MAINTENANCE…..6706
    GUIDES TO MAINTENANCE…..6707
    OUTLINE OF SERVICE…..6709
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..6709
      OUTLINE OF ELECTRIC SYSTEM…..6713
    WEAR PARTS…..6714
      WEAR PARTS LIST…..6714
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..6715
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..6716
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..6718
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..6719
      TORQUE LIST…..6719
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..6721
      SAFETY CRITICAL PARTS…..6722
    MAINTENANCE SCHEDULE CHART…..6723
      MAINTENANCE SCHEDULE CHART…..6723
    SERVICE PROCEDURE…..6726
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..6726
      WHEN REQUIRED…..6727
      CHECK BEFORE STARTING…..6744
      EVERY 50 HOURS SERVICE…..6745
      EVERY 250 HOURS SERVICE…..6746
      EVERY 500 HOURS SERVICE…..6760
      EVERY 1000 HOURS SERVICE…..6767
      EVERY 2000 HOURS SERVICE…..6786
      EVERY 4000 HOURS SERVICE…..6793
      EVERY 6000 HOURS SERVICE…..6796
      EVERY 8000 HOURS SERVICE…..6797
  SPECIFICATIONS…..6798
    SPECIFICATIONS…..6799
  ATTACHMENTS, OPTIONS…..6802
    HANDLING AUTOMATIC RETARDER, ACCELERATORCONTROL(ARAC)…..6803
      EXPLANATION OF COMPONENTS…..6803
      METHOD OF OPERATION…..6804
    USE OF REAR VIEW MONITOR…..6805
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..6805
      SETTING OF REAR VIEW MONITOR…..6808
      CAUTIONS WHEN USING REAR VIEW MONITOR…..6808
    HANDLING DUMPING COUNTER…..6809
    HANDLING BATTERY DISCONNECTOR SWITCH…..6810
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..6812
      BASIC PRECAUTIONS…..6812
  INDEX…..6814
SEBM024910 – Articulated Dump Truck HM350-1 Shop Manual…..6818
  COVER…..6818
  CONTENTS…..6819
  01 GENERAL…..6844
    SPECIFICATION DRAWINGS…..6845
    SPECIFICATIONS…..6846
    WEIGHT TABLE…..6849
    FUEL, COOLANT AND LUBRICANTS…..6850
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..6852
    RADIATOR, OIL COOLER, AFTERCOOLER…..6853
    POWER TRAIN SKELETON…..6854
    OUTPUT SHAFT…..6858
    TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…..6860
    TORQUE CONVERTER…..6862
    TRANSMISSION…..6868
    TRANSMISSION VALVE…..6886
    ECMV (ELECTRONIC CONTROL MODULATION VALVE)…..6887
    MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…..6894
    DRIVE SHAFT…..6896
    AXLE…..6897
    DIFFERENTIAL…..6900
    LIMITED SLIP DIFFERENTIAL…..6913
    FINAL DRIVE…..6917
    STEERING COLUMN…..6922
    BRAKE PIPING…..6923
    BRAKE VALVE…..6925
    ACCUMULATOR CHARGE VALVE…..6928
    PROPORTIONAL REDUCING VALVE…..6930
    BRAKE SYSTEM TANK…..6931
    PARKING BRAKE…..6932
    PARKING BRAKE CALIPER…..6934
    SPRING CYLINDER…..6935
    PARKING BRAKE SOLENOID…..6936
    SUSPENSION…..6937
    SUSPENSION CYLINDER…..6942
    OSCILLATION HITCH…..6944
    STEERING, HOIST OIL PRESSURE PIPING DIAGRAM…..6947
    DUMP BODY CONTROL…..6948
    HYDRAULIC TANK AND FILTER…..6949
    FLOW AMP VALVE…..6950
    STEERING VALVE…..6953
    STEERING CYLINDER…..6957
    HOIST VALVE…..6958
    EPC VALVE…..6964
    PILOT CHECK VALVE…..6965
    HOIST CYLINDER…..6966
    HYDRAULIC PUMP…..6967
    CAB TILT…..6973
    AIR CONDITIONER…..6974
    MACHINE MONITOR SYSTEM…..6979
    AUTOMATIC SHIFT CONTROL SYSTEM…..6993
    TRANSMISSION CONTROLLER…..6995
    AUTO EMERGENCY STEERING SYSTEM…..7001
    SENSORS, SWITCHES…..7002
    RETARDER CONTROL SYSTEM…..7010
    BRAKE CONTROL SYSTEM (E-SPEC)…..7020
    DUMP CONTROL LEVER…..7030
  20 TESTING AND ADJUSTING…..7035
    STANDARD VALUE TABLE FOR ENGINE…..7036
    STANDARD VALUE TABLE FOR CHASSIS…..7037
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..7041
    TESTING AND ADJUSTING…..7055
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..7056
      MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…..7058
      MEASURING EXHAUST TEMPERATURE…..7059
      MEASURING EXHAUST COLOR…..7061
      MEASURING COMPRESSION PRESSURE…..7062
      ADJUSTING VALVE CLEARANCE…..7063
      MEASURING BLOW-BY PRESSURE…..7064
      MEASURING ENGINE OIL PRESSURE…..7065
      HANDING EQUIPMENT IN FUEL CIRCUIT…..7066
      RELEASING REMAINING PRESSURE IN FUEL SYSTEM…..7066
      MEASURING FUEL PRESSURE…..7067
      BLEEDING AIR FROM FUEL CIRCUIT…..7068
      REDUCED CYLINDER MODE OPERATION…..7069
      CHECKING FOR LEAKAGE IN FUEL CIRCUIT…..7070
      ADJUSTING ENGINE SPEED SENSOR…..7071
      TESTING AND ADJUSTING FAN BELT TENSION…..7072
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION…..7073
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..7073
      TESTING TORQUE CONVERTER STALL SPEED…..7074
      MEASURING POWER TRAIN OIL PRESSURE…..7075
      TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7083
      ADJUSTING TRANSMISSION SPEED SENSOR…..7088
      TESTING AND ADJUSTING BRAKE OIL PRESSURE…..7090
      TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS…..7095
      TESTING BRAKE PERFORMANCE…..7099
      BLEEDING AIR FROM BRAKE CIRCUIT…..7101
      TESTING WEAR OF WHEEL BRAKE DISC…..7103
      TESTING WEAR OF PARKING BRAKE PAD…..7104
      METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE…..7106
      TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE…..7107
      TESTING AND ADJUSTING SUSPENSION CYLINDER…..7109
      METHOD OF TILTING CAB UP…..7113
      TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE…..7115
      ADJUSTING BODY POSITIONER SENSOR…..7118
      PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT…..7119
      HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…..7119
      ADJUSTING TRANSMISSION CONTROLLER…..7120
      METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…..7121
      ADJUSTING MACHINE MONITOR…..7125
      SPECIAL FUNCTIONS OF MACHINE MONITOR…..7129
      PM-CLINIC INSPECTION SHEET…..7165
    TROUBLESHOOTING…..7168
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…..7169
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…..7170
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..7171
      CHECKS BEFORE TROUBLESHOOTING…..7179
      CONNECTOR TYPES AND MOUNTING LOCATIONS…..7180
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..7194
      T-ADAPTER TABLE…..7217
      CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS…..7220
      TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)…..7224
        ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..7226
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..7229
        ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))…..7241
        ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))…..7242
        ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))…..7243
        ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))…..7243
        ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))…..7244
        ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))…..7246
        ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))…..7246
        ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))…..7247
        ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))…..7248
        ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))…..7249
        ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))…..7250
        ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7251
        ENG-13 FAILURE CODE [ADZKKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..7252
        ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7256
        ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7257
        ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7258
        ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..7259
        ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7263
        ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..7264
        ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))…..7265
        ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))…..7266
        ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))…..7267
        ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7268
        ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7270
        ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))…..7271
        ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..7273
        ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))…..7274
        ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…..7275
        ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))…..7277
        ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))…..7278
        ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))…..7279
        ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))…..7280
        ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))…..7282
        ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))…..7284
        ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))…..7285
        ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7286
        ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7287
        ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7289
        ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7291
        ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))…..7293
        ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))…..7294
        ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)…..7295
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)…..7298
        TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..7301
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..7307
        TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))…..7333
        TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))…..7334
        TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))…..7335
        TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))…..7336
        TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))…..7337
        TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))…..7338
        TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))…..7339
        TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))…..7340
        TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))…..7341
        TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) …..7342
        TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7343
        TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))…..7344
        TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7345
        TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))…..7346
        TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7347
        TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))…..7348
        TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7349
        TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))…..7350
        TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7351
        TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))…..7352
        TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7353
        TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))…..7354
        TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7355
        TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))…..7356
        TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))…..7357
        TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))…..7358
        TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))  …..7359
        TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX))…..7361
        TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))…..7362
        TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7363
        TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))…..7364
        TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))…..7366
        TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))…..7367
        TM-34 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))…..7368
        TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))…..7369
        TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))…..7370
        TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7371
        TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..7373
        TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7374
        TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))…..7375
        TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..7377
        TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..7378
        TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..7379
        TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..7380
        TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..7381
        TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))…..7382
        TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP))…..7383
        TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..7384
        TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..7385
        TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))…..7385
        TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))…..7386
        TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..7387
        TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))…..7388
        TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))…..7389
        TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))…..7390
        TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))…..7391
        TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))…..7392
        TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))…..7393
        TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))…..7394
        TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))…..7396
        TM-62 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7398
        TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8))…..7399
        TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))…..7400
        TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7401
        TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7402
        TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))…..7404
        TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6))…..7405
        TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7406
        TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))…..7408
        TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))…..7409
        TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..7410
        TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..7411
        TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))…..7412
        TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..7413
        TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..7414
        TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..7415
        TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))…..7416
        TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))…..7417
        TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..7418
        TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))…..7419
        TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))…..7420
        TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))…..7421
        TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))…..7422
        TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))…..7423
        TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))…..7424
        TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))…..7425
        TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))…..7426
        TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))…..7427
        TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))…..7428
        TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))…..7429
        TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))…..7430
        TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))…..7431
        TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY…..7432
      TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)…..7435
        BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..7437
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..7443
        BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7457
        BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7458
        BK-3 FAILURE CODE [2A62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7459
        BK-4 FAILURE CODE [2A62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7460
        BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX))…..7461
        BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA))…..7462
        BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))…..7463
        BK-8 FAILURE CODE [2D03CA] (FRONT BRAKE (RIGHT): WEAR (CA))…..7464
        BK-9 FAILURE CODE [2D04CA] (FRONT BRAKE (LEFT): WEAR (CA))…..7465
        BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))…..7466
        BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))…..7466
        BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7467
        BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7468
        BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7469
        BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..7470
        BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..7471
        BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..7472
        BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..7473
        BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..7474
        BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))…..7475
        BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))…..7476
        BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))…..7478
        BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))…..7480
        BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))…..7483
        BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))…..7485
        BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..7486
        BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))…..7488
        BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))…..7489
        BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)…..7490
        BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7491
        BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..7492
        BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..7493
        BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..7494
        BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..7495
        BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..7496
        BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..7497
        BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..7498
        BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))…..7499
        BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))…..7500
        BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..7501
        BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7502
        BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7503
        BK-45 PARKING BRAKE DOES NOT WORK PROPERLY…..7505
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)…..7508
        MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..7509
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …..7513
        MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))…..7515
        MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))…..7515
        MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))…..7515
        MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..7516
        MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..7517
        MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…..7518
        MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..7519
        MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..7521
        MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..7523
        MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))…..7525
        MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY…..7526
        MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED…..7527
        MON-14 ALARM BUZZER DOES NOT SOUND…..7528
        MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY…..7529
        MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY…..7531
        MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY…..7532
        MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY…..7535
        MON-19 AISS FUNCTION DOES NOT WORK PROPERLY…..7536
        MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..7537
        MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY…..7540
        MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)…..7541
        MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY…..7543
        MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY…..7544
        MON-25 NIGHT LIGHTING IS NOT NORMAL…..7549
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..7555
        H-1 MACHINE DOES NOT START…..7556
        H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…..7557
        H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)…..7557
        H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…..7558
        H-5 TRANSMISSION DOES NOT SHIFT UP…..7558
        H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…..7559
        H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…..7562
        H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…..7563
        H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…..7564
        H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..7565
        H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..7566
        H-12 STEERING WHEEL IS HEAVY…..7567
        H-13 STEERING WHEEL DOES NOT WORK…..7568
        H-14 STEERING WHEEL VIBRATES…..7569
        H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER…..7570
        H-16 DUMP DOES NOT WORK…..7571
        H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…..7572
      TROUBLESHOOTING OF THE ENGINE BODY (S MODE)…..7573
        POINTS TO REMEMBER WHEN TROUBLESHOOTING…..7574
        METHOD OF USING TROUBLESHOOTING CHARTS…..7575
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..7578
        S-2 ENGINE DOES NOT START…..7579
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..7582
        S-4 ENGINE STOPS DURING OPERATIONS…..7583
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..7584
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..7585
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..7586
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..7587
        S-9 OIL BECOMES CONTAMINATED QUICKLY…..7588
        S-10 FUEL CONSUMPTION IS EXCESSIVE…..7589
        S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)…..7590
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..7591
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..7592
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..7593
        S-15 ABNORMAL NOISE IS MADE…..7594
        S-16 VIBRATION IS EXCESSIVE…..7595
  30 DISASSEMBLY AND ASSEMBLY…..7596
    HOW TO READ THIS MANUAL…..7598
      REMOVAL AND INSTALLATION OF ASSEMBLIES…..7598
      DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES…..7599
    REECAUTIONS WHEN CARRYING OUT OPERATION…..7600
    SPECIAL TOOL LIST…..7602
    SKETCHES OF SPECIAL TOOLS…..7607
    REMOVAL OF FUEL SUPPLY PUMP…..7618
    INSTALLATION OF FUEL SUPPLY PUMP…..7619
    REMOVAL OF ENGINE ASSEMBLY…..7620
    INSTALLATION OF ENGINE ASSEMBLY…..7625
    REMOVAL OF CYLINDER HEAD ASSEMBLY…..7626
    INSTALLATION OF CYLINDER HEAD…..7630
    REMOVAL AND INSTALLATION OF NOZZLE TIP…..7635
      SPECIAL TOOL…..7635
      REMOVAL…..7635
      INSTALLATION…..7636
      SCHEMATIC DRAWING OF SPECIAL TOOL…..7637
    REMOVAL OF RADIATOR ASSEMBLY…..7638
    INSTALLATION OF RADIATOR ASSEMBLY…..7640
    REMOVAL OF OUTPUT SHAFT ASSEMBLY…..7641
    INSTALLATION OF OUTPUT SHAFT ASSEMBLY…..7644
    DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..7645
    ASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..7646
    REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..7648
    INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..7654
    DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION…..7656
    COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION…..7656
    DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY…..7657
    ASSEMBLY OF TORUE CONVERTER ASSEMBLY…..7661
    DISASSEMBLY OF TRANSMISSION ASSEMBLY…..7665
    ASSEMBLY OF TRANSMISSION ASSEMBLY…..7684
    DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..7710
    ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..7717
    REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY…..7729
    INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…..7731
    DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..7733
    ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..7739
    REMOVAL OF REAR DIFFERENTIAL ASSEMBLY…..7749
    INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…..7750
    DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..7750
    ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..7754
    REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..7762
    INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..7763
    DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..7764
    ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..7770
    REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..7777
    INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..7778
    DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..7779
    ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..7783
    REMOVAL OF REAR FINAL DRIVE ASSEMBLY…..7789
    INSTALLATION OF REAR FINAL DRIVE ASSEMBLY…..7790
    DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..7790
    ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..7792
    REMOVAL OF CENTER AXLE ASSEMBLY…..7797
    INSTALLATION OF CENTER AXLE ASSEMBLY…..7799
    REMOVAL OF REAR AXLE ASSEMBLY…..7800
    INSTALLATION OF REAR AXLE ASSEMBLY…..7802
    REMOVAL OD FRONT SUSPENSION CYLINDER ASSEMBLY…..7803
    INSTALLATION OF FRONT SUSPENSION CYLIDER ASSEMBLY…..7804
    REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY…..7804
    INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY…..7805
    REMOVAL OF EQUALIZER BAR ASSEMBLY…..7805
    INSTALLATION OF EQUALIZER BAR ASSEMBLY…..7807
    REMOVAL OF FRONT WHEEL ASSEMBLY…..7808
    INSTALLATION OF FRONT WHEEL ASSEMBLY…..7808
    REMOVAL OF CENTER WHEEL ASSEMBLY…..7809
    INSTALLATION OF CENTER WHEEL ASSEMBLY…..7809
    REMOVAL OF REAR WHEEL ASSEMBLY…..7809
    INSTALLATION OF REAR WHEEL ASSEMBLY…..7809
    REMOVAL OF HITCH FRAME ASSEMBLY…..7810
    INSTALLATION OF HITCH FRAME ASSEMBLY…..7814
    DISASSEMBLY OF HITCH FRAME…..7816
    ASSEMBLY OF HITCH FRAME ASSEMBLY…..7817
    STANDARD INTEGRAL ORBIT-TOLL…..7819
    DISASSEMBLY OF STEERING VALVE…..7821
    ASSEMBLY OF STEERING VALVE…..7823
    REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY…..7828
    INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY…..7829
    REMOVAL OF HOIST VALVE ASSEMBLY…..7830
    INSTALLATION OF HOIST VALVE ASSEMBLY…..7831
    DISASSEMBLY OF HOIST VALVE ASSEMBLY…..7832
    ASSEMBLY OF HOIST VALVE ASSEMBLY…..7833
    DISASSEMBLY OF STEERING CYLINDER ASSEMBLY…..7834
    ASSEMBLY OF STEERING CYLINDER ASSEMBLY…..7835
    DISASSEMBLY OF HOIST CYLINDER ASSEMBLY…..7837
    ASSEMBLY OF HOIST CYLINDER ASSEMBLY…..7838
    REMOVAL OF BODY ASSEMBLY…..7840
    INSTALLATION OF BODY ASSEMBLY…..7841
    DISASSEMBLY AND ASSEMBLY OF OPERATOR&apos;S SEAT ASSEMBLY…..7842
  90 OTHERS…..7851
    POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..7852
    STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…..7853
    DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM…..7854
    BRAKE HYDRAULIC CIRCUIT DIAGRAM…..7855
    BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…..7856
    DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER…..7857
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)…..7858
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)…..7859
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)…..7860
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)…..7861
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2)…..7862
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2)…..7863
SEBM024912 – Articulated Dump Truck HM350-1 Shop Manual…..7864
  COVER…..7864
  CONTENTS…..7865
  01 GENERAL…..7890
    SPECIFICATION DRAWINGS…..7891
    SPECIFICATIONS…..7892
    WEIGHT TABLE…..7895
    FUEL, COOLANT AND LUBRICANTS…..7896
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..7898
    RADIATOR, OIL COOLER, AFTERCOOLER…..7899
    POWER TRAIN SKELETON…..7900
    OUTPUT SHAFT…..7904
    TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…..7906
    TORQUE CONVERTER…..7908
    TRANSMISSION…..7914
    TRANSMISSION VALVE…..7932
    ECMV (ELECTRONIC CONTROL MODULATION VALVE)…..7933
    MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…..7940
    DRIVE SHAFT…..7942
    AXLE…..7943
    DIFFERENTIAL…..7946
    LIMITED SLIP DIFFERENTIAL…..7959
    FINAL DRIVE…..7963
    STEERING COLUMN…..7968
    BRAKE PIPING…..7969
    BRAKE VALVE…..7971
    ACCUMULATOR CHARGE VALVE…..7974
    PROPORTIONAL REDUCING VALVE…..7976
    BRAKE SYSTEM TANK…..7977
    PARKING BRAKE…..7978
    PARKING BRAKE CALIPER…..7980
    SPRING CYLINDER…..7981
    PARKING BRAKE SOLENOID…..7982
    SUSPENSION…..7983
    SUSPENSION CYLINDER…..7988
    OSCILLATION HITCH…..7990
    STEERING, HOIST OIL PRESSURE PIPING DIAGRAM…..7993
    DUMP BODY CONTROL…..7994
    HYDRAULIC TANK AND FILTER…..7995
    FLOW AMP VALVE…..7996
    STEERING VALVE…..7999
    STEERING CYLINDER…..8003
    HOIST VALVE…..8004
    EPC VALVE…..8010
    PILOT CHECK VALVE…..8011
    HOIST CYLINDER…..8012
    HYDRAULIC PUMP…..8013
    CAB TILT…..8019
    AIR CONDITIONER…..8020
    MACHINE MONITOR SYSTEM…..8025
    AUTOMATIC SHIFT CONTROL SYSTEM…..8039
    TRANSMISSION CONTROLLER…..8041
    AUTO EMERGENCY STEERING SYSTEM…..8047
    SENSORS, SWITCHES…..8048
    RETARDER CONTROL SYSTEM…..8056
    BRAKE CONTROL SYSTEM (E-SPEC)…..8066
    DUMP CONTROL LEVER…..8076
  20 TESTING AND ADJUSTING…..8081
    STANDARD VALUE TABLE FOR ENGINE…..8082
    STANDARD VALUE TABLE FOR CHASSIS…..8083
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..8087
    TESTING AND ADJUSTING…..8101
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..8102
      MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…..8104
      MEASURING EXHAUST TEMPERATURE…..8105
      MEASURING EXHAUST COLOR…..8107
      MEASURING COMPRESSION PRESSURE…..8108
      ADJUSTING VALVE CLEARANCE…..8109
      MEASURING BLOW-BY PRESSURE…..8110
      MEASURING ENGINE OIL PRESSURE…..8111
      HANDING EQUIPMENT IN FUEL CIRCUIT…..8112
      RELEASING REMAINING PRESSURE IN FUEL SYSTEM…..8112
      MEASURING FUEL PRESSURE…..8113
      BLEEDING AIR FROM FUEL CIRCUIT…..8114
      REDUCED CYLINDER MODE OPERATION…..8115
      CHECKING FOR LEAKAGE IN FUEL CIRCUIT…..8116
      ADJUSTING ENGINE SPEED SENSOR…..8117
      TESTING AND ADJUSTING FAN BELT TENSION…..8118
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION…..8119
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..8119
      ADJUSTING THE BODY MOUNT…..8120
      TESTING TORQUE CONVERTER STALL SPEED…..8122
      MEASURING POWER TRAIN OIL PRESSURE…..8123
      TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8131
      ADJUSTING TRANSMISSION SPEED SENSOR…..8136
      TESTING AND ADJUSTING BRAKE OIL PRESSURE…..8138
      TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS…..8143
      TESTING BRAKE PERFORMANCE…..8147
      BLEEDING AIR FROM BRAKE CIRCUIT…..8149
      TESTING WEAR OF WHEEL BRAKE DISC…..8151
      TESTING WEAR OF PARKING BRAKE PAD…..8152
      METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE…..8154
      TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE…..8155
      TESTING AND ADJUSTING SUSPENSION CYLINDER…..8157
      METHOD OF TILTING CAB UP…..8161
      TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE…..8163
      ADJUSTING BODY POSITIONER SENSOR…..8166
      PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT…..8167
      HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…..8167
      ADJUSTING TRANSMISSION CONTROLLER…..8168
      METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…..8169
      ADJUSTING MACHINE MONITOR…..8173
      SPECIAL FUNCTIONS OF MACHINE MONITOR…..8177
      PM-CLINIC INSPECTION SHEET…..8213
    TROUBLESHOOTING…..8216
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…..8217
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…..8218
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..8219
      CHECKS BEFORE TROUBLESHOOTING…..8227
      CONNECTOR TYPES AND MOUNTING LOCATIONS…..8228
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..8242
      T-ADAPTER TABLE…..8265
      CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS…..8268
      TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)…..8272
        ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..8274
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..8277
        ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))…..8289
        ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))…..8290
        ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))…..8291
        ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))…..8291
        ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))…..8292
        ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))…..8294
        ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))…..8294
        ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))…..8295
        ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))…..8296
        ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))…..8297
        ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))…..8298
        ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8299
        ENG-13 FAILURE CODE [ADZKKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..8300
        ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8304
        ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8305
        ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8306
        ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..8307
        ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8311
        ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..8312
        ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))…..8313
        ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))…..8314
        ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))…..8315
        ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8316
        ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8318
        ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))…..8319
        ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..8321
        ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))…..8322
        ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…..8323
        ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))…..8325
        ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))…..8326
        ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))…..8327
        ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))…..8328
        ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))…..8330
        ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))…..8332
        ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))…..8333
        ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8334
        ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8335
        ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8337
        ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8339
        ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))…..8341
        ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))…..8342
        ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)…..8343
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)…..8346
        TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..8349
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..8355
        TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))…..8381
        TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))…..8382
        TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))…..8383
        TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))…..8384
        TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))…..8385
        TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))…..8386
        TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))…..8387
        TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))…..8388
        TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))…..8389
        TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) …..8390
        TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8391
        TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))…..8392
        TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8393
        TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))…..8394
        TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8395
        TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))…..8396
        TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8397
        TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))…..8398
        TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8399
        TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))…..8400
        TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8401
        TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))…..8402
        TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8403
        TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))…..8404
        TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))…..8405
        TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))…..8406
        TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))  …..8407
        TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX))…..8409
        TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))…..8410
        TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8411
        TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))…..8412
        TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))…..8414
        TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))…..8415
        TM-34 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))…..8416
        TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))…..8417
        TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))…..8418
        TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8419
        TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..8421
        TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8422
        TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))…..8423
        TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..8425
        TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..8426
        TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..8427
        TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..8428
        TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..8429
        TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))…..8430
        TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP))…..8431
        TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..8432
        TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..8433
        TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))…..8433
        TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))…..8434
        TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..8435
        TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))…..8436
        TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))…..8437
        TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))…..8438
        TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))…..8439
        TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))…..8440
        TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))…..8441
        TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))…..8442
        TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))…..8444
        TM-62 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8446
        TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8))…..8447
        TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))…..8448
        TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8449
        TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8450
        TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))…..8452
        TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6))…..8453
        TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8454
        TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))…..8456
        TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))…..8457
        TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..8458
        TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..8459
        TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))…..8460
        TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..8461
        TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..8462
        TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..8463
        TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))…..8464
        TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))…..8465
        TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..8466
        TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))…..8467
        TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))…..8468
        TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))…..8469
        TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))…..8470
        TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))…..8471
        TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))…..8472
        TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))…..8473
        TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))…..8474
        TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))…..8475
        TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))…..8476
        TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))…..8477
        TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))…..8478
        TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))…..8479
        TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY…..8480
      TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)…..8483
        BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..8485
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..8491
        BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8505
        BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8506
        BK-3 FAILURE CODE [2A62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8507
        BK-4 FAILURE CODE [2A62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8508
        BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX))…..8509
        BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA))…..8510
        BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))…..8511
        BK-8 FAILURE CODE [2D03CA] (FRONT BRAKE (RIGHT): WEAR (CA))…..8512
        BK-9 FAILURE CODE [2D04CA] (FRONT BRAKE (LEFT): WEAR (CA))…..8513
        BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))…..8514
        BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))…..8514
        BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8515
        BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8516
        BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8517
        BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..8518
        BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..8519
        BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..8520
        BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..8521
        BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..8522
        BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))…..8523
        BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))…..8524
        BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))…..8526
        BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))…..8528
        BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))…..8531
        BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))…..8533
        BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..8534
        BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))…..8536
        BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))…..8537
        BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)…..8538
        BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8539
        BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..8540
        BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..8541
        BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..8542
        BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..8543
        BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..8544
        BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..8545
        BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..8546
        BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))…..8547
        BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))…..8548
        BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..8549
        BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8550
        BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8551
        BK-45 PARKING BRAKE DOES NOT WORK PROPERLY…..8553
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)…..8556
        MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..8557
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …..8561
        MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))…..8563
        MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))…..8563
        MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))…..8563
        MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..8564
        MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..8565
        MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…..8566
        MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..8567
        MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..8569
        MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..8571
        MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))…..8573
        MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY…..8574
        MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED…..8575
        MON-14 ALARM BUZZER DOES NOT SOUND…..8576
        MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY…..8577
        MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY…..8579
        MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY…..8580
        MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY…..8583
        MON-19 AISS FUNCTION DOES NOT WORK PROPERLY…..8584
        MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..8585
        MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY…..8588
        MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)…..8589
        MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY…..8591
        MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY…..8592
        MON-25 NIGHT LIGHTING IS NOT NORMAL…..8597
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..8603
        H-1 MACHINE DOES NOT START…..8604
        H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…..8605
        H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)…..8605
        H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…..8606
        H-5 TRANSMISSION DOES NOT SHIFT UP…..8606
        H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…..8607
        H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…..8610
        H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…..8611
        H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…..8612
        H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..8613
        H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..8614
        H-12 STEERING WHEEL IS HEAVY…..8615
        H-13 STEERING WHEEL DOES NOT WORK…..8616
        H-14 STEERING WHEEL VIBRATES…..8617
        H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER…..8618
        H-16 DUMP DOES NOT WORK…..8619
        H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…..8620
      TROUBLESHOOTING OF THE ENGINE BODY (S MODE)…..8621
        POINTS TO REMEMBER WHEN TROUBLESHOOTING…..8622
        METHOD OF USING TROUBLESHOOTING CHARTS…..8623
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..8626
        S-2 ENGINE DOES NOT START…..8627
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..8630
        S-4 ENGINE STOPS DURING OPERATIONS…..8631
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..8632
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..8633
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..8634
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..8635
        S-9 OIL BECOMES CONTAMINATED QUICKLY…..8636
        S-10 FUEL CONSUMPTION IS EXCESSIVE…..8637
        S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)…..8638
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..8639
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..8640
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..8641
        S-15 ABNORMAL NOISE IS MADE…..8642
        S-16 VIBRATION IS EXCESSIVE…..8643
  30 DISASSEMBLY AND ASSEMBLY…..8644
    HOW TO READ THIS MANUAL…..8646
      REMOVAL AND INSTALLATION OF ASSEMBLIES…..8646
      DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES…..8647
    REECAUTIONS WHEN CARRYING OUT OPERATION…..8648
    SPECIAL TOOL LIST…..8650
    SKETCHES OF SPECIAL TOOLS…..8655
    REMOVAL OF FUEL SUPPLY PUMP…..8666
    INSTALLATION OF FUEL SUPPLY PUMP…..8667
    REMOVAL OF ENGINE ASSEMBLY…..8668
    INSTALLATION OF ENGINE ASSEMBLY…..8673
    REMOVAL OF CYLINDER HEAD ASSEMBLY…..8674
    INSTALLATION OF CYLINDER HEAD…..8678
    REMOVAL AND INSTALLATION OF NOZZLE TIP…..8683
      SPECIAL TOOL…..8683
      REMOVAL…..8683
      INSTALLATION…..8684
      SCHEMATIC DRAWING OF SPECIAL TOOL…..8685
    REMOVAL OF RADIATOR ASSEMBLY…..8686
    INSTALLATION OF RADIATOR ASSEMBLY…..8688
    REMOVAL OF OUTPUT SHAFT ASSEMBLY…..8689
    INSTALLATION OF OUTPUT SHAFT ASSEMBLY…..8692
    DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..8693
    ASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..8694
    REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..8696
    INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..8702
    DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION…..8704
    COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION…..8704
    DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY…..8705
    ASSEMBLY OF TORUE CONVERTER ASSEMBLY…..8709
    DISASSEMBLY OF TRANSMISSION ASSEMBLY…..8713
    ASSEMBLY OF TRANSMISSION ASSEMBLY…..8732
    DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..8758
    ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..8765
    REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY…..8777
    INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…..8779
    DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..8781
    ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..8787
    REMOVAL OF REAR DIFFERENTIAL ASSEMBLY…..8797
    INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…..8798
    DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..8798
    ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..8802
    REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..8810
    INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..8811
    DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..8812
    ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..8818
    REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..8825
    INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..8826
    DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..8827
    ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..8831
    REMOVAL OF REAR FINAL DRIVE ASSEMBLY…..8837
    INSTALLATION OF REAR FINAL DRIVE ASSEMBLY…..8838
    DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..8838
    ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..8840
    REMOVAL OF CENTER AXLE ASSEMBLY…..8845
    INSTALLATION OF CENTER AXLE ASSEMBLY…..8847
    REMOVAL OF REAR AXLE ASSEMBLY…..8848
    INSTALLATION OF REAR AXLE ASSEMBLY…..8850
    REMOVAL OD FRONT SUSPENSION CYLINDER ASSEMBLY…..8851
    INSTALLATION OF FRONT SUSPENSION CYLIDER ASSEMBLY…..8852
    REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY…..8852
    INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY…..8853
    REMOVAL OF EQUALIZER BAR ASSEMBLY…..8853
    INSTALLATION OF EQUALIZER BAR ASSEMBLY…..8857
    REMOVAL OF FRONT WHEEL ASSEMBLY…..8858
    INSTALLATION OF FRONT WHEEL ASSEMBLY…..8858
    REMOVAL OF CENTER WHEEL ASSEMBLY…..8859
    INSTALLATION OF CENTER WHEEL ASSEMBLY…..8859
    REMOVAL OF REAR WHEEL ASSEMBLY…..8859
    INSTALLATION OF REAR WHEEL ASSEMBLY…..8859
    REMOVAL OF HITCH FRAME ASSEMBLY…..8860
    INSTALLATION OF HITCH FRAME ASSEMBLY…..8864
    DISASSEMBLY OF HITCH FRAME…..8866
    ASSEMBLY OF HITCH FRAME ASSEMBLY…..8867
    STANDARD INTEGRAL ORBIT-TOLL…..8869
    DISASSEMBLY OF STEERING VALVE…..8871
    ASSEMBLY OF STEERING VALVE…..8873
    REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY…..8878
    INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY…..8879
    REMOVAL OF HOIST VALVE ASSEMBLY…..8880
    INSTALLATION OF HOIST VALVE ASSEMBLY…..8881
    DISASSEMBLY OF HOIST VALVE ASSEMBLY…..8882
    ASSEMBLY OF HOIST VALVE ASSEMBLY…..8883
    DISASSEMBLY OF STEERING CYLINDER ASSEMBLY…..8884
    ASSEMBLY OF STEERING CYLINDER ASSEMBLY…..8885
    DISASSEMBLY OF HOIST CYLINDER ASSEMBLY…..8887
    ASSEMBLY OF HOIST CYLINDER ASSEMBLY…..8888
    REMOVAL OF BODY ASSEMBLY…..8890
    INSTALLATION OF BODY ASSEMBLY…..8891
    DISASSEMBLY AND ASSEMBLY OF OPERATOR&apos;S SEAT ASSEMBLY…..8892
  90 OTHERS…..8901
    POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..8902
    STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…..8903
    DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM…..8904
    BRAKE HYDRAULIC CIRCUIT DIAGRAM…..8905
    BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…..8906
    DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER…..8907
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)…..8908
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)…..8909
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)…..8910
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)…..8911
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2)…..8912
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2)…..8913
SEBM030302 – Articulated Dump Truck HM350-1 (-40C degree Spec.) Shop Manual…..8914
  COVER…..8914
  CONTENTS…..8915
  01 GENERAL…..8920
    SPECIFICATION DRAWINGS…..8921
    SPECIFICATIONS…..8922
    WEIGHT TABLE…..8925
    FUEL,COOLANT AND LUBRICANTS…..8926
  10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD…..8928
    RADIATOR,OIL COOLER, AFTERCOOLER…..8929
    POWER TRAIN SKELETON…..8930
    OUTPUT SHAFT…..8934
    TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…..8936
    TORQUE CONVERTER…..8938
    TRANSMISSION…..8944
    TRANSMISSION VALVE…..8965
    ECMV (ELECTRONIC CONTROL MODULATION VALVE)…..8966
    MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…..8973
    DRIVE SHAFT…..8975
    AXLE…..8976
    DIFFERENTIAL…..8979
    LIMITED SLIP DIFFERENTIAL…..8992
    FINAL DRIVE…..8996
    STEERING COLUMN…..9001
    BRAKE PIPING…..9002
    BRAKE VALVE…..9004
    ACCUMULATOR CHARGE VALVE…..9007
    ACCUMULATOR…..9011
    SLACK ADJUSTER…..9012
    BRAKE…..9014
    PROPORTIONAL REDUCING VALVE…..9019
    BRAKE SYSTEM TANK…..9020
    PRAKING BRAKE…..9021
    PARKING BRAKE CALIPER…..9023
    SPRING CYLINDER…..9024
    PARKING BRAKE SOLENOID…..9025
    SUSPENSION…..9026
    SUSPENSION CYLINDER…..9031
    OSCILLATION HITCH…..9033
    STEERING,HOIST OIL PRESSURE PIPING DIAGRAM…..9036
    DUMP BODY CONTROL…..9037
    HYDRAULIC TANK AND FILTER…..9038
    FLOW AMP VALVE…..9039
    STEERING VALVE…..9042
    STEERING CYLINDER…..9046
    HOIST VALVE…..9047
    EPC VALVE…..9053
    PILOT CHECK VALVE…..9054
    HOIST CYLINDER…..9055
    HYDRAULIC PUMP…..9056
    CAB TILT…..9062
    AIR CONDITIONER…..9063
    MACHINE MONITOR SYSTEM…..9068
    AUTOMATIC SHIFT CONTROL SYSTEM…..9082
    TRANSMISSION CONTROLLER…..9084
    AUTO EMERGENCY STEERING SYSTEM…..9090
    SENSORS,SWITCHES…..9091
    RETARDER CONTROL SYSTEM…..9099
    BRAKE CONTROL SYSTEM (E-SPEC)…..9109
    DUMP CONTROL LEVER…..9119
  20 TESTING AND ADJUSTING…..9124
    STANDARD VALUE TABLE FOR ENGINE…..9125
    STANDARD VALUE TABLE FOR CHASSIS…..9126
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..9130
    TESTING AND ADJUSTING…..9144
      TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…..9145
      MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…..9147
      MEASURING EXHAUST TEMPERATURE…..9148
      MEASURING EXHAUST COLOR…..9150
      MEASURING COMPRESSION PRESSURE…..9151
      ADJUSTING VALVE CLEARANCE…..9152
      MEASURING BLOW-BY PRESSURE…..9153
      MEASURING ENGINE OIL PRESSURE…..9154
      HANDLING EQUIPMENT IN FUEL CIRCUIT…..9155
      RELEASING REMAINING PRESSURE IN FUEL SYSTEM…..9155
      MEASURING FUEL PRESSURE…..9156
      BLEEDING AIR FROM FUEL CIRCUIT…..9157
      REDUCED CYLINDER MODE OPERATION…..9158
      CHECKING FOR LEAKAGE IN FUEL CIRCUIT…..9159
      ADJUSTING ENGINE SPEED SENSOR…..9160
      TESTING AND ADJUSTING FAN BELT TENSION…..9161
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION…..9162
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..9162
      ADJUSTING THE BODY MOUNT…..9163
      TESTING TORQUE CONVERTER STALL SPEED…..9165
      MEASURING POWER TRAIN OIL PRESSURE…..9166
      TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)…..9174
      ADJUSTING TRANSMISSION SPEED SENSOR…..9179
      TESTING AND ADJUSTING BRAKE OIL PRESSURE…..9180
      TESTING BRAKE PERFORMANCE…..9185
      BLEEDING AIR FORM BRAKE CIRCUIT…..9187
      TESTING WEAR OF WHEEL BRAKE DISC…..9189
      TESTING WEAR OF PARKING BRAKE PAD…..9190
      METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE…..9192
      TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE…..9193
      TESTING AND ADJUSTING SUSPENSION CYLINDER…..9195
      METHOD OF TILTING CAB UP…..9199
      TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE…..9201
      ADJUSTING BODY POSITIONER SENSOR…..9204
      HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…..9205
      ADJUSTING TRANSMISSION CONTROLLER…..9206
      METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…..9207
      ADJUSTING MACHINE MONITOR…..9211
      SPECIAL FUNCTIONS OF MACHINE MONITOR…..9215
    TROUBLESHOOTING…..9256
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…..9257
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…..9258
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..9259
      CHECKS BEFORE TROUBLESHOOTING…..9267
      CONNECTOR TYPES AND MOUNTING LOCATIONS…..9268
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..9282
      CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS…..9304
      TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)…..9308
        ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..9310
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..9313
        ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))…..9325
        ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX)…..9326
        ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))…..9327
        ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))…..9327
        ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))…..9328
        ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))…..9330
        ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))…..9330
        ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))…..9331
        ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))…..9332
        ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))…..9333
        ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))…..9334
        ENG-12 FAILURE CODE [ADA1KA] (NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..9335
        ENG-13 FAILURE CODE [ADZKKB] (NO. 1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..9336
        ENG-14 FAILURE CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..9340
        ENG-15 FAILURE CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..9341
        ENG-16 FAILURE CODE [ADD1KA] (NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..9342
        ENG-17 FAILURE CODE [ADDZKB] (NO. 4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…..9343
        ENG-18 FAILURE CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)…..9347
        ENG-19 FAILURE CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…..9348
        ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))…..9349
        ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))…..9350
        ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))…..9351
        ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9352
        ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9354
        ENG-25 FAILURE CODE [D1DDKB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))…..9355
        ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..9357
        ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))…..9358
        ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE,INPUT (KK))…..9359
        ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))…..9361
        ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))…..9362
        ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))…..9363
        ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))…..9364
        ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))…..9366
        ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))…..9368
        ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))…..9369
        ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9370
        ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9371
        ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9373
        ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9375
        ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))…..9377
        ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))…..9378
        ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)…..9379
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)…..9382
        TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..9385
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..9391
        TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))…..9417
        TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))…..9418
        TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))…..9419
        TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))…..9420
        TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))…..9421
        TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))…..9422
        TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))…..9423
        TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))…..9424
        TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))…..9425
        TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1))…..9426
        TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9427
        TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))…..9428
        TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9429
        TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))…..9430
        TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9431
        TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))…..9432
        TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9433
        TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))…..9434
        TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9435
        TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))…..9436
        TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9437
        TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))…..9438
        TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9439
        TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))…..9440
        TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))…..9441
        TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING  (MW))…..9442
        TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) …..9443
        TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX))…..9445
        TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))…..9446
        TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9447
        TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))…..9448
        TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))…..9450
        TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))…..9451
        TM-34 FAILURE CODE [B@BCZK] (RADIATOR WATER: DROP IN LEVEL (ZK))…..9452
        TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))…..9453
        TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))…..9454
        TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9455
        TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..9457
        TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9458
        TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))…..9459
        TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…..9461
        TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..9462
        TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..9463
        TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..9464
        TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…..9465
        TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))…..9466
        TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP))…..9467
        TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..9468
        TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))…..9469
        TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))…..9469
        TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))…..9470
        TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..9471
        TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))…..9472
        TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))…..9473
        TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))…..9474
        TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))…..9475
        TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))…..9476
        TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))…..9477
        TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))…..9478
        TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))…..9480
        TM-61 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9482
        TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8))…..9483
        TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))…..9484
        TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9485
        TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9486
        TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))…..9488
        TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6))…..9489
        TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9490
        TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))…..9492
        TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))…..9493
        TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..9494
        TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..9495
        TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))…..9496
        TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..9497
        TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…..9498
        TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))…..9499
        TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))…..9500
        TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))…..9501
        TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…..9502
        TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))…..9503
        TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))…..9504
        TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))…..9505
        TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))…..9506
        TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))…..9507
        TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))…..9508
        TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))…..9509
        TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))…..9510
        TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))…..9511
        TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))…..9512
        TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))…..9513
        TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))…..9514
        TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))…..9515
        TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY…..9516
      TROUBLESHOOTING OF RETARDER CONTROLLER(※1) SYSTEM (BK MODE)…..9519
        BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..9521
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…..9527
        BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1))…..9541
        BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH))…..9542
        BK-3 FAILURE CODE [2B62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1))…..9543
        BK-4 FAILURE CODE [2B62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH))…..9544
        BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX))…..9545
        BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA))…..9546
        BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))…..9547
        BK-8 FAILURE CODE [2D03CA] (CENTER BRAKE (RIGHT): WEAR (CA))…..9548
        BK-9 FAILURE CODE [2D04CA] (CENTER BRAKE (LEFT): WEAR (CA))…..9549
        BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))…..9550
        BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))…..9550
        BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9551
        BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9552
        BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9553
        BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…..9554
        BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…..9555
        BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…..9556
        BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…..9557
        BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..9558
        BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))…..9559
        BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))…..9560
        BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))…..9562
        BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))…..9564
        BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))…..9567
        BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))…..9569
        BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…..9570
        BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))…..9572
        BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))…..9573
        BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9574
        BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9575
        BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9576
        BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..9577
        BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..9578
        BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..9579
        BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…..9580
        BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…..9581
        BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..9582
        BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))…..9583
        BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))…..9584
        BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…..9585
        BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9586
        BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…..9587
        BK-45 PARKING BRAKE DOES NOT WORK PROPERLY…..9589
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)…..9592
        MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…..9593
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …..9597
        MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))…..9599
        MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))…..9599
        MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))…..9599
        MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..9600
        MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…..9601
        MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…..9602
        MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..9603
        MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..9605
        MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…..9607
        MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))…..9609
        MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY…..9610
        MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED…..9611
        MON-14 ALARM BUZZER DOES NOT SOUND…..9612
        MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY…..9613
        MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY…..9615
        MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY…..9616
        MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY…..9619
        MON-19 AISS FUNCTION DOES NOT WORK PROPERLY…..9620
        MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY…..9621
        MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY…..9624
        MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)…..9625
        MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY…..9627
        MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY…..9628
        MON-25 NIGHT LIGHTING IS NOT NORMAL…..9633
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..9639
        H-1 MACHINE DOES NOT START…..9640
        H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…..9641
        H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)…..9641
        H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…..9642
        H-5 TRANSMISSION DOES NOT SHIFT UP…..9642
        H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…..9643
        H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…..9646
        H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…..9647
        H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…..9648
        H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..9649
        H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…..9650
        H-12 STEERING WHEEL IS HEAVY…..9651
        H-13 STEERING WHEEL DOES NOT WORK…..9652
        H-14 STEEIRNG WHEEL VIBRATES…..9653
        H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER…..9654
        H-16 DUMP DOES NOT WORK…..9655
        H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…..9656
  30 DISASSEMBLY AND ASSEMBLY…..9657
    METHOD OF USING MANUAL…..9658
    PRECAUTIONS WHEN CARRYING OUT OPERATION…..9659
    SPECIAL TOOL LIST…..9661
    SKETCHES OF SPECIAL TOOLS…..9666
    REMOVAL OF ENGINE ASSEMBLY…..9677
    INSTALLATION OF ENGINE ASSEMBLY…..9680
    REMOVAL OF CYLINDER HEAD ASSEMBLY…..9680
    INSTALLATION OF CYLINDER HEAD…..9684
    REMOVAL OF RADIATOR ASSEMBLY…..9690
    INSTALLATION OF RADIATOR ASSEMBLY…..9692
    REMOVAL OF OUTPUT SHAFT ASSEMBLY…..9693
    INSTALLATION OF OUTPUT SHAFT ASSEMBLY…..9696
    DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..9697
    ASSEMBLY OF OUTPUT SHAFT ASSEMBLY…..9698
    REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..9700
    INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…..9706
    DISCONNECTION OF FRONT FINAL DRIVE AND TRANSMISSION…..9708
    COUPLING OF FRONT FINAL DRIVE AND TRANSMISSION…..9708
    DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY…..9709
    ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…..9713
    DISASSEMBLY OF TRANSMISSION ASSEMBLY…..9717
    ASSEMBLY OF TRANSMISSION ASSEMBLY…..9736
    DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..9763
    ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…..9770
    REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY…..9782
    INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…..9784
    DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..9786
    ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…..9792
    REMOVAL OF REAR DIFFERENTIAL ASSEMBLY…..9802
    INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…..9803
    DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..9803
    ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…..9807
    REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..9815
    INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..9816
    DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..9817
    ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…..9823
    REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY …..9830
    INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..9831
    DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..9832
    ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…..9836
    REMOVAL OF REAR FINAL DRIVE ASSEMBLY …..9842
    INSTALLATION OF REAR FINAL DRIVE ASSEMBLY…..9843
    DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..9843
    ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…..9845
    REMOVAL OF CENTER AXLE ASSEMBLY …..9850
    INSTALLATION OF CENTER AXLE ASSEMBLY …..9852
    REMOVAL OF REAR AXLE ASSEMBLY …..9853
    INSTALLATION OF REAR AXLE ASSEMBLY …..9855
    REMOVAL OF FRONT SUSPENSION CYLINDER ASSEMBLY…..9856
    INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY…..9857
    REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY…..9857
    INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY…..9858
    REMOVAL OF EQUALIZER BAR ASSEMBLY …..9858
    INSTALLATION OF EQUALIZER BAR ASSEMBLY…..9860
    REMOVAL OF FRONT WHEEL ASSEMBLY …..9861
    INSTALLATION OF FRONT WHEEL ASSEMBLY…..9861
    REMOVAL OF CENTER WHEEL ASSEMBLY…..9862
    INSTALLATION OF CENTER WHEEL ASSEMBLY…..9862
    REMOVAL OF REAR WHEEL ASSEMBLY…..9862
    INSTALLATION OF REAR WHEEL ASSEMBLY…..9862
    REMOVAL OF HITCH FRAME ASSEMBLY …..9863
    INSTALLATION OF HITCH FRAME ASSEMBLY…..9867
    DISASSEMBLY OF HITCH FRAME…..9869
    ASSEMBLY OF HITCH FRAME ASSEMBLY …..9870
    STANDARD INTEGRAL ORBIT-TOLL…..9872
    DISASSEMBLY OF STEERING VALVE…..9874
    ASSEMBLY OF STEERING VALVE…..9876
    REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY…..9881
    INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY…..9881
    REMOVAL OF HOIST VALVE ASSEMBLY…..9882
    INSTALLATION OF HOIST VALVE ASSEMBLY…..9882
    DISASSEMBLY OF HOIST VALVE ASSEMBLY…..9883
    ASSEMBLY OF HOIST VALVE ASSEMBLY…..9884
    DISASSEMBLY OF STEERING CYLINDER ASSEMBLY…..9885
    ASSEMBLY OF STEERING CYLINDER ASSEMBLY…..9886
    DISASSEMBLY OF HOIST CYLINDER ASSEMBLY…..9888
    ASSEMBLY OF HOIST CYLINDER ASSEMBLY…..9889
    REMOVAL OF BODY ASSEMBLY…..9891
    INSTALLATION OF BODY ASSEMBLY…..9892
  90 OTHERS…..9893
    POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..9894
    STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…..9895
    DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM…..9896
    BRAKE HYDRAULIC CIRCUIT DIAGRAM…..9897
    BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…..9898
    DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER…..9899
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)…..9900
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)…..9901
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)…..9902
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)…..9903
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2)…..9904
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2)…..9905
    EXTERNAL POWER SUPPLY HEATER…..9906
SEN00238-08 – Articulated Dump Truck HM350-2 Shop Manual…..9907
  COVER…..9907
  00 Index and foreword…..0
    Index…..9909
      Composition of shop manual…..9910
      Table of contents…..9912
    Foreword and general information…..9923
      Safety notice…..9924
      How to read the shop manual…..9929
      Explanation of terms for maintenance standard…..9931
      Handling of electric equipment and hydraulic component…..9933
      Handling of connectors newly used for engines…..9942
      How to read electric wire code…..9945
      Precautions when carrying out operation…..9948
      Method of disassembling and connecting push-pull type coupler…..9951
      Standard tightening torque table…..9954
      Conversion table…..9958
  01 Specification…..0
    Specification and technical data…..9965
      Specification drawings…..9966
      Specifications…..9967
      Weight table…..9970
      Fuel, coolant and lubricants…..9971
  10 Structure, function and maintenance standard…..0
    Engine and cooling system…..9975
      Radiator, oil cooler, aftercooler…..9976
      Output shaft…..9977
    Power train, Part 1…..9981
      Power train skeleton…..9982
      Torque converter and transmission hydraulic piping…..9986
      Brake cooling oil control valve (BCV)…..9988
      Power train pump…..9989
      Torque converter…..9992
      Transmission…..9998
      Transmission control valve…..10026
      ECMV…..10027
      Main relief, torque converter relief valve…..10034
    Power train, Part 2…..10037
      Drive shaft…..10038
      Axle…..10042
      Differential…..10046
      Limited slip differential…..10058
      Final drive…..10062
    Steering system…..10069
      Steering column…..10070
    Brake system…..10073
      Brake piping…..10074
      Brake valve…..10076
      Accumulator charge valve…..10079
      Accumulator…..10083
      Slack adjuster…..10084
      Brake…..10086
      Proportional reducing valve…..10091
      Brake system tank…..10092
      Parking brake…..10094
      Parking brake solenoid valve…..10098
    Undercarriage and frame…..10101
      Suspension…..10102
      Suspension cylinder…..10107
      Oscillation hitch…..10109
    Hydraulic system…..10113
      Steering, hoist oil pressure piping diagram…..10114
      Dump body control…..10115
      Hydraulic tank and filter…..10116
      Flow amp valve…..10117
      Steering valve…..10120
      Steering cylinder…..10124
      Hoist valve…..10126
      Dump control valve (EPC valve)…..10132
      Pilot check valve…..10136
      Hoist cylinder…..10137
      Hydraulic pump…..10138
    Cab and its attachments…..10143
      ROPS cab…..10144
      Cab tilt…..10145
      Air conditioner…..10146
      Rear view monitor…..10154
      Controller related…..10157
    Electrical system, Part 1…..10159
      Machine monitor system…..10160
    Electrical system, Part 2…..10181
      Automatic shift control system…..10182
      Transmission controller…..10185
      Retarder control system…..10214
      Auto emergency steering system…..10226
      Battery disconnector switch…..10228
      Dump control lever…..10230
    Electrical system, Part 3…..10235
      Sensors, switches…..10236
      KOMTRAX terminal system (if equipped)…..10244
  20 Standard value table…..0
    Standard service value table…..10247
      Standard value table for engine…..10248
      Standard value table for chassis…..10249
  30 Testing and adjusting…..0
    Testing and adjusting, Part 1…..10255
      Tools for testing, adjusting, and troubleshooting…..10257
      Sketches of special tools…..10261
      Measuring engine speed…..10262
      Testing intake air pressure (boost pressure)…..10263
      Testing exhaust temperature…..10264
      Testing exhaust gas color…..10265
      Adjusting valve clearance…..10266
      Testing compression pressure…..10267
      Testing blow-by pressure…..10269
      Testing engine oil pressure…..10270
      Testing EGR valve and bypass valve drive oil pressure…..10271
      Handling of fuel system devices…..10272
      Releasing residual pressure from fuel system…..10272
      Testing fuel pressure…..10273
      Testing fuel return and leakage amount…..10274
      Bleeding air from fuel circuit…..10277
      Testing the fuel circuit for leakage…..10279
      Testing and adjusting fan belt tension…..10280
      Testing and adjusting alternator belt tension…..10281
      Testing and adjusting air conditioner compressor belt tension…..10282
    Testing and adjusting, Part 2…..10285
      Testing torque converter stall speed…..10287
      Testing power train oil pressure…..10288
      Testing and adjusting of differential lock oil pressure (differential lock spec.)…..10296
      Adjusting transmission speed sensor…..10301
      Testing and adjusting brake oil pressure…..10303
      Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…..10307
      Testing brake performance…..10311
      Bleeding air from brake circuit…..10312
      Testing wear of wheel brake disc…..10313
      Testing the parking brake pad wear…..10314
      Emergency release of the parking brake…..10315
      Testing and adjusting steering circuit oil pressure…..10316
      Testing and adjusting suspension cylinder…..10318
      Method of tilting cab up…..10322
      Testing and adjusting dump circuit oil pressure…..10324
      Adjusting body positioner sensor…..10326
      Adjusting length of spring in body heating spherical joint…..10327
      Handling of voltage circuit of engine controller…..10327
      Adjusting transmission controller…..10327
      Method for emergency escape at electrical system failure…..10328
    Testing and adjusting, Part 3…..10333
      Setting and adjusting various equipments…..10334
      Special function of machine monitor…..10343
      How to start operation of KOMTRAX terminal…..10388
      Lamp display of KOMTRAX terminal…..10393
      Pm Clinic check sheet…..10396
  40 Troubleshooting…..0
    General information on troubleshooting…..10401
      Points to remember when troubleshooting…..10402
      Sequence of events in troubleshooting…..10403
      Check before troubleshooting…..10404
      Classification and procedures for troubleshooting…..10405
      Connection table for connector pin numbers…..10408
      T- branch box and T- branch adapter table…..10444
    Troubleshooting by failure code, General…..10449
      Troubleshooting by failure code, General…..10450
        Failure codes table…..10450
        Before troubleshooting by failure code…..10458
        Information in troubleshooting table…..10466
    Troubleshooting by failure code, Part 1…..10469
      Troubleshooting by failure code, Part 1…..10471
        Failure code [1500L0] Double engagement…..10471
        Failure code [15B0NX] Transmission oil filter: Clogged…..10472
        Failure code [15F0KM] R → F shifting abuse 1…..10474
        Failure code [15F0MB] R → F shifting abuse 2…..10474
        Failure code [15F7KM] Transmission forward clutch abuse…..10475
        Failure code [15G0MW] Trouble in reverse clutch system (Slip)…..10476
        Failure code [15G7KM] Transmission reverse clutch abuse…..10478
        Failure code [15H0MW] Trouble in Hi clutch system (Slip)…..10480
        Failure code [15J0MW] Trouble in Lo clutch system (Slip)…..10482
        Failure code [15K0MW] Trouble in 1st clutch system (Slip)…..10484
        Failure code [15L0MW] Trouble in 2nd clutch system (Slip)…..10486
        Failure code [15M0MW] Trouble in 3rd clutch system (Slip)…..10488
        Failure code [15SBL1] Trouble in reverse clutch pressure control valve I…..10490
        Failure code [15SBMA] Trouble in reverse clutch pressure control valve II…..10494
        Failure code [15SCL1] Trouble in Hi clutch pressure control valve I…..10496
        Failure code [15SCMA] Trouble in Hi clutch pressure control valve II…..10500
        Failure code [15SDL1] Trouble in Lo clutch pressure control valve I…..10502
        Failure code [15SDMA] Trouble in Lo clutch pressure control valve II…..10504
    Troubleshooting by failure code, Part 2…..10509
      Failure code [15SEL1] Trouble in 1st clutch pressure control valve I…..10511
      Failure code [15SEMA] Trouble in 1st clutch pressure control valve II…..10514
      Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I…..10516
      Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II…..10520
      Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I…..10522
      Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II…..10526
      Failure code [15SJMA] Trouble in lockup clutch pressure control valve II…..10528
      Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II…..10530
      Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2…..10532
      Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1…..10534
      Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2…..10536
      Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1…..10538
      Failure code [2C4MNX] Clogging of retarder cooling oil filter…..10540
      Failure code [2F00KM] Dragging of parking brake…..10542
      Failure code [2G42ZG] Lowering of accumulator oil pressure (front)…..10544
      Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)…..10544
      Failure code [989A00] Operation of engine overrun prevention system…..10545
      Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)…..10545
      Failure code [A570NX] Clogging of engine oil filter…..10546
      Failure code [AA10NX] Clogging of air cleaner…..10548
      Failure code [AB00MA] Trouble in battery charge circuit…..10550
      Failure code [B@BAZG] Lowering of engine oil pressure…..10551
      Failure code [B@BAZK] Lowering of engine oil level…..10552
      Failure code [B@BCNS] Overheating of engine…..10553
      Failure code [B@BCZK] Lowering of coolant level…..10554
      Failure code [B@BFZK] Lowering of fuel level…..10556
      Failure code [B@C6NS] Overheating of brake cooling oil (front)…..10557
      Failure code [B@C8NS] Overheating of brake cooling oil (center)…..10557
      Failure code [B@CENS] Overheating of torque converter oil…..10558
      Failure code [B@JANS] Overheating of steering oil…..10558
    Troubleshooting by failure code, Part 3…..10561
      Failure code [CA111] Trouble in engine controller…..10564
      Failure code [CA115] Trouble in engine Ne and Bkup speed sensors…..10566
      Failure code [CA122] Abnormally high charge pressure…..10568
      Failure code [CA123] Abnormally low charge pressure…..10570
      Failure code [CA131] Abnormally high throttle sensor signal…..10572
      Failure code [CA132] Abnormally low throttle sensor signal…..10574
      Failure code [CA135] Abnormally high engine oil pressure…..10576
      Failure code [CA141] Abnormally low engine oil pressure…..10578
      Failure code [CA144] Abnormally high coolant temperature…..10580
      Failure code [CA145] Abnormally low coolant temperature…..10582
      Failure code [CA153] Abnormally high charge temperature…..10584
      Failure code [CA154] Abnormally low charge temperature…..10586
      Failure code [CA187] Abnormally low voltage in sensor power supply 2…..10587
      Failure code [CA221] Abnormally high ambient pressure…..10588
      Failure code [CA222] Abnormally low ambient pressure…..10590
      Failure code [CA227] Abnormally high voltage in sensor power supply 2…..10592
      Failure code [CA234] Engine overspeed…..10594
      Failure code [CA238] Trouble in Ne speed sensor power supply…..10596
      Failure code [CA263] Abnormally high fuel temperature…..10598
      Failure code [CA265] Abnormally low fuel temperature…..10600
      Failure code [CA271] Short circuit in PCV1…..10601
      Failure code [CA272] Disconnection in PCV1…..10602
      Failure code [CA273] Short circuit in PCV2…..10603
      Failure code [CA274] Disconnection in PCV2…..10604
      Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)…..10606
      Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)…..10608
      Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)…..10610
      Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)…..10612
      Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)…..10614
      Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)…..10616
      Failure code [CA342] Matching error in engine controller data…..10618
      Failure code [CA351] Trouble in injector drive circuit…..10620
      Failure code [CA352] Abnormally low voltage in sensor power supply 1…..10622
      Failure code [CA386] Abnormally high voltage in sensor power supply 1…..10624
    Troubleshooting by failure code, Part 4…..10627
      Failure code [CA431] Trouble in idle validation switch…..10630
      Failure code [CA432] Trouble in idle validation process…..10634
      Failure code [CA441] Abnormally low voltage in power supply…..10634
      Failure code [CA442] Abnormally high voltage in power supply…..10635
      Failure code [CA449] Abnormally high common rail pressure 2…..10635
      Failure code [CA451] Abnormally high common rail pressure…..10636
      Failure code [CA452] Abnormally low common rail pressure…..10638
      Failure code [CA553] Abnormally high common rail pressure 1…..10638
      Failure code [CA554] In-range error in common rail pressure sensor…..10639
      Failure code [CA559] Supply pump low pressure 1…..10641
      Failure code [CA689] Trouble in engine Ne speed sensor…..10644
      Failure code [CA731] Phase error in engine Bkup speed sensor…..10646
      Failure code [CA757] Loss of all data in engine controller…..10646
      Failure code [CA778] Trouble in engine Bkup speed sensor…..10648
      Failure code [CA1117] Loss of partial data in engine controller…..10650
      Failure code [CA1228] Trouble in EGR valve servo 1…..10650
      Failure code [CA1625] Trouble in EGR valve servo 2…..10651
      Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit…..10652
      Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit…..10654
      Failure code [CA1628] Trouble in bypass valve servo 1…..10655
      Failure code [CA1629] Trouble in bypass valve servo 2…..10656
      Failure code [CA1631] Abnormally high signal in bypass valve lift sensor…..10658
      Failure code [CA1632] Abnormally low signal in bypass valve lift sensor…..10660
      Failure code [CA1633] Trouble in KOMNET…..10662
      Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor…..10664
      Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor…..10666
      Failure code [CA2185] Abnormally high voltage in throttle sensor power supply…..10668
      Failure code [CA2186] Abnormally low voltage in throttle sensor power supply…..10670
      Failure code [CA2249] Low pressure in supply pump 2…..10670
      Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor…..10672
      Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor…..10674
      Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit…..10676
      Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit…..10678
      Failure code [CA2555] Disconnection in intake air heater relay…..10678
      Failure code [CA2556] Short circuit in intake air heater relay…..10680
    Troubleshooting by failure code, Part 5…..10683
      Failure code [DAF9KM] Wrong connection of connector…..10685
      Failure code [DAFRKR] Trouble in CAN communication (machine monitor)…..10686
      Failure code [DAQ0KK] Lowering of source voltage…..10688
      Failure code [DAQ0KT] Trouble in non-volatile memory…..10690
      Failure code [DAQ2KK] Trouble in solenoid power supply system…..10692
      Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)…..10694
      Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)…..10696
      Failure code [DAQRMA] Disagreement of option setting (Transmission controller)…..10698
      Failure code [DB10KT] Trouble in non-volatile memory…..10698
      Failure code [DB12KK] Trouble in solenoid power supply system…..10700
      Failure code [DB13KK] Lowering of battery direct voltage…..10702
      Failure code [DB19KQ] Disagreement of model selection (Retarder controller)…..10704
      Failure code [DB1QMA] Disagreement of option setting (Retarder controller)…..10704
      Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)…..10706
      Failure code [DB2RKR] Trouble in CAN communication (Engine controller)…..10708
      Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal…..10710
      Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve…..10712
      Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve…..10713
      Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve…..10714
      Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve…..10715
      Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve…..10716
      Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve…..10717
      Failure code [DF10KA] Input of no lever signals…..10718
      Failure code [DF10KB] Input of multiple lever signals…..10722
      Failure code [DGF1KX] Transmission oil temperature out of range…..10726
      Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)…..10728
      Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center)…..10730
      Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)…..10732
      Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)…..10734
      Failure code [DGR6KX] Steering oil temperature out of range…..10736
    Troubleshooting by failure code, Part 6…..10739
      Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system…..10742
      Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system…..10744
      Failure code [DHT5L6] Trouble in torque converter oil pressure sensor…..10746
      Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system…..10748
      Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system…..10750
      Failure code [DJF1KA] Disconnection in fuel level sensor system…..10752
      Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS…..10754
      Failure code [DK52KX] Trouble in dump lever potentiometer 1…..10756
      Failure code [DK53L8] Trouble in dump lever potentiometer 2…..10758
      Failure code [DK54KX] Trouble in dump positioner sensor…..10760
      Failure code [DKH0KX] Pitch angle sensor signal out of range…..10762
      Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system…..10764
      Failure code [DLF1LC] Trouble in transmission input shaft speed sensor…..10765
      Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor…..10766
      Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system…..10767
      Failure code [DLF4KA] Disconnection in transmission differential speed sensor system…..10768
      Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system…..10769
      Failure code [DV00KB] Short circuit in buzzer output circuit…..10770
      Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system…..10772
      Failure code [DW73KZ] Trouble in dump selector valve output system…..10774
      Failure code [DW78KZ] Trouble in rear wheel BCV command output system…..10776
      Failure code [DW79KZ] Trouble in front wheel BCV command output system…..10778
      Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1…..10780
      Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve…..10782
      Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve…..10784
      Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve…..10786
      Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2…..10788
      Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1…..10790
      Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve…..10792
      Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve…..10794
      Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve…..10796
      Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2…..10798
    Troubleshooting by failure code, Part 7…..10801
      Troubleshooting by failure code, Part 7…..10804
        Failure code [DX13KA] Disconnection in output circuit of dump EPC valve…..10804
        Failure code [DX13KB] Ground fault in output circuit of dump EPC valve…..10806
        Failure code [DX13KY] Hot short in output circuit of dump EPC valve…..10808
        Failure code [DX14KZ] Trouble in rear wheel differential lock command output system…..10810
        Failure code [DX15KZ] Trouble in front wheel differential lock command output system…..10812
        Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid…..10814
        Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid…..10816
        Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid…..10818
        Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid…..10819
        Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid…..10820
        Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid…..10822
        Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid…..10824
        Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve…..10826
        Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve…..10828
        Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid…..10832
        Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve…..10834
        Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve…..10836
        Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid…..10840
        Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve…..10842
        Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve…..10844
    Troubleshooting by failure code, Part 8…..10849
      Troubleshooting by failure code, Part 8…..10850
        Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid…..10850
        Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve…..10852
        Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve…..10854
        Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid…..10858
        Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve…..10860
        Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve…..10862
        Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid…..10866
        Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve…..10868
        Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve…..10870
    Troubleshooting for electrical system (E-mode)…..10875
      Before troubleshooting for electrical system…..10877
      Information in troubleshooting table…..10883
      E-1 Engine does not start (Starting motor does not turn)…..10884
      E-2 Auto preheater does not operate…..10888
      E-3 When starting switch is turned ON, machine monitor displays nothing…..10892
      E-4 When starting switch is turned OFF, machine monitor cannot be operated…..10894
      E-5 Alarm buzzer does not stop sounding…..10896
      E-6 Machine monitor does not normally display gauges, caution lamps, and character display section…..10897
      E-7 Display of character display section cannot be changed…..10898
      E-8 Power mode selection function does not operate normally…..10902
      E-9 AISS function does not operate normally…..10904
      E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)…..10906
      E-11 Interaxle differential lock-up function does not operate normally…..10910
      E-12 Display of seat belt caution lamp is abnormal…..10912
      E-13 Turn signal lamps and pilot lamps do not operate normally…..10914
      E-14 Night lighting is abnormal…..10919
      E-15 Backup lamp and backup buzzer operate abnormally…..10925
      E-16 Emergency steering system does not operate…..10929
      E-17 Air conditioner does not operate normally…..10933
    Troubleshooting of hydraulic and mechanical system (H-mode)…..10939
      Troubleshooting of hydraulic and mechanical system (H-mode)…..10941
        Information in troubleshooting table…..10941
        H-1 Machine does not start…..10942
        H-2 Travel is not smooth (Machine hunts)…..10944
        H-3 Lockup is not reset…..10944
        H-4 Start shock and gear shift shock are abnormally large…..10945
        H-5 Gear is not shifted up…..10946
        H-6 Travel speed or power is low…..10948
        H-7 Start and gearshift time lag is large…..10952
        H-8 Torque converter oil temperature is high…..10954
        H-9 Torque converter oil temperature is low…..10955
        H-10 Front brake does not work fully…..10956
        H-11 Center brake does not work fully…..10957
        H-12 Rear brake does not work fully…..10958
        H-13 Steering wheel is heavy…..10959
        H-14 Steering wheel does not move…..10960
        H-15 Steering wheel waggle…..10961
        H-16 Dump body raising speed is low…..10962
        H-17 Dump body does not move…..10963
        H-18 Hydraulic drift of dump body is large…..10964
    Troubleshooting of engine (S-mode)…..10967
      Method of using troubleshooting chart…..10970
      S-1  Starting performance of engine is poor…..10974
      S-2  Engine does not start…..10976
      S-3  Engine does not pick up smoothly…..10980
      S-4  Engine stops during operation…..10981
      S-5  Engine does not rotate smoothly…..10982
      S-6  Engine lack output (or lacks power)…..10983
      S-7  Exhaust gas is black (incomplete combustion)…..10984
      S-8  Oil consumption is excessive (or exhaust gas is blue)…..10986
      S-9  Oil becomes dirty quickly…..10987
      S-10  Fuel consumption is excessive…..10988
      S-11  Oil is in coolant (or coolant spurts back or coolant level goes down)…..10989
      S-12  Oil pressure drops…..10990
      S-13  Oil level rises (Entry of coolant or fuel)…..10992
      S-14  Coolant temperature becomes too high (Overheating)…..10994
      S-15  Abnormal noise is made…..10995
      S-16  Vibration is excessive…..10996
  50 Disassembly and assembly…..0
    General information on disassembly and assembly…..10999
      How to read this manual…..11000
      Coating materials list…..11002
      Special tool list…..11005
      Sketches of special tools…..11011
    Engine and cooling system…..11025
      Removal and installation of fuel supply pump…..11026
      Removal and installation of engine assembly…..11029
      Removal and installation of cylinder head assembly…..11037
      Removal and installation of fuel injector assembly…..11050
      Removal and installation of radiator assembly…..11055
      Removal and installation of cooling assembly…..11059
      Removal and installation of aftercooler…..11063
      Removal and installation of engine front seal…..11066
      Removal and installation of engine rear seal…..11068
    Power train, Part 1…..11073
      Removal and installation of output shaft assembly…..11074
      Disassembly and assembly of output shaft assembly…..11078
      Removal and installation of transmission and front differential assembly…..11081
      Disconnection and coupling of front differential and transmission…..11089
      Disassembly and assembly of torque converter assembly…..11090
      Disassembly and assembly of transmission assembly…..11098
    Power train, Part 2…..11141
      Disassembly and assembly of front differential assembly…..11142
      Removal and installation of center differential assembly…..11161
      Disassembly and assembly of center differential assembly…..11165
      Removal and installation of rear differential assembly…..11181
      Disassembly and assembly of rear differential assembly…..11183
    Power train, Part 3…..11197
      Removal and installation of front final drive and brake assembly…..11198
      Disassembly and assembly of front final drive and brake assembly…..11200
      Removal and installation of center final drive and brake assembly…..11213
      Disassembly and assembly of center final drive and brake assembly…..11215
      Removal and installation of rear final drive assembly…..11226
      Disassembly and assembly of rear final drive assembly…..11228
      Removal and installation of center axle assembly…..11235
      Removal and installation of rear axle assembly…..11238
    Undercarriage and frame…..11243
      Removal and installation of front suspension cylinder assembly…..11244
      Removal and installation of rear suspension cylinder assembly…..11246
      Removal and installation of equalizer bar assembly…..11247
      Removal and installation of front wheel assembly…..11249
      Removal and installation of rear front wheel assembly…..11250
      Removal and installation of rear rear wheel assembly…..11250
      Removal and installation of hitch frame assembly…..11251
      Disassembly and assembly of hitch frame…..11257
      Removal and installation of body assembly…..11260
    Hydraulic system…..11263
      Disassembly and assembly of steering valve…..11264
      Removal and installation of flow amplifier valve assembly…..11274
      Removal and installation of hoist valve assembly…..11276
      Disassembly and assembly of hoist valve assembly…..11278
      Disassembly and assembly of steering cylinder assembly…..11280
      Disassembly and assembly of hoist cylinder assembly…..11286
    Cab and its attachments…..11295
      Removal and installation of operator’s cab…..11296
      Removal and installation of operator’s cab glass (Stuck glass)…..11301
      Disassembly and assembly of operator&apos;s seat assembly…..11308
      Removal and installation of air conditioner unit assembly…..11318
    Electrical system…..11325
      Removal and installation of retarder controller assembly…..11326
      Removal and installation of transmission controller assembly…..11328
      Removal and installation of engine controller assembly…..11330
  90 Diagrams and drawings…..0
    Hydraulic diagrams and drawings…..11333
    Electrical diagrams and drawings…..11334
SEN00238-13 – Articulated Dump Truck HM350-2 Shop Manual…..11335
  COVER …..11335
  00 Index and foreword…..0
    Index…..11337
      Composition of shop manual…..11338
      Table of contents…..11340
    Foreword and general information…..11351
      Safety notice…..11352
      How to read the shop manual…..11357
      Explanation of terms for maintenance standard…..11359
      Handling of electric equipment and hydraulic component…..11361
      Handling of connectors newly used for engines…..11370
      How to read electric wire code…..11373
      Precautions when carrying out operation…..11376
      Method of disassembling and connecting push-pull type coupler…..11379
      Standard tightening torque table…..11382
      Conversion table…..11386
  01 Specification…..0
    Specification and technical data…..11393
      Specification drawings…..11394
      Specifications…..11395
      Weight table…..11398
      Fuel, coolant and lubricants…..11399
  10 Structure, function and maintenance standard…..0
    Engine and cooling system…..11403
      Radiator, oil cooler, aftercooler…..11404
      Output shaft…..11405
    Power train, Part 1…..11409
      Power train skeleton…..11410
      Torque converter and transmission hydraulic piping…..11414
      Brake cooling oil control valve (BCV)…..11416
      Power train pump…..11417
      Torque converter…..11420
      Transmission…..11426
      Transmission control valve…..11454
      ECMV…..11455
      Main relief, torque converter relief valve…..11462
    Power train, Part 2…..11465
      Drive shaft…..11466
      Axle…..11470
      Differential…..11474
      Limited slip differential…..11486
      Final drive…..11490
    Steering system…..11497
      Steering column…..11498
    Brake system…..11501
      Brake piping…..11502
      Brake valve…..11504
      Accumulator charge valve…..11507
      Accumulator…..11511
      Slack adjuster…..11512
      Brake…..11514
      Proportional reducing valve…..11519
      Brake system tank…..11520
      Parking brake…..11522
      Parking brake solenoid valve…..11526
    Undercarriage and frame…..11529
      Suspension…..11530
      Suspension cylinder…..11535
      Oscillation hitch…..11537
    Hydraulic system…..11541
      Steering, hoist oil pressure piping diagram…..11542
      Dump body control…..11543
      Hydraulic tank and filter…..11544
      Flow amp valve…..11545
      Steering valve…..11548
      Steering cylinder…..11552
      Hoist valve…..11554
      Dump control valve (EPC valve)…..11560
      Pilot check valve…..11564
      Hoist cylinder…..11565
      Hydraulic pump…..11566
    Cab and its attachments…..11571
      ROPS cab…..11572
      Cab tilt…..11573
      Air conditioner…..11574
      Rear view monitor…..11582
      Controller related…..11585
    Electrical system, Part 1…..11587
      Machine monitor system…..11588
    Electrical system, Part 2…..11609
      Automatic shift control system…..11610
      Transmission controller…..11613
      Retarder control system…..11642
      Auto emergency steering system…..11654
      Battery disconnector switch…..11656
      Dump control lever…..11658
    Electrical system, Part 3…..11663
      Sensors, switches…..11664
      KOMTRAX terminal system (if equipped)…..11672
  20 Standard value table…..0
    Standard service value table…..11675
      Standard value table for engine…..11676
      Standard value table for chassis…..11677
  30 Testing and adjusting…..0
    Testing and adjusting, Part 1…..11683
      Tools for testing, adjusting, and troubleshooting…..11685
      Sketches of special tools…..11690
      Measuring engine speed…..11691
      Testing intake air pressure (boost pressure)…..11692
      Testing exhaust temperature…..11693
      Testing exhaust gas color…..11694
      Adjusting valve clearance…..11695
      Testing compression pressure…..11696
      Testing blow-by pressure…..11698
      Testing engine oil pressure…..11699
      Testing EGR valve and bypass valve drive oil pressure…..11700
      Handling of fuel system devices…..11701
      Releasing residual pressure from fuel system…..11701
      Testing fuel pressure…..11702
      Testing fuel return and leakage amount…..11703
      Bleeding air from fuel circuit…..11706
      Testing the fuel circuit for leakage…..11708
      Testing and adjusting fan belt tension…..11709
      Testing and adjusting alternator belt tension…..11710
      Testing and adjusting air conditioner compressor belt tension…..11711
    Testing and adjusting, Part 2…..11713
      Testing torque converter stall speed…..11715
      Testing power train oil pressure…..11716
      Testing and adjusting of differential lock oil pressure (differential lock spec.)…..11724
      Adjusting transmission speed sensor…..11729
      Testing and adjusting brake oil pressure…..11731
      Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…..11735
      Testing brake performance…..11739
      Bleeding air from brake circuit…..11740
      Testing wear of wheel brake disc…..11741
      Testing the parking brake pad wear…..11742
      Emergency release of the parking brake…..11743
      Testing and adjusting steering circuit oil pressure…..11744
      Testing and adjusting suspension cylinder…..11746
      Method of tilting cab up…..11750
      Testing and adjusting dump circuit oil pressure…..11752
      Adjusting body positioner sensor…..11754
      Adjusting length of spring in body heating spherical joint…..11755
      Handling of voltage circuit of engine controller…..11755
      Adjusting transmission controller…..11755
      Method for emergency escape at electrical system failure…..11756
    Testing and adjusting, Part 3…..11761
      Setting and adjusting various equipments…..11762
      Special function of machine monitor…..11771
      How to start operation of KOMTRAX terminal…..11816
      Lamp display of KOMTRAX terminal…..11821
      Pm Clinic check sheet…..11824
  40 Troubleshooting…..0
    General information on troubleshooting…..11829
      Points to remember when troubleshooting…..11830
      Sequence of events in troubleshooting…..11831
      Check before troubleshooting…..11832
      Classification and procedures for troubleshooting…..11833
      Connection table for connector pin numbers…..11836
      T- branch box and T- branch adapter table…..11872
    Troubleshooting by failure code, General…..11877
      Troubleshooting by failure code, General…..11878
        Failure codes table…..11878
        Before troubleshooting by failure code…..11886
        Information in troubleshooting table…..11893
    Troubleshooting by failure code, Part 1…..11896
      Troubleshooting by failure code, Part 1…..11898
        Failure code [1500L0] Double engagement…..11898
        Failure code [15B0NX] Transmission oil filter: Clogged…..11899
        Failure code [15F0KM] R → F shifting abuse 1…..11901
        Failure code [15F0MB] R → F shifting abuse 2…..11901
        Failure code [15F7KM] Transmission forward clutch abuse…..11902
        Failure code [15G0MW] Trouble in reverse clutch system (Slip)…..11903
        Failure code [15G7KM] Transmission reverse clutch abuse…..11905
        Failure code [15H0MW] Trouble in Hi clutch system (Slip)…..11906
        Failure code [15J0MW] Trouble in Lo clutch system (Slip)…..11908
        Failure code [15K0MW] Trouble in 1st clutch system (Slip)…..11910
        Failure code [15L0MW] Trouble in 2nd clutch system (Slip)…..11912
        Failure code [15M0MW] Trouble in 3rd clutch system (Slip)…..11914
        Failure code [15SBL1] Trouble in reverse clutch pressure control valve I…..11916
        Failure code [15SBMA] Trouble in reverse clutch pressure control valve II…..11919
        Failure code [15SCL1] Trouble in Hi clutch pressure control valve I…..11921
        Failure code [15SCMA] Trouble in Hi clutch pressure control valve II…..11924
        Failure code [15SDL1] Trouble in Lo clutch pressure control valve I…..11926
        Failure code [15SDMA] Trouble in Lo clutch pressure control valve II…..11928
    Troubleshooting by failure code, Part 2…..11932
      Failure code [15SEL1] Trouble in 1st clutch pressure control valve I…..11934
      Failure code [15SEMA] Trouble in 1st clutch pressure control valve II…..11937
      Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I…..11939
      Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II…..11943
      Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I…..11945
      Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II…..11949
      Failure code [15SJMA] Trouble in lockup clutch pressure control valve II…..11951
      Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II…..11953
      Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2…..11955
      Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1…..11957
      Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2…..11959
      Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1…..11961
      Failure code [2C4MNX] Clogging of retarder cooling oil filter…..11963
      Failure code [2F00KM] Dragging of parking brake…..11965
      Failure code [2G42ZG] Lowering of accumulator oil pressure (front)…..11967
      Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)…..11967
      Failure code [989A00] Operation of engine overrun prevention system…..11968
      Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)…..11968
      Failure code [A570NX] Clogging of engine oil filter…..11969
      Failure code [AA10NX] Clogging of air cleaner…..11971
      Failure code [AB00MA] Trouble in battery charge circuit…..11973
      Failure code [B@BAZG] Lowering of engine oil pressure…..11974
      Failure code [B@BAZK] Lowering of engine oil level…..11975
      Failure code [B@BCNS] Overheating of engine…..11976
      Failure code [B@BCZK] Lowering of coolant level…..11977
      Failure code [B@BFZK] Lowering of fuel level…..11979
      Failure code [B@C6NS] Overheating of brake cooling oil (front)…..11980
      Failure code [B@C8NS] Overheating of brake cooling oil (center)…..11980
      Failure code [B@CENS] Overheating of torque converter oil…..11981
      Failure code [B@JANS] Overheating of steering oil…..11981
    Troubleshooting by failure code, Part 3…..11984
      Failure code [CA111] Trouble in engine controller…..11987
      Failure code [CA115] Trouble in engine Ne and Bkup speed sensors…..11989
      Failure code [CA122] Abnormally high charge pressure…..11991
      Failure code [CA123] Abnormally low charge pressure…..11993
      Failure code [CA131] Abnormally high throttle sensor signal…..11995
      Failure code [CA132] Abnormally low throttle sensor signal…..11997
      Failure code [CA135] Abnormally high engine oil pressure…..11999
      Failure code [CA141] Abnormally low engine oil pressure…..12001
      Failure code [CA144] Abnormally high coolant temperature…..12003
      Failure code [CA145] Abnormally low coolant temperature…..12005
      Failure code [CA153] Abnormally high charge temperature…..12007
      Failure code [CA154] Abnormally low charge temperature…..12009
      Failure code [CA187] Abnormally low voltage in sensor power supply 2…..12010
      Failure code [CA221] Abnormally high ambient pressure…..12011
      Failure code [CA222] Abnormally low ambient pressure…..12013
      Failure code [CA227] Abnormally high voltage in sensor power supply 2…..12015
      Failure code [CA234] Engine overspeed…..12017
      Failure code [CA238] Trouble in Ne speed sensor power supply…..12019
      Failure code [CA263] Abnormally high fuel temperature…..12021
      Failure code [CA265] Abnormally low fuel temperature…..12023
      Failure code [CA271] Short circuit in PCV1…..12024
      Failure code [CA272] Disconnection in PCV1…..12025
      Failure code [CA273] Short circuit in PCV2…..12026
      Failure code [CA274] Disconnection in PCV2…..12027
      Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)…..12029
      Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)…..12031
      Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)…..12033
      Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)…..12035
      Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)…..12037
      Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)…..12039
      Failure code [CA342] Matching error in engine controller data…..12041
      Failure code [CA351] Trouble in injector drive circuit…..12043
      Failure code [CA352] Abnormally low voltage in sensor power supply 1…..12045
      Failure code [CA386] Abnormally high voltage in sensor power supply 1…..12047
    Troubleshooting by failure code, Part 4…..12050
      Failure code [CA431] Trouble in idle validation switch…..12053
      Failure code [CA432] Trouble in idle validation process…..12057
      Failure code [CA441] Abnormally low voltage in power supply…..12057
      Failure code [CA442] Abnormally high voltage in power supply…..12058
      Failure code [CA449] Abnormally high common rail pressure 2…..12058
      Failure code [CA451] Abnormally high common rail pressure…..12059
      Failure code [CA452] Abnormally low common rail pressure…..12061
      Failure code [CA553] Abnormally high common rail pressure 1…..12061
      Failure code [CA554] In-range error in common rail pressure sensor…..12062
      Failure code [CA559] Supply pump low pressure 1…..12064
      Failure code [CA689] Trouble in engine Ne speed sensor…..12067
      Failure code [CA731] Phase error in engine Bkup speed sensor…..12069
      Failure code [CA757] Loss of all data in engine controller…..12069
      Failure code [CA778] Trouble in engine Bkup speed sensor…..12071
      Failure code [CA1117] Loss of partial data in engine controller…..12073
      Failure code [CA1228] Trouble in EGR valve servo 1…..12073
      Failure code [CA1625] Trouble in EGR valve servo 2…..12074
      Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit…..12075
      Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit…..12077
      Failure code [CA1628] Trouble in bypass valve servo 1…..12078
      Failure code [CA1629] Trouble in bypass valve servo 2…..12079
      Failure code [CA1631] Abnormally high signal in bypass valve lift sensor…..12081
      Failure code [CA1632] Abnormally low signal in bypass valve lift sensor…..12083
      Failure code [CA1633] Trouble in KOMNET…..12085
      Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor…..12087
      Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor…..12089
      Failure code [CA2185] Abnormally high voltage in throttle sensor power supply…..12091
      Failure code [CA2186] Abnormally low voltage in throttle sensor power supply…..12093
      Failure code [CA2249] Low pressure in supply pump 2…..12093
      Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor…..12095
      Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor…..12097
      Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit…..12099
      Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit…..12101
      Failure code [CA2555] Disconnection in intake air heater relay…..12101
      Failure code [CA2556] Short circuit in intake air heater relay…..12103
    Troubleshooting by failure code, Part 5…..12106
      Failure code [DAF9KM] Wrong connection of connector…..12108
      Failure code [DAFRKR] Trouble in CAN communication (machine monitor)…..12109
      Failure code [DAQ0KK] Lowering of source voltage…..12111
      Failure code [DAQ0KT] Trouble in non-volatile memory…..12113
      Failure code [DAQ2KK] Trouble in solenoid power supply system…..12115
      Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)…..12117
      Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)…..12119
      Failure code [DAQRMA] Disagreement of option setting (Transmission controller)…..12121
      Failure code [DB10KT] Trouble in non-volatile memory…..12121
      Failure code [DB12KK] Trouble in solenoid power supply system…..12123
      Failure code [DB13KK] Lowering of battery direct voltage…..12125
      Failure code [DB19KQ] Disagreement of model selection (Retarder controller)…..12127
      Failure code [DB1QMA] Disagreement of option setting (Retarder controller)…..12127
      Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)…..12129
      Failure code [DB2RKR] Trouble in CAN communication (Engine controller)…..12131
      Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal…..12133
      Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve…..12135
      Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve…..12136
      Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve…..12137
      Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve…..12138
      Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve…..12139
      Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve…..12140
      Failure code [DF10KA] Input of no lever signals…..12141
      Failure code [DF10KB] Input of multiple lever signals…..12145
      Failure code [DGF1KX] Transmission oil temperature out of range…..12149
      Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)…..12151
      Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center)…..12153
      Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)…..12155
      Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)…..12157
      Failure code [DGR6KX] Steering oil temperature out of range…..12159
    Troubleshooting by failure code, Part 6…..12162
      Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system…..12165
      Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system…..12167
      Failure code [DHT5L6] Trouble in torque converter oil pressure sensor…..12169
      Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system…..12171
      Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system…..12173
      Failure code [DJF1KA] Disconnection in fuel level sensor system…..12175
      Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS…..12177
      Failure code [DK52KX] Trouble in dump lever potentiometer 1…..12179
      Failure code [DK53L8] Trouble in dump lever potentiometer 2…..12181
      Failure code [DK54KX] Trouble in dump positioner sensor…..12183
      Failure code [DKH0KX] Pitch angle sensor signal out of range…..12185
      Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system…..12187
      Failure code [DLF1LC] Trouble in transmission input shaft speed sensor…..12188
      Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor…..12189
      Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system…..12190
      Failure code [DLF4KA] Disconnection in transmission differential speed sensor system…..12191
      Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system…..12192
      Failure code [DV00KB] Short circuit in buzzer output circuit…..12193
      Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system…..12195
      Failure code [DW73KZ] Trouble in dump selector valve output system…..12197
      Failure code [DW78KZ] Trouble in rear wheel BCV command output system…..12199
      Failure code [DW79KZ] Trouble in front wheel BCV command output system…..12201
      Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1…..12203
      Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve…..12205
      Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve…..12207
      Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve…..12209
      Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2…..12211
      Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1…..12213
      Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve…..12215
      Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve…..12217
      Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve…..12219
      Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2…..12221
    Troubleshooting by failure code, Part 7…..12224
      Troubleshooting by failure code, Part 7…..12226
        Failure code [DX13KA] Disconnection in output circuit of dump EPC valve…..12226
        Failure code [DX13KB] Ground fault in output circuit of dump EPC valve…..12228
        Failure code [DX13KY] Hot short in output circuit of dump EPC valve…..12230
        Failure code [DX14KZ] Trouble in rear wheel differential lock command output system…..12231
        Failure code [DX15KZ] Trouble in front wheel differential lock command output system…..12233
        Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid…..12235
        Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid…..12237
        Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid…..12239
        Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid…..12240
        Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid…..12241
        Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid…..12243
        Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid…..12244
        Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve…..12246
        Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve…..12248
        Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid…..12251
        Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve…..12253
        Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve…..12255
        Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid…..12258
        Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve…..12260
        Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve…..12262
    Troubleshooting by failure code, Part 8…..12266
      Troubleshooting by failure code, Part 8…..12267
        Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid…..12267
        Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve…..12269
        Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve…..12271
        Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid…..12274
        Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve…..12276
        Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve…..12278
        Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid…..12281
        Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve…..12283
        Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve…..12285
    Troubleshooting for electrical system (E-mode)…..12289
      Before troubleshooting for electrical system…..12291
      Information in troubleshooting table…..12297
      E-1 Engine does not start (Starting motor does not turn)…..12298
      E-2 Auto preheater does not operate…..12302
      E-3 When starting switch is turned ON, machine monitor displays nothing…..12306
      E-4 When starting switch is turned OFF, machine monitor cannot be operated…..12308
      E-5 Alarm buzzer does not stop sounding…..12310
      E-6 Machine monitor does not normally display gauges, caution lamps, and character display section…..12311
      E-7 Display of character display section cannot be changed…..12312
      E-8 Power mode selection function does not operate normally…..12316
      E-9 AISS function does not operate normally…..12318
      E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)…..12320
      E-11 Interaxle differential lock-up function does not operate normally…..12324
      E-12 Display of seat belt caution lamp is abnormal…..12326
      E-13 Turn signal lamps and pilot lamps do not operate normally…..12328
      E-14 Night lighting is abnormal…..12333
      E-15 Backup lamp and backup buzzer operate abnormally…..12339
      E-16 Emergency steering system does not operate…..12343
      E-17 Air conditioner does not operate normally…..12347
    Troubleshooting of hydraulic and mechanical system (H-mode)…..12353
      Troubleshooting of hydraulic and mechanical system (H-mode)…..12355
        Information in troubleshooting table…..12355
        H-1 Machine does not start…..12356
        H-2 Travel is not smooth (Machine hunts)…..12358
        H-3 Lockup is not reset…..12358
        H-4 Start shock and gear shift shock are abnormally large…..12359
        H-5 Gear is not shifted up…..12360
        H-6 Travel speed or power is low…..12362
        H-7 Start and gearshift time lag is large…..12365
        H-8 Torque converter oil temperature is high…..12367
        H-9 Torque converter oil temperature is low…..12368
        H-10 Front brake does not work fully…..12369
        H-11 Center brake does not work fully…..12370
        H-12 Rear brake does not work fully…..12371
        H-13 Steering wheel is heavy…..12372
        H-14 Steering wheel does not move…..12373
        H-15 Steering wheel waggle…..12374
        H-16 Dump body raising speed is low…..12375
        H-17 Dump body does not move…..12376
        H-18 Hydraulic drift of dump body is large…..12377
    Troubleshooting of engine (S-mode)…..12379
      Method of using troubleshooting chart…..12382
      S-1  Starting performance of engine is poor…..12386
      S-2  Engine does not start…..12388
      S-3  Engine does not pick up smoothly…..12392
      S-4  Engine stops during operation…..12393
      S-5  Engine does not rotate smoothly…..12394
      S-6  Engine lack output (or lacks power)…..12395
      S-7  Exhaust gas is black (incomplete combustion)…..12396
      S-8  Oil consumption is excessive (or exhaust gas is blue)…..12398
      S-9  Oil becomes dirty quickly…..12399
      S-10  Fuel consumption is excessive…..12400
      S-11  Oil is in coolant (or coolant spurts back or coolant level goes down)…..12401
      S-12  Oil pressure drops…..12402
      S-13  Oil level rises (Entry of coolant or fuel)…..12404
      S-14  Coolant temperature becomes too high (Overheating)…..12406
      S-15  Abnormal noise is made…..12407
      S-16  Vibration is excessive…..12408
  50 Disassembly and assembly…..0
    General information on disassembly and assembly…..12411
      How to read this manual…..12412
      Coating materials list…..12414
      Special tool list…..12417
      Sketches of special tools…..12423
    Engine and cooling system…..12437
      Removal and installation of fuel supply pump…..12438
      Removal and installation of engine assembly…..12441
      Removal and installation of cylinder head assembly…..12449
      Removal and installation of fuel injector assembly…..12462
      Removal and installation of radiator assembly…..12467
      Removal and installation of cooling assembly…..12471
      Removal and installation of aftercooler…..12475
      Removal and installation of engine front seal…..12478
      Removal and installation of engine rear seal…..12480
      Replacement procedure of exhaust pipe fire prevention cover1…..12484
    Power train, Part 1…..12493
      Removal and installation of output shaft assembly…..12494
      Disassembly and assembly of output shaft assembly…..12498
      Removal and installation of transmission and front differential assembly…..12501
      Disconnection and coupling of front differential and transmission…..12509
      Disassembly and assembly of torque converter assembly…..12510
      Disassembly and assembly of transmission assembly…..12518
    Power train, Part 2…..12561
      Disassembly and assembly of front differential assembly…..12562
      Removal and installation of center differential assembly…..12581
      Disassembly and assembly of center differential assembly…..12585
      Removal and installation of rear differential assembly…..12601
      Disassembly and assembly of rear differential assembly…..12603
    Power train, Part 3…..12617
      Removal and installation of front final drive and brake assembly…..12618
      Disassembly and assembly of front final drive and brake assembly…..12620
      Removal and installation of center final drive and brake assembly…..12633
      Disassembly and assembly of center final drive and brake assembly…..12635
      Removal and installation of rear final drive assembly…..12646
      Disassembly and assembly of rear final drive assembly…..12648
      Removal and installation of center axle assembly…..12655
      Removal and installation of rear axle assembly…..12658
    Undercarriage and frame…..12662
      Removal and installation of front suspension cylinder assembly…..12663
      Removal and installation of rear suspension cylinder assembly…..12665
      Disassembly and assembly of front and rear suspension cylinder assembly…..12666
      Removal and installation of equalizer bar assembly…..12668
      Removal and installation of front wheel assembly…..12670
      Removal and installation of rear front wheel assembly…..12671
      Removal and installation of rear rear wheel assembly…..12671
      Removal and installation of hitch frame assembly…..12672
      Disassembly and assembly of hitch frame…..12680
      Removal and installation of body assembly…..12685
    Hydraulic system…..12688
      Disassembly and assembly of steering valve…..12689
      Removal and installation of flow amplifier valve assembly…..12699
      Removal and installation of hoist valve assembly…..12701
      Disassembly and assembly of hoist valve assembly…..12703
      Disassembly and assembly of steering cylinder assembly…..12705
      Disassembly and assembly of hoist cylinder assembly…..12711
    Cab and its attachments…..12720
      Removal and installation of operator’s cab…..12721
      Removal and installation of operator’s cab glass (Stuck glass)…..12726
      Disassembly and assembly of operator&apos;s seat assembly…..12733
      Removal and installation of air conditioner unit assembly…..12743
    Electrical system…..12750
      Removal and installation of retarder controller assembly…..12751
      Removal and installation of transmission controller assembly…..12753
      Removal and installation of engine controller assembly…..12755
  90 Diagrams and drawings…..0
    Hydraulic diagrams and drawings…..12758
      Power train hydraulic circuit diagram…..12760
      Steering and hoist hydraulic circuit diagram…..12761
      Brake hydraulic circuit diagram…..12763
      Brake cooling hydraulic circuit diagram…..12764
      Differential lock hydraulic circuit diagram…..12765
    Electrical diagrams and drawings…..12767
      Electrical circuit diagram for inside cab (1/4)…..12769
      Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2092…..12770
      Electrical circuit diagram for inside cab (2/4) Serial No.: 2093 and up…..12771
      Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2092…..12772
      Electrical circuit diagram for inside cab (3/4) Serial No.: 2093 and up…..12773
      Electrical circuit diagram for inside cab (4/4)…..12774
      Electrical circuit diagram for outside cab (1/3)…..12775
      Electrical circuit diagram for outside cab (2/3)…..12776
      Electrical circuit diagram for outside cab (3/3)…..12777
      Connectors table and arrangement drawing…..12778
SEN00238-15 – Articulated Dump Truck HM350-2 Shop Manual…..12781
  COVER …..12781
  00 Index and foreword…..0
    Index…..12783
      Composition of shop manual…..12784
      Table of contents…..12786
    Foreword and general information…..12797
      Safety notice…..12798
      How to read the shop manual…..12803
      Explanation of terms for maintenance standard…..12805
      Handling of electric equipment and hydraulic component…..12807
      Handling of connectors newly used for engines…..12816
      How to read electric wire code…..12819
      Precautions when carrying out operation…..12822
      Method of disassembling and connecting push-pull type coupler…..12825
      Standard tightening torque table…..12828
      Conversion table…..12832
  01 Specification…..0
    Specification and technical data…..12839
      Specification drawings…..12840
      Specifications…..12841
      Weight table…..12844
      Fuel, coolant and lubricants…..12845
  10 Structure, function and maintenance standard…..0
    Engine and cooling system…..12849
      Radiator, oil cooler, aftercooler…..12850
      Output shaft…..12851
    Power train, Part 1…..12855
      Power train skeleton…..12856
      Torque converter and transmission hydraulic piping…..12860
      Brake cooling oil control valve (BCV)…..12862
      Power train pump…..12863
      Torque converter…..12866
      Transmission…..12872
      Transmission control valve…..12900
      ECMV…..12901
      Main relief, torque converter relief valve…..12908
    Power train, Part 2…..12911
      Drive shaft…..12912
      Axle…..12916
      Differential…..12920
      Limited slip differential…..12932
      Final drive…..12936
    Steering system…..12943
      Steering column…..12944
    Brake system…..12947
      Brake piping…..12948
      Brake valve…..12950
      Accumulator charge valve…..12953
      Accumulator…..12957
      Slack adjuster…..12958
      Brake…..12960
      Proportional reducing valve…..12965
      Brake system tank…..12966
      Parking brake…..12968
      Parking brake solenoid valve…..12972
    Undercarriage and frame…..12975
      Suspension…..12976
      Suspension cylinder…..12981
      Oscillation hitch…..12983
    Hydraulic system…..12987
      Steering, hoist oil pressure piping diagram…..12988
      Dump body control…..12989
      Hydraulic tank and filter…..12990
      Flow amp valve…..12991
      Steering valve…..12994
      Steering cylinder…..12998
      Hoist valve…..13000
      Dump control valve (EPC valve)…..13006
      Pilot check valve…..13010
      Hoist cylinder…..13011
      Hydraulic pump…..13012
    Cab and its attachments…..13017
      ROPS cab…..13018
      Cab tilt…..13019
      Air conditioner…..13020
      Rear view monitor…..13028
      Controller related…..13031
    Electrical system, Part 1…..13033
      Machine monitor system…..13034
    Electrical system, Part 2…..13055
      Automatic shift control system…..13056
      Transmission controller…..13059
      Retarder control system…..13088
      Auto emergency steering system…..13100
      Battery disconnector switch…..13102
      Dump control lever…..13104
    Electrical system, Part 3…..13109
      Sensors, switches…..13110
      KOMTRAX terminal system (if equipped)…..13118
  20 Standard value table…..0
    Standard service value table…..13121
      Standard value table for engine…..13122
      Standard value table for chassis…..13123
  30 Testing and adjusting…..0
    Testing and adjusting, Part 1…..13129
      Tools for testing, adjusting, and troubleshooting…..13131
      Sketches of special tools…..13136
      Measuring engine speed…..13137
      Testing intake air pressure (boost pressure)…..13138
      Testing exhaust temperature…..13139
      Testing exhaust gas color…..13140
      Adjusting valve clearance…..13141
      Testing compression pressure…..13142
      Testing blow-by pressure…..13144
      Testing engine oil pressure…..13145
      Testing EGR valve and bypass valve drive oil pressure…..13146
      Handling of fuel system devices…..13147
      Releasing residual pressure from fuel system…..13147
      Testing fuel pressure…..13148
      Testing fuel return and leakage amount…..13149
      Bleeding air from fuel circuit…..13152
      Testing the fuel circuit for leakage…..13154
      Testing and adjusting fan belt tension…..13155
      Testing and adjusting alternator belt tension…..13156
      Testing and adjusting air conditioner compressor belt tension…..13157
      Adjusting the body mount…..13158
    Testing and adjusting, Part 2…..13161
      Testing torque converter stall speed…..13163
      Testing power train oil pressure…..13164
      Testing and adjusting of differential lock oil pressure (differential lock spec.)…..13172
      Adjusting transmission speed sensor…..13177
      Testing and adjusting brake oil pressure…..13179
      Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…..13183
      Testing brake performance…..13187
      Bleeding air from brake circuit…..13188
      Testing wear of wheel brake disc…..13189
      Testing the parking brake pad wear…..13190
      Emergency release of the parking brake…..13191
      Testing and adjusting steering circuit oil pressure…..13192
      Testing and adjusting suspension cylinder…..13194
      Method of tilting cab up…..13198
      Testing and adjusting dump circuit oil pressure…..13200
      Adjusting body positioner sensor…..13202
      Adjusting length of spring in body heating spherical joint…..13203
      Handling of voltage circuit of engine controller…..13203
      Adjusting transmission controller…..13203
      Method for emergency escape at electrical system failure…..13204
    Testing and adjusting, Part 3…..13209
      Setting and adjusting various equipments…..13210
      Special function of machine monitor…..13219
      How to start operation of KOMTRAX terminal…..13264
      Lamp display of KOMTRAX terminal…..13269
      Pm Clinic check sheet…..13272
  40 Troubleshooting…..0
    General information on troubleshooting…..13277
      Points to remember when troubleshooting…..13278
      Sequence of events in troubleshooting…..13279
      Check before troubleshooting…..13280
      Classification and procedures for troubleshooting…..13281
      Connection table for connector pin numbers…..13284
      T- branch box and T- branch adapter table…..13320
    Troubleshooting by failure code, General…..13325
      Troubleshooting by failure code, General…..13326
        Failure codes table…..13326
        Before troubleshooting by failure code…..13334
        Information in troubleshooting table…..13341
    Troubleshooting by failure code, Part 1…..13344
      Troubleshooting by failure code, Part 1…..13346
        Failure code [1500L0] Double engagement…..13346
        Failure code [15B0NX] Transmission oil filter: Clogged…..13347
        Failure code [15F0KM] R → F shifting abuse 1…..13349
        Failure code [15F0MB] R → F shifting abuse 2…..13349
        Failure code [15F7KM] Transmission forward clutch abuse…..13350
        Failure code [15G0MW] Trouble in reverse clutch system (Slip)…..13351
        Failure code [15G7KM] Transmission reverse clutch abuse…..13353
        Failure code [15H0MW] Trouble in Hi clutch system (Slip)…..13354
        Failure code [15J0MW] Trouble in Lo clutch system (Slip)…..13356
        Failure code [15K0MW] Trouble in 1st clutch system (Slip)…..13358
        Failure code [15L0MW] Trouble in 2nd clutch system (Slip)…..13360
        Failure code [15M0MW] Trouble in 3rd clutch system (Slip)…..13362
        Failure code [15SBL1] Trouble in reverse clutch pressure control valve I…..13364
        Failure code [15SBMA] Trouble in reverse clutch pressure control valve II…..13367
        Failure code [15SCL1] Trouble in Hi clutch pressure control valve I…..13369
        Failure code [15SCMA] Trouble in Hi clutch pressure control valve II…..13372
        Failure code [15SDL1] Trouble in Lo clutch pressure control valve I…..13374
        Failure code [15SDMA] Trouble in Lo clutch pressure control valve II…..13376
    Troubleshooting by failure code, Part 2…..13380
      Failure code [15SEL1] Trouble in 1st clutch pressure control valve I…..13382
      Failure code [15SEMA] Trouble in 1st clutch pressure control valve II…..13385
      Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I…..13387
      Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II…..13391
      Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I…..13393
      Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II…..13397
      Failure code [15SJMA] Trouble in lockup clutch pressure control valve II…..13399
      Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II…..13401
      Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2…..13403
      Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1…..13405
      Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2…..13407
      Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1…..13409
      Failure code [2C4MNX] Clogging of retarder cooling oil filter…..13411
      Failure code [2F00KM] Dragging of parking brake…..13413
      Failure code [2G42ZG] Lowering of accumulator oil pressure (front)…..13415
      Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)…..13415
      Failure code [989A00] Operation of engine overrun prevention system…..13416
      Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)…..13416
      Failure code [A570NX] Clogging of engine oil filter…..13417
      Failure code [AA10NX] Clogging of air cleaner…..13419
      Failure code [AB00MA] Trouble in battery charge circuit…..13421
      Failure code [B@BAZG] Lowering of engine oil pressure…..13422
      Failure code [B@BAZK] Lowering of engine oil level…..13423
      Failure code [B@BCNS] Overheating of engine…..13424
      Failure code [B@BCZK] Lowering of coolant level…..13425
      Failure code [B@BFZK] Lowering of fuel level…..13427
      Failure code [B@C6NS] Overheating of brake cooling oil (front)…..13428
      Failure code [B@C8NS] Overheating of brake cooling oil (center)…..13428
      Failure code [B@CENS] Overheating of torque converter oil…..13429
      Failure code [B@JANS] Overheating of steering oil…..13429
    Troubleshooting by failure code, Part 3…..13432
      Failure code [CA111] Trouble in engine controller…..13435
      Failure code [CA115] Trouble in engine Ne and Bkup speed sensors…..13437
      Failure code [CA122] Abnormally high charge pressure…..13439
      Failure code [CA123] Abnormally low charge pressure…..13441
      Failure code [CA131] Abnormally high throttle sensor signal…..13443
      Failure code [CA132] Abnormally low throttle sensor signal…..13445
      Failure code [CA135] Abnormally high engine oil pressure…..13447
      Failure code [CA141] Abnormally low engine oil pressure…..13449
      Failure code [CA144] Abnormally high coolant temperature…..13451
      Failure code [CA145] Abnormally low coolant temperature…..13453
      Failure code [CA153] Abnormally high charge temperature…..13455
      Failure code [CA154] Abnormally low charge temperature…..13457
      Failure code [CA187] Abnormally low voltage in sensor power supply 2…..13458
      Failure code [CA221] Abnormally high ambient pressure…..13459
      Failure code [CA222] Abnormally low ambient pressure…..13461
      Failure code [CA227] Abnormally high voltage in sensor power supply 2…..13463
      Failure code [CA234] Engine overspeed…..13465
      Failure code [CA238] Trouble in Ne speed sensor power supply…..13467
      Failure code [CA263] Abnormally high fuel temperature…..13469
      Failure code [CA265] Abnormally low fuel temperature…..13471
      Failure code [CA271] Short circuit in PCV1…..13472
      Failure code [CA272] Disconnection in PCV1…..13473
      Failure code [CA273] Short circuit in PCV2…..13474
      Failure code [CA274] Disconnection in PCV2…..13475
      Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)…..13477
      Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)…..13479
      Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)…..13481
      Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)…..13483
      Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)…..13485
      Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)…..13487
      Failure code [CA342] Matching error in engine controller data…..13489
      Failure code [CA351] Trouble in injector drive circuit…..13491
      Failure code [CA352] Abnormally low voltage in sensor power supply 1…..13493
      Failure code [CA386] Abnormally high voltage in sensor power supply 1…..13495
    Troubleshooting by failure code, Part 4…..13498
      Failure code [CA431] Trouble in idle validation switch…..13501
      Failure code [CA432] Trouble in idle validation process…..13505
      Failure code [CA441] Abnormally low voltage in power supply…..13505
      Failure code [CA442] Abnormally high voltage in power supply…..13506
      Failure code [CA449] Abnormally high common rail pressure 2…..13506
      Failure code [CA451] Abnormally high common rail pressure…..13507
      Failure code [CA452] Abnormally low common rail pressure…..13509
      Failure code [CA553] Abnormally high common rail pressure 1…..13509
      Failure code [CA554] In-range error in common rail pressure sensor…..13510
      Failure code [CA559] Supply pump low pressure 1…..13512
      Failure code [CA689] Trouble in engine Ne speed sensor…..13515
      Failure code [CA731] Phase error in engine Bkup speed sensor…..13517
      Failure code [CA757] Loss of all data in engine controller…..13517
      Failure code [CA778] Trouble in engine Bkup speed sensor…..13519
      Failure code [CA1117] Loss of partial data in engine controller…..13521
      Failure code [CA1228] Trouble in EGR valve servo 1…..13521
      Failure code [CA1625] Trouble in EGR valve servo 2…..13522
      Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit…..13523
      Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit…..13525
      Failure code [CA1628] Trouble in bypass valve servo 1…..13526
      Failure code [CA1629] Trouble in bypass valve servo 2…..13527
      Failure code [CA1631] Abnormally high signal in bypass valve lift sensor…..13529
      Failure code [CA1632] Abnormally low signal in bypass valve lift sensor…..13531
      Failure code [CA1633] Trouble in KOMNET…..13533
      Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor…..13535
      Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor…..13537
      Failure code [CA2185] Abnormally high voltage in throttle sensor power supply…..13539
      Failure code [CA2186] Abnormally low voltage in throttle sensor power supply…..13541
      Failure code [CA2249] Low pressure in supply pump 2…..13541
      Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor…..13543
      Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor…..13545
      Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit…..13547
      Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit…..13549
      Failure code [CA2555] Disconnection in intake air heater relay…..13549
      Failure code [CA2556] Short circuit in intake air heater relay…..13551
    Troubleshooting by failure code, Part 5…..13554
      Failure code [DAF9KM] Wrong connection of connector…..13556
      Failure code [DAFRKR] Trouble in CAN communication (machine monitor)…..13557
      Failure code [DAQ0KK] Lowering of source voltage…..13559
      Failure code [DAQ0KT] Trouble in non-volatile memory…..13561
      Failure code [DAQ2KK] Trouble in solenoid power supply system…..13563
      Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)…..13565
      Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)…..13567
      Failure code [DAQRMA] Disagreement of option setting (Transmission controller)…..13569
      Failure code [DB10KT] Trouble in non-volatile memory…..13569
      Failure code [DB12KK] Trouble in solenoid power supply system…..13571
      Failure code [DB13KK] Lowering of battery direct voltage…..13573
      Failure code [DB19KQ] Disagreement of model selection (Retarder controller)…..13575
      Failure code [DB1QMA] Disagreement of option setting (Retarder controller)…..13575
      Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)…..13577
      Failure code [DB2RKR] Trouble in CAN communication (Engine controller)…..13579
      Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal…..13581
      Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve…..13583
      Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve…..13584
      Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve…..13585
      Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve…..13586
      Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve…..13587
      Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve…..13588
      Failure code [DF10KA] Input of no lever signals…..13589
      Failure code [DF10KB] Input of multiple lever signals…..13593
      Failure code [DGF1KX] Transmission oil temperature out of range…..13597
      Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)…..13599
      Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center)…..13601
      Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)…..13603
      Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)…..13605
      Failure code [DGR6KX] Steering oil temperature out of range…..13607
    Troubleshooting by failure code, Part 6…..13610
      Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system…..13613
      Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system…..13615
      Failure code [DHT5L6] Trouble in torque converter oil pressure sensor…..13617
      Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system…..13619
      Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system…..13621
      Failure code [DJF1KA] Disconnection in fuel level sensor system…..13623
      Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS…..13625
      Failure code [DK52KX] Trouble in dump lever potentiometer 1…..13627
      Failure code [DK53L8] Trouble in dump lever potentiometer 2…..13629
      Failure code [DK54KX] Trouble in dump positioner sensor…..13631
      Failure code [DKH0KX] Pitch angle sensor signal out of range…..13633
      Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system…..13635
      Failure code [DLF1LC] Trouble in transmission input shaft speed sensor…..13636
      Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor…..13637
      Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system…..13638
      Failure code [DLF4KA] Disconnection in transmission differential speed sensor system…..13639
      Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system…..13640
      Failure code [DV00KB] Short circuit in buzzer output circuit…..13641
      Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system…..13643
      Failure code [DW73KZ] Trouble in dump selector valve output system…..13645
      Failure code [DW78KZ] Trouble in rear wheel BCV command output system…..13647
      Failure code [DW79KZ] Trouble in front wheel BCV command output system…..13649
      Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1…..13651
      Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve…..13653
      Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve…..13655
      Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve…..13657
      Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2…..13659
      Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1…..13661
      Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve…..13663
      Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve…..13665
      Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve…..13667
      Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2…..13669
    Troubleshooting by failure code, Part 7…..13672
      Troubleshooting by failure code, Part 7…..13674
        Failure code [DX13KA] Disconnection in output circuit of dump EPC valve…..13674
        Failure code [DX13KB] Ground fault in output circuit of dump EPC valve…..13676
        Failure code [DX13KY] Hot short in output circuit of dump EPC valve…..13678
        Failure code [DX14KZ] Trouble in rear wheel differential lock command output system…..13679
        Failure code [DX15KZ] Trouble in front wheel differential lock command output system…..13681
        Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid…..13683
        Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid…..13685
        Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid…..13687
        Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid…..13688
        Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid…..13689
        Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid…..13691
        Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid…..13692
        Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve…..13694
        Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve…..13696
        Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid…..13699
        Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve…..13701
        Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve…..13703
        Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid…..13706
        Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve…..13708
        Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve…..13710
    Troubleshooting by failure code, Part 8…..13714
      Troubleshooting by failure code, Part 8…..13715
        Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid…..13715
        Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve…..13717
        Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve…..13719
        Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid…..13722
        Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve…..13724
        Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve…..13726
        Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid…..13729
        Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve…..13731
        Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve…..13733
    Troubleshooting for electrical system (E-mode)…..13737
      Before troubleshooting for electrical system…..13739
      Information in troubleshooting table…..13745
      E-1 Engine does not start (Starting motor does not turn)…..13746
      E-2 Auto preheater does not operate…..13750
      E-3 When starting switch is turned ON, machine monitor displays nothing…..13754
      E-4 When starting switch is turned OFF, machine monitor cannot be operated…..13756
      E-5 Alarm buzzer does not stop sounding…..13758
      E-6 Machine monitor does not normally display gauges, caution lamps, and character display section…..13759
      E-7 Display of character display section cannot be changed…..13760
      E-8 Power mode selection function does not operate normally…..13764
      E-9 AISS function does not operate normally…..13766
      E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)…..13768
      E-11 Interaxle differential lock-up function does not operate normally…..13772
      E-12 Display of seat belt caution lamp is abnormal…..13774
      E-13 Turn signal lamps and pilot lamps do not operate normally…..13776
      E-14 Night lighting is abnormal…..13781
      E-15 Backup lamp and backup buzzer operate abnormally…..13787
      E-16 Emergency steering system does not operate…..13791
      E-17 Air conditioner does not operate normally…..13795
    Troubleshooting of hydraulic and mechanical system (H-mode)…..13801
      Troubleshooting of hydraulic and mechanical system (H-mode)…..13803
        Information in troubleshooting table…..13803
        H-1 Machine does not start…..13804
        H-2 Travel is not smooth (Machine hunts)…..13806
        H-3 Lockup is not reset…..13806
        H-4 Start shock and gear shift shock are abnormally large…..13807
        H-5 Gear is not shifted up…..13808
        H-6 Travel speed or power is low…..13810
        H-7 Start and gearshift time lag is large…..13813
        H-8 Torque converter oil temperature is high…..13815
        H-9 Torque converter oil temperature is low…..13816
        H-10 Front brake does not work fully…..13817
        H-11 Center brake does not work fully…..13818
        H-12 Rear brake does not work fully…..13819
        H-13 Steering wheel is heavy…..13820
        H-14 Steering wheel does not move…..13821
        H-15 Steering wheel waggle…..13822
        H-16 Dump body raising speed is low…..13823
        H-17 Dump body does not move…..13824
        H-18 Hydraulic drift of dump body is large…..13825
    Troubleshooting of engine (S-mode)…..13827
      Method of using troubleshooting chart…..13830
      S-1  Starting performance of engine is poor…..13834
      S-2  Engine does not start…..13836
      S-3  Engine does not pick up smoothly…..13840
      S-4  Engine stops during operation…..13841
      S-5  Engine does not rotate smoothly…..13842
      S-6  Engine lack output (or lacks power)…..13843
      S-7  Exhaust gas is black (incomplete combustion)…..13844
      S-8  Oil consumption is excessive (or exhaust gas is blue)…..13846
      S-9  Oil becomes dirty quickly…..13847
      S-10  Fuel consumption is excessive…..13848
      S-11  Oil is in coolant (or coolant spurts back or coolant level goes down)…..13849
      S-12  Oil pressure drops…..13850
      S-13  Oil level rises (Entry of coolant or fuel)…..13852
      S-14  Coolant temperature becomes too high (Overheating)…..13854
      S-15  Abnormal noise is made…..13855
      S-16  Vibration is excessive…..13856
  50 Disassembly and assembly…..0
    General information on disassembly and assembly…..13859
      How to read this manual…..13860
      Coating materials list…..13862
      Special tool list…..13865
      Sketches of special tools…..13871
    Engine and cooling system…..13885
      Removal and installation of fuel supply pump…..13886
      Removal and installation of engine assembly…..13889
      Removal and installation of cylinder head assembly…..13897
      Removal and installation of fuel injector assembly…..13910
      Removal and installation of radiator assembly…..13915
      Removal and installation of cooling assembly…..13919
      Removal and installation of aftercooler…..13923
      Removal and installation of engine front seal…..13926
      Removal and installation of engine rear seal…..13928
      Replacement procedure of exhaust pipe fire prevention cover1…..13932
    Power train, Part 1…..13941
      Removal and installation of output shaft assembly…..13942
      Disassembly and assembly of output shaft assembly…..13946
      Removal and installation of transmission and front differential assembly…..13949
      Disconnection and coupling of front differential and transmission…..13957
      Disassembly and assembly of torque converter assembly…..13958
      Disassembly and assembly of transmission assembly…..13966
    Power train, Part 2…..14009
      Disassembly and assembly of front differential assembly…..14010
      Removal and installation of center differential assembly…..14029
      Disassembly and assembly of center differential assembly…..14033
      Removal and installation of rear differential assembly…..14049
      Disassembly and assembly of rear differential assembly…..14051
    Power train, Part 3…..14065
      Removal and installation of front final drive and brake assembly…..14066
      Disassembly and assembly of front final drive and brake assembly…..14068
      Removal and installation of center final drive and brake assembly…..14081
      Disassembly and assembly of center final drive and brake assembly…..14083
      Removal and installation of rear final drive assembly…..14094
      Disassembly and assembly of rear final drive assembly…..14096
      Removal and installation of center axle assembly…..14103
      Removal and installation of rear axle assembly…..14106
    Undercarriage and frame…..14110
      Removal and installation of front suspension cylinder assembly…..14111
      Removal and installation of rear suspension cylinder assembly…..14113
      Disassembly and assembly of front and rear suspension cylinder assembly…..14114
      Removal and installation of equalizer bar assembly…..14116
      Removal and installation of front wheel assembly…..14118
      Removal and installation of rear front wheel assembly…..14119
      Removal and installation of rear rear wheel assembly…..14119
      Removal and installation of hitch frame assembly…..14120
      Disassembly and assembly of hitch frame…..14128
      Removal and installation of body assembly…..14133
    Hydraulic system…..14136
      Disassembly and assembly of steering valve…..14137
      Removal and installation of flow amplifier valve assembly…..14147
      Removal and installation of hoist valve assembly…..14149
      Disassembly and assembly of hoist valve assembly…..14151
      Disassembly and assembly of steering cylinder assembly…..14153
      Disassembly and assembly of hoist cylinder assembly…..14159
    Cab and its attachments…..14168
      Removal and installation of operator’s cab…..14169
      Removal and installation of operator’s cab glass (Stuck glass)…..14174
      Disassembly and assembly of operator&apos;s seat assembly…..14181
      Removal and installation of air conditioner unit assembly…..14191
    Electrical system…..14198
      Removal and installation of retarder controller assembly…..14199
      Removal and installation of transmission controller assembly…..14201
      Removal and installation of engine controller assembly…..14203
  90 Diagrams and drawings…..0
    Hydraulic diagrams and drawings…..14206
      Power train hydraulic circuit diagram…..14208
      Steering and hoist hydraulic circuit diagram…..14209
      Brake hydraulic circuit diagram…..14211
      Brake cooling hydraulic circuit diagram…..14212
      Differential lock hydraulic circuit diagram…..14213
    Electrical diagrams and drawings…..14215
      Electrical circuit diagram for inside cab (1/4)…..14217
      Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2092…..14218
      Electrical circuit diagram for inside cab (2/4) Serial No.: 2093 and up…..14219
      Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2092…..14220
      Electrical circuit diagram for inside cab (3/4) Serial No.: 2093 and up…..14221
      Electrical circuit diagram for inside cab (4/4)…..14222
      Electrical circuit diagram for outside cab (1/3)…..14223
      Electrical circuit diagram for outside cab (2/3)…..14224
      Electrical circuit diagram for outside cab (3/3)…..14225
      Connectors table and arrangement drawing…..14226
TEN00047-10 – Articulated Dump Truck HM350-1 Operation & Maintenance Manual…..14229
  COVER…..14229
  FOREWORD…..14230
    FOREWORD…..14231
    SAFETY INFORMATION…..14232
    INTENDED USE…..14234
      DIRECTIONS OF MACHINE…..14234
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14235
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..14235
      ENGINE SERIAL NO. PLATE POSITION…..14235
      SERVICE METER POSITION…..14236
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14236
    CONTENTS…..14237
  SAFETY…..14240
    SAFETY…..14241
    SAFETY LABELS…..14243
      POSITION FOR ATTACHING SAFETY LABELS…..14244
      SAFETY LABELS…..14245
    GENERAL PRECAUTIONS…..14250
    PRECAUTIONS DURING OPERATION…..14259
      STARTING ENGINE…..14259
      OPERATION…..14261
      TRANSPORTATION…..14264
      BATTERY…..14265
      TOWING…..14267
    PRECAUTIONS FOR MAINTENANCE…..14268
    PRECAUTIONS WITH TIRES…..14275
  OPERATION…..14276
    GENERAL VIEW…..14277
      GENERAL VIEW OF MACHINE…..14277
      GENERAL VIEW OF CONTROLS AND GAUGES…..14278
    EXPLANATION OF COMPONENTS…..14280
      MACHINE MONITOR…..14280
      OTHER FUNCTIONS OF MACHINE MONITOR…..14301
      SWITCHES…..14305
      CONTROL LEVERS AND PEDALS…..14316
      BODY PIVOT PIN…..14322
      ARTICULATE LOCK…..14322
      DUST INDICATOR…..14323
      FUSES…..14324
      CAR RADIO…..14327
      CAR STEREO…..14333
      AIR CONDITIONER…..14341
    OPERATION…..14346
      CHECK BEFORE STARTING ENGINE…..14346
      STARTING ENGINE…..14359
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..14362
      STOPPING ENGINE…..14363
      CHECKS AFTER STOPPING ENGINE…..14363
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..14364
      SHIFTING GEAR…..14369
      TRAVELING DOWNHILL…..14370
      STEERING THE MACHINE…..14378
      OPERATION USING DIFFERENTIAL LOCK…..14379
      LOADING OPERATIONS…..14382
      DUMP OPERATIONS…..14383
      CAB TILT OPERATION…..14385
      PRECAUTIONS FOR OPERATION…..14387
      PARKING MACHINE…..14388
      CHECKS AFTER COMPLETION OF WORK…..14389
      LOCKING…..14389
      HANDLING TIRES…..14390
    DETERMINING AND MAINTAINING TRAVEL ROAD…..14391
      DETERMINING TRAVEL ROAD…..14391
      MAINTAINING TRAVEL ROAD…..14391
    TRANSPORTATION…..14392
      PRECAUTIONS WHEN TRANSPORTING…..14392
      STEPS FOR TRANSPORTATION…..14392
      METHOD OF SECURING MACHINE…..14393
      METHOD OF LIFTING MACHINE…..14394
    COLD WEATHER OPERATION…..14398
      PRECAUTIONS FOR LOW TEMPERATURE…..14398
      AFTER COLD WEATHER…..14400
    LONG-TERM STORAGE…..14401
    BEFORE STORAGE…..14401
      DURING STORAGE…..14401
      AFTER STORAGE…..14401
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..14401
    TROUBLESHOOTING…..14402
      AFTER RUNNING OUT OF FUEL…..14402
      IF TRANSMISSION HAS TROUBLE…..14403
      METHOD OF TOWING MACHINE…..14404
      IF BATTERY IS DISCHARGED…..14408
      OTHER TROUBLE…..14412
  MAINTENANCE…..14418
    GUIDES TO MAINTENANCE…..14419
    OUTLINE OF SERVICE…..14421
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..14421
      OUTLINE OF ELECTRIC SYSTEM…..14425
    WEAR PARTS…..14426
      WEAR PARTS LIST…..14426
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..14427
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..14428
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..14430
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..14431
      TORQUE LIST…..14431
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..14433
      SAFETY CRITICAL PARTS…..14433
    MAINTENANCE SCHEDULE CHART…..14434
      MAINTENANCE SCHEDULE CHART…..14434
      ADJUST INJECTOR…..14437
    SERVICE PROCEDURE…..14438
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..14438
      WHEN REQUIRED…..14439
      CHECK BEFORE STARTING…..14454
      EVERY 50 HOURS SERVICE…..14455
      EVERY 250 HOURS SERVICE…..14456
      EVERY 500 HOURS SERVICE…..14466
      EVERY 1000 HOURS SERVICE…..14473
      EVERY 2000 HOURS SERVICE…..14489
      EVERY 4000 HOURS SERVICE…..14497
      EVERY 6000 HOURS SERVICE…..14500
      EVERY 8000 HOURS SERVICE…..14501
  SPECIFICATIONS…..14502
    SPECIFICATIONS…..14503
  ATTACHMENTS, OPTIONS…..14504
    HANDLING TACHOGRAPH (TCO20-90W)…..14505
      EXPLANATION OF COMPONENTS…..14505
      METHOD OF USE…..14508
  INDEX…..14512
TEN00129-04 – Articulated Dump Truck GALEO HM350-2 Operation & Maintenance Manual…..14516
  COVER…..14516
  FOREWORD…..14517
    FOREWORD…..14518
    SAFETY INFORMATION…..14521
    INTENDED USE…..14523
      DIRECTIONS OF MACHINE…..14523
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14524
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..14524
      EPA REGULATIONS, ENGINE NUMBER PLATE…..14524
      SERVICE METER POSITION…..14525
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14525
  CONTENTS…..14526
  SAFETY…..14529
    SAFETY…..14530
    SAFETY LABELS…..14532
      POSITION FOR ATTACHING SAFETY LABELS…..14532
      SAFETY LABELS…..14533
    GENERAL PRECAUTIONS…..14538
      SAFETY RULES…..14538
      IF PROBLEMS ARE FOUND…..14538
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..14538
      FIRE EXTINGUISHER AND FIRST AID KIT…..14538
      SAFETY FEATURES…..14539
      KEEP MACHINE CLEAN…..14539
      INSIDE OPERATOR&apos;S COMPARTMENT…..14539
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR&apos;S SEAT…..14539
      HANDRAILS AND STEPS…..14540
      MOUNTING AND DISMOUNTING…..14540
      CRUSHING OR CUTTING PREVENTION…..14540
      PREVENTION OF BURNS…..14541
      FIRE PREVENTION…..14542
      ACTION IF FIRE OCCURS…..14542
      WINDOW WASHER LIQUID…..14543
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..14543
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..14543
      UNAUTHORIZED MODIFICATION…..14543
      SAFETY AT WORKSITE…..14543
      WORKING ON LOOSE GROUND…..14544
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..14544
      ENSURE GOOD VISIBILITY…..14545
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..14545
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..14545
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..14545
      ASBESTOS DUST HAZARD PREVENTION…..14546
    PRECAUTIONS DURING OPERATION…..14547
      STARTING ENGINE…..14547
        CHECKS BEFORE STARTING ENGINE, ADJUST…..14547
        PRECAUTIONS WHEN STARTING…..14547
        PRECAUTIONS IN COLD AREAS…..14548
      OPERATION…..14549
        CHECKS BEFORE STARTING OPERATION…..14549
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..14549
        PRECAUTIONS WHEN TRAVELING…..14550
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..14550
        PRECAUTIONS WHEN OPERATING DUMP BODY…..14551
        PRECAUTIONS WHEN OPERATING…..14551
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..14551
        PARKING MACHINE…..14552
      TRANSPORTATION…..14553
        LOADING AND UNLOADING…..14553
        SHIPPING…..14553
      BATTERY…..14554
        BATTERY HAZARD PREVENTION…..14554
        STARTING WITH BOOSTER CABLES…..14555
      TOWING…..14556
        WHEN TOWING…..14556
    PRECAUTIONS FOR MAINTENANCE…..14557
      WARNING TAG…..14557
      KEEP WORK PLACE CLEAN AND TIDY…..14557
      APPOINT LEADER WHEN WORKING WITH OTHERS…..14557
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..14558
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..14559
      PROPER TOOLS…..14560
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..14560
      PERSONNEL…..14560
      WORK UNDER THE MACHINE…..14560
      NOISE…..14560
      PRECAUTIONS WHEN USING HAMMER…..14561
      REPAIR WELDING…..14561
      REMOVING BATTERY TERMINAL…..14561
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..14561
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..14561
      HANDLING HIGH-PRESSURE HOSES, PIPING…..14562
      PRECAUTIONS FOR HIGH VOLTAGE…..14562
      WASTE MATERIALS…..14562
      MAINTENANCE OF AIR CONDITIONER…..14562
      COMPRESSED AIR…..14562
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..14563
    PRECAUTIONS WITH TIRES…..14564
      HANDLING TIRES…..14564
      PRECAUTIONS WHEN STORING TIRE…..14564
  OPERATION…..14565
    GENERAL VIEW…..14566
      GENERAL VIEW OF MACHINE…..14566
      GENERAL VIEW OF CONTROLS AND GAUGES…..14567
    EXPLANATION OF COMPONENTS…..14569
      MACHINE MONITOR…..14569
      OTHER FUNCTIONS OF MACHINE MONITOR…..14590
      SWITCHES…..14594
      CONTROL LEVERS AND PEDALS…..14605
      BODY PIVOT PIN…..14610
      ARTICULATE LOCK…..14610
      LOCATION OF FIRE EXTINGUISHER…..14611
      DUST INDICATOR…..14611
      CIRCUIT BREAKER…..14611
      FUSES…..14612
      CAR RADIO…..14615
      CAR STEREO…..14621
      AIR CONDITIONER…..14629
    OPERATION…..14635
      CHECK BEFORE STARTING ENGINE…..14635
      STARTING ENGINE…..14649
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..14651
      STOPPING ENGINE…..14652
      CHECKS AFTER STOPPING ENGINE…..14652
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..14653
      SHIFTING GEAR…..14658
      TRAVELING DOWNHILL…..14660
      STEERING THE MACHINE…..14666
      OPERATION USING DIFFERENTIAL LOCK…..14666
      LOADING OPERATIONS…..14668
      DUMP OPERATIONS…..14669
      CAB TILT OPERATION…..14671
      PRECAUTIONS FOR OPERATION…..14674
      PARKING MACHINE…..14675
      CHECKS AFTER COMPLETION OF WORK…..14676
      LOCKING…..14676
      HANDLING TIRES…..14677
    DETERMINING AND MAINTAINING TRAVEL ROAD…..14678
      DETERMINING TRAVEL ROAD…..14678
      MAINTAINING TRAVEL ROAD…..14678
    TRANSPORTATION…..14679
      PRECAUTIONS WHEN TRANSPORTING…..14679
      STEPS FOR TRANSPORTATION…..14679
      METHOD OF SECURING MACHINE…..14680
      METHOD OF LIFTING MACHINE…..14681
    COLD WEATHER OPERATION…..14685
      PRECAUTIONS FOR LOW TEMPERATURE…..14685
      PRECAUTIONS AFTER COMPLETION OF WORK…..14686
      AFTER COLD WEATHER…..14687
    LONG-TERM STORAGE…..14688
      BEFORE STORAGE…..14688
      DURING STORAGE…..14688
      AFTER STORAGE…..14688
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..14688
    TROUBLESHOOTING…..14689
      AFTER RUNNING OUT OF FUEL…..14689
      IF TRANSMISSION HAS TROUBLE…..14690
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..14690
      METHOD OF TOWING MACHINE…..14691
      IF BATTERY IS DISCHARGED…..14695
      OTHER TROUBLE…..14699
  MAINTENANCE…..14705
    GUIDES TO MAINTENANCE…..14706
    OUTLINE OF SERVICE…..14708
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..14708
      OUTLINE OF ELECTRIC SYSTEM…..14712
    WEAR PARTS…..14713
      WEAR PARTS LIST…..14713
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..14714
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..14715
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..14716
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..14717
      TORQUE LIST…..14717
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..14719
      SAFETY CRITICAL PARTS…..14720
    MAINTENANCE SCHEDULE CHART…..14721
      MAINTENANCE SCHEDULE CHART…..14721
    SERVICE PROCEDURE…..14724
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..14724
      WHEN REQUIRED…..14725
        CHECK, CLEAN OR REPLACE AIR CLEANER…..14725
        CLEAN INSIDE OF COOLING SYSTEM…..14731
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..14734
        CLEAN AIR CONDITIONER AIR FILTER…..14734
        CHECK REFRIGERANT (GAS) LEVEL…..14735
        CHECK DUMP BODY…..14736
        BLEED AIR FROM FRONT BRAKE…..14737
        BLEED AIR FROM CENTER BRAKE…..14738
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..14739
        SELECTION AND INSPECTION OF TIRES…..14740
      CHECK BEFORE STARTING…..14743
      EVERY 50 HOURS SERVICE…..14744
        LUBRICATION…..14744
      EVERY 250 HOURS SERVICE…..14745
        LUBRICATION…..14745
        LUBRICATE DRIVE SHAFT…..14747
        CHECK DRIVE SHAFT…..14747
        CLEAN BREATHERS…..14748
        CLEAN OVERFLOW HOSE…..14750
        CHECK LEVEL OF BATTERY ELECTROLYTE…..14751
        CHECK ALTERNATOR BELT TENSION, ADJUST…..14753
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..14754
        CHECK FRAME, A-ARM…..14755
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..14756
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..14756
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..14757
        CHECK WEAR OF PARKING BRAKE PADS…..14757
        CHECK LENGTH OF SUSPENSION CYLINDER…..14758
        CHECK OF ACCUMULATOR GAS PRESSURE…..14759
      EVERY 500 HOURS SERVICE…..14760
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..14760
        REPLACE FUEL PREFILTER CARTRIDGE…..14761
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..14762
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..14762
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..14763
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..14765
        CHECK FAN BELT TENSION, ADJUST…..14766
        RECOVER OIL LEAKING FROM FLOATING SEAL…..14767
      EVERY 1000 HOURS SERVICE…..14768
        REPLACE FUEL MAIN FILTER CARTRIDGE…..14768
        REPLACE CORROSION RESISTOR CARTRIDGE…..14769
        REPLACE TRANSMISSION FILTER ELEMENT…..14770
        CHANGE OIL IN TRANSMISSION CASE…..14771
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..14773
        LUBRICATION…..14776
        CHECK WEAR OF BRAKE DISC…..14778
        CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS…..14779
      EVERY 2000 HOURS SERVICE…..14780
        CHANGE OIL IN FINAL DRIVE CASE…..14780
        CHANGE OIL IN DIFFERENTIAL CASE…..14781
        REPLACE HYDRAULIC FILTER ELEMENT…..14783
        CLEAN HYDRAULIC TANK STRAINER…..14784
        CLEAN TRANSMISSION CASE STRAINER…..14784
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..14785
        CLEAN BREATHER…..14786
        CHECK ACCUMULATOR GAS PRESSURE…..14786
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..14786
      EVERY 4000 HOURS SERVICE…..14787
        CHANGE OIL IN HYDRAULIC TANK…..14787
        LUBRICATE FAN PULLEY…..14787
        CHECK ALTERNATOR, STARTING MOTOR…..14787
        CHECK WATER PUMP…..14787
        CHECK AIR COMPRESSOR…..14787
        CHECK FAN PULLEY AND TENSION PULLEY…..14787
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..14788
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..14788
      EVERY 6000 HOURS SERVICE…..14789
        LUBRICATE DRIVE SHAFT…..14789
      EVERY 8000 HOURS SERVICE…..14790
        REPLACE HIGH-PRESSURE PIPING CLAMP…..14790
        REPLACE FUEL SPRAY PREVENTION CAP…..14790
        OVERHAUL STARTING MOTOR AND ALTERNATOR…..14790
  SPECIFICATIONS…..14791
    SPECIFICATIONS…..14792
  ATTACHMENTS, OPTIONS…..14793
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..14794
      EXPLANATION OF COMPONENTS…..14794
      METHOD OF OPERATION…..14795
    USE OF REAR VIEW MONITOR…..14796
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..14796
      SETTING OF REAR VIEW MONITOR…..14799
      CAUTIONS WHEN USING REAR VIEW MONITOR…..14799
    HANDLING DUMPING COUNTER…..14800
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..14801
      BASIC PRECAUTIONS…..14801
  INDEX…..14803
TEN00229-06 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..14807
  COVER…..14807
  FOREWORD…..14808
    BEFORE READING THIS MANUAL…..14809
    SAFETY INFORMATION…..14810
    INTENDED USE…..14811
      USE OF MACHINE…..14811
      DIRECTIONS OF MACHINE…..14811
      VISIBILITY FROM OPERATOR&apos;S SEAT…..14811
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14812
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..14812
      ENGINE SERIAL NO. PLATE…..14812
      SERVICE METER POSITION…..14813
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..14813
    CONTENTS…..14814
  SAFETY…..14818
    SAFETY…..14819
    SAFETY LABELS…..14822
      POSITION FOR ATTACHING SAFETY LABELS…..14823
      SAFETY LABELS…..14824
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..14829
      PRECAUTIONS BEFORE STARTING OPERATION…..14829
      PREPARATIONS FOR SAFE OPERATION…..14829
      FIRE PREVENTION…..14831
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..14832
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..14834
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..14834
      UNAUTHORIZED MODIFICATION…..14834
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..14835
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..14835
    PRECAUTIONS FOR OPERATION…..14836
      PRECAUTIONS FOR JOBSITE…..14836
      STARTING ENGINE…..14838
      OPERATION…..14841
      TRANSPORTATION…..14845
      TOWING…..14846
    PRECAUTIONS FOR MAINTENANCE…..14847
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..14847
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..14852
      TIRES…..14857
  OPERATION…..14860
    GENERAL VIEW…..14861
      GENERAL VIEW OF MACHINE…..14861
      GENERAL VIEW OF CONTROLS AND GAUGES…..14862
    EXPLANATION OF COMPONENTS…..14864
      MACHINE MONITOR…..14864
      OTHER FUNCTIONS OF MACHINE MONITOR…..14885
      SWITCHES…..14889
      CONTROL LEVERS AND PEDALS…..14900
      BODY PIVOT PIN…..14905
      ARTICULATE LOCK…..14905
      LOCATION OF FIRE EXTINGUISHER…..14906
      DUST INDICATOR…..14906
      CIRCUIT BREAKER…..14906
      FUSES…..14907
      CAR RADIO…..14910
      CAR STEREO…..14916
      AIR CONDITIONER…..14924
    OPERATION…..14929
      CHECK BEFORE STARTING ENGINE…..14929
      STARTING ENGINE…..14945
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..14947
      STOPPING ENGINE…..14948
      CHECKS AFTER STOPPING ENGINE…..14948
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..14949
      SHIFTING GEAR…..14954
      TRAVELING DOWNHILL…..14956
      STEERING THE MACHINE…..14962
      OPERATION USING DIFFERENTIAL LOCK…..14962
      LOADING OPERATIONS…..14965
      DUMP OPERATIONS…..14966
      CAB TILT OPERATION…..14968
      PRECAUTIONS FOR OPERATION…..14971
      PARKING MACHINE…..14972
      CHECKS AFTER COMPLETION OF WORK…..14973
      LOCKING…..14973
      HANDLING TIRES…..14974
    DETERMINING AND MAINTAINING TRAVEL ROAD…..14975
      DETERMINING TRAVEL ROAD…..14975
      MAINTAINING TRAVEL ROAD…..14975
    TRANSPORTATION…..14976
      PRECAUTIONS WHEN TRANSPORTING…..14976
      STEPS FOR TRANSPORTATION…..14976
      METHOD OF SECURING MACHINE…..14977
      METHOD OF LIFTING MACHINE…..14978
    COLD WEATHER OPERATION…..14982
      PRECAUTIONS FOR LOW TEMPERATURE…..14982
      PRECAUTIONS AFTER COMPLETION OF WORK…..14983
      AFTER COLD WEATHER…..14984
    LONG-TERM STORAGE…..14985
      BEFORE STORAGE…..14985
      DURING STORAGE…..14985
      AFTER STORAGE…..14985
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..14985
    TROUBLESHOOTING…..14986
      AFTER RUNNING OUT OF FUEL…..14986
      IF TRANSMISSION HAS TROUBLE…..14986
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..14986
      METHOD OF TOWING MACHINE…..14987
      IF BATTERY IS DISCHARGED…..14991
      OTHER TROUBLE…..14995
  MAINTENANCE…..15002
    GUIDES TO MAINTENANCE…..15003
    OUTLINE OF SERVICE…..15005
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..15005
      OUTLINE OF ELECTRIC SYSTEM…..15009
    WEAR PARTS…..15010
      WEAR PARTS LIST…..15010
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..15011
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..15012
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..15013
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..15014
      TORQUE LIST…..15014
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..15016
      SAFETY CRITICAL PARTS…..15017
    MAINTENANCE SCHEDULE CHART…..15018
      MAINTENANCE SCHEDULE CHART…..15018
    SERVICE PROCEDURE…..15021
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..15021
      WHEN REQUIRED…..15022
      CHECK BEFORE STARTING…..15044
      EVERY 50 HOURS SERVICE…..15045
      EVERY 250 HOURS SERVICE…..15046
      EVERY 500 HOURS SERVICE…..15060
      EVERY 1000 HOURS SERVICE…..15067
      EVERY 2000 HOURS SERVICE…..15079
      EVERY 4000 HOURS SERVICE…..15086
      EVERY 6000 HOURS SERVICE…..15089
      EVERY 8000 HOURS SERVICE…..15090
  SPECIFICATIONS…..15092
    SPECIFICATIONS…..15093
  ATTACHMENTS, OPTIONS…..15094
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..15095
      EXPLANATION OF COMPONENTS…..15095
      METHOD OF OPERATION…..15096
    USE OF REAR VIEW MONITOR…..15097
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..15097
      SETTING OF REAR VIEW MONITOR…..15100
      CAUTIONS WHEN USING REAR VIEW MONITOR…..15100
    HANDLING DUMPING COUNTER…..15101
    HANDLING BATTERY DISCONNECTOR SWITCH…..15102
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..15104
      BASIC PRECAUTIONS…..15104
  INDEX…..15106
TEN00239-00 – Articulated Dump Truck GALEO HM350-1 Operation & Maintenance Manual…..15110
  COVER…..15110
  FOREWORD…..15111
    FOREWORD…..15112
    SAFETY INFORMATION…..15115
    INTENDED USE…..15117
      DIRECTIONS OF MACHINE…..15117
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15118
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..15118
      ENGINE SERIAL NO. PLATE POSITION…..15118
      SERVICE METER POSITION…..15119
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15119
  CONTENTS…..15120
  SAFETY…..15123
    SAFETY…..15124
    SAFETY LABELS…..15126
      POSITION FOR ATTACHING SAFETY LABELS…..15126
      SAFETY LABELS…..15127
    GENERAL PRECAUTIONS…..15132
      SAFETY RULES…..15132
      IF PROBLEMS ARE FOUND…..15132
      CLOTHING AND PERSONAL PROTECTIVE ITEMS…..15132
      FIRE EXTINGUISHER AND FIRST AID KIT…..15132
      SAFETY FEATURES…..15133
      KEEP MACHINE CLEAN…..15133
      INSIDE OPERATOR&apos;S COMPARTMENT…..15133
      ALWAYS APPLY LOCK WHEN LEAVING OPERATOR&apos;S SEAT…..15133
      HANDRAILS AND STEPS…..15134
      MOUNTING AND DISMOUNTING…..15134
      CRUSHING OR CUTTING PREVENTION…..15134
      PREVENTION OF BURNS…..15135
      FIRE PREVENTION…..15136
      ACTION IF FIRE OCCURS…..15136
      WINDOW WASHER LIQUID…..15137
      PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..15137
      PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..15137
      UNAUTHORIZED MODIFICATION…..15137
      SAFETY AT WORKSITE…..15137
      WORKING ON LOOSE GROUND…..15138
      DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..15138
      ENSURE GOOD VISIBILITY…..15139
      PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS…..15139
      CHECKING SIGNALMAN&apos;S SIGNALS AND SIGNS…..15139
      EMERGENCY ESCAPE FROM OPERATOR&apos;S CAB…..15139
      ASBESTOS DUST HAZARD PREVENTION…..15140
    PRECAUTIONS DURING OPERATION…..15141
      STARTING ENGINE…..15141
        CHECKS BEFORE STARTING ENGINE, ADJUST…..15141
        PRECAUTIONS WHEN STARTING…..15141
        PRECAUTIONS IN COLD AREAS…..15142
      OPERATION…..15143
        CHECKS BEFORE STARTING OPERATION…..15143
        PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..15143
        PRECAUTIONS WHEN TRAVELING…..15144
        PRECAUTIONS WHEN TRAVELING ON SLOPES…..15144
        PRECAUTIONS WHEN OPERATING DUMP BODY…..15144
        PRECAUTIONS WHEN OPERATING…..15144
        PRECAUTIONS FOR ACCUMULATED SNOW, ICE…..15145
        PARKING MACHINE…..15145
      TRANSPORTATION…..15146
        LOADING AND UNLOADING…..15146
        SHIPPING…..15146
      BATTERY…..15147
        BATTERY HAZARD PREVENTION…..15147
        STARTING WITH BOOSTER CABLES…..15148
      TOWING…..15149
        WHEN TOWING…..15149
    PRECAUTIONS FOR MAINTENANCE…..15150
      WARNING TAG…..15150
      KEEP WORK PLACE CLEAN AND TIDY…..15150
      APPOINT LEADER WHEN WORKING WITH OTHERS…..15150
      STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…..15151
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..15152
      PROPER TOOLS…..15153
      HANDLING SUSPENSION CYLINDER, ACCUMULATOR…..15153
      PERSONNEL…..15153
      WORK UNDER THE MACHINE…..15153
      NOISE…..15153
      PRECAUTIONS WHEN USING HAMMER…..15154
      REPAIR WELDING…..15154
      REMOVING BATTERY TERMINAL…..15154
      PRECAUTIONS WITH HIGH-PRESSURE OIL…..15154
      PRECAUTIONS FOR HIGH-PRESSURE FUEL…..15154
      HANDLING HIGH-PRESSURE HOSES, PIPING…..15155
      PRECAUTIONS FOR HIGH VOLTAGE…..15155
      WASTE MATERIALS…..15155
      MAINTENANCE OF AIR CONDITIONER…..15155
      COMPRESSED AIR…..15155
      PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS…..15156
    PRECAUTIONS WITH TIRES…..15157
      HANDLING TIRES…..15157
      PRECAUTIONS WHEN STORING TIRE…..15157
  OPERATION…..15159
    GENERAL VIEW…..15160
      GENERAL VIEW OF MACHINE…..15160
      GENERAL VIEW OF CONTROLS AND GAUGES…..15161
    EXPLANATION OF COMPONENTS…..15163
      MACHINE MONITOR…..15163
      OTHER FUNCTIONS OF MACHINE MONITOR…..15184
      SWITCHES…..15188
      CONTROL LEVERS AND PEDALS…..15199
      MECHATRONICS EQUIPMENT CONTROLLER…..15204
      BODY PIVOT PIN…..15205
      ARTICULATE LOCK…..15205
      DUST INDICATOR…..15206
      FUSES…..15207
      CAR RADIO…..15210
      CAR STEREO…..15216
      AIR CONDITIONER…..15224
    OPERATION…..15229
      CHECK BEFORE STARTING ENGINE…..15229
      STARTING ENGINE…..15242
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..15245
      STOPPING ENGINE…..15246
      CHECKS AFTER STOPPING ENGINE…..15246
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..15247
      SHIFTING GEAR…..15252
      TRAVELING DOWNHILL…..15253
      STEERING THE MACHINE…..15261
      OPERATION USING DIFFERENTIAL LOCK…..15261
      LOADING OPERATIONS…..15263
      DUMP OPERATIONS…..15264
      CAB TILT OPERATION…..15266
      PRECAUTIONS FOR OPERATION…..15268
      PARKING MACHINE…..15269
      CHECKS AFTER COMPLETION OF WORK…..15270
      LOCKING…..15270
      HANDLING TIRES…..15271
    DETERMINING AND MAINTAINING TRAVEL ROAD…..15272
      DETERMINING TRAVEL ROAD…..15272
      MAINTAINING TRAVEL ROAD…..15272
    TRANSPORTATION…..15273
      PRECAUTIONS WHEN TRANSPORTING…..15273
      STEPS FOR TRANSPORTATION…..15273
      METHOD OF SECURING MACHINE…..15274
      METHOD OF LIFTING MACHINE…..15275
    COLD WEATHER OPERATION…..15279
      PRECAUTIONS FOR LOW TEMPERATURE…..15279
      PRECAUTIONS AFTER COMPLETION OF WORK…..15280
      AFTER COLD WEATHER…..15281
    LONG-TERM STORAGE…..15282
      BEFORE STORAGE…..15282
      DURING STORAGE…..15282
      AFTER STORAGE…..15282
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..15282
    TROUBLESHOOTING…..15283
      AFTER RUNNING OUT OF FUEL…..15283
      METHOD OF TOWING MACHINE…..15284
      IF BATTERY IS DISCHARGED…..15288
      OTHER TROUBLE…..15292
  MAINTENANCE…..15299
    GUIDES TO MAINTENANCE…..15300
    OUTLINE OF SERVICE…..15302
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..15302
      OUTLINE OF ELECTRIC SYSTEM…..15306
    WEAR PARTS…..15307
      WEAR PARTS LIST…..15307
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..15308
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..15309
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN  KOMATSU GENUINE OIL…..15311
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..15312
      TORQUE LIST…..15312
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..15314
      SAFETY CRITICAL PARTS…..15315
    MAINTENANCE SCHEDULE CHART…..15316
      MAINTENANCE SCHEDULE CHART…..15316
      ADJUST INJECTOR…..15319
    SERVICE PROCEDURE…..15320
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..15320
      WHEN REQUIRED…..15321
        CHECK, CLEAN OR REPLACE AIR CLEANER…..15321
        CLEAN INSIDE OF COOLING SYSTEM…..15324
        CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID…..15326
        CLEAN AIR CONDITIONER AIR FILTER…..15327
        CHECK REFRIGERANT (GAS) LEVEL…..15327
        CHECK DUMP BODY…..15328
        CHECK ELECTRIC INTAKE AIR HEATER…..15328
        BLEED AIR FROM FRONT BRAKE…..15328
        BLEED AIR FROM CENTER BRAKE…..15329
        CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT…..15330
        SELECTION AND INSPECTION OF TIRES…..15331
      CHECK BEFORE STARTING…..15334
      EVERY 50 HOURS SERVICE…..15335
        LUBRICATION…..15335
      EVERY 250 HOURS SERVICE…..15336
        LUBRICATION…..15336
        LUBRICATE DRIVE SHAFT…..15337
        CHECK DRIVE SHAFT…..15338
        CHECK LEVEL OF BATTERY ELECTROLYTE…..15339
        CHECK ALTERNATOR BELT TENSION, ADJUST…..15341
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..15342
        CHECK FRAME, A-ARM…..15343
        CHECK BRAKING CAPACITY OF FOOT BRAKE…..15344
        CHECK BRAKING CAPACITY OF RETARDER BRAKE…..15344
        CHECK BRAKING CAPACITY OF PARKING BRAKE…..15345
        CHECK WEAR OF PARKING BRAKE PADS…..15345
        CHECK LENGTH OF SUSPENSION CYLINDER…..15346
      EVERY 500 HOURS SERVICE…..15347
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..15347
        REPLACE FUEL FILTER CARTRIDGE…..15348
        CLEAN FUEL TANK STRAINER…..15349
        LUBRICATE CAB MOUNT PIN (LEFT AND RIGHT: 1 PLACE EACH)…..15349
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..15350
        CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL…..15351
        CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS…..15352
        CHECK FAN BELT TENSION, ADJUST…..15353
      EVERY 1000 HOURS SERVICE…..15354
        REPLACE CORROSION RESISTOR CARTRIDGE…..15354
        REPLACE TRANSMISSION FILTER ELEMENT…..15355
        CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER…..15356
        CHANGE OIL IN BRAKE OIL TANK, REPLACE BRAKE OIL FILTER ELEMENT…..15358
        LUBRICATION…..15360
        CHECK WEAR OF BRAKE DISC…..15361
        CHECK TIGHTENING PARTS OF TURBOCHARGER…..15361
      EVERY 2000 HOURS SERVICE…..15362
        CHANGE OIL IN FINAL DRIVE CASE…..15362
        CHANGE OIL IN DIFFERENTIAL CASE…..15363
        REPLACE HYDRAULIC FILTER ELEMENT…..15364
        CLEAN HYDRAULIC TANK STRAINER…..15365
        CLEAN STRAINER IN DIFFERENTIAL LOCK HYDRAULIC CIRCUIT…..15366
        CLEAN BREATHER…..15367
        CLEAN ENGINE BREATHER ELEMENT…..15369
        CHECK ALTERNATOR, STARTING MOTOR…..15369
        CHECK, ADJUST ENGINE VALVE CLEARANCE…..15369
        CHECK INJECTOR (EPA EXHAUST GAS REGULATION AREAS ONLY)…..15369
        CLEAN, CHECK TURBOCHARGER…..15369
        CHECK PLAY OF TURBOCHARGER ROTOR…..15369
      EVERY 4000 HOURS SERVICE…..15370
        CHANGE OIL IN HYDRAULIC TANK…..15370
        CHECK WATER PUMP…..15370
        CHECK AIR COMPRESSOR…..15370
        CHECK FAN PULLEY AND TENSION PULLEY…..15370
        CHECK VIBRATION DAMPER…..15370
        CHECK INJECTOR (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)…..15370
        REPLACE INJECTOR ASSEMBLY (EPA EXHAUST GAS REGULATION AREAS ONLY)…..15370
        CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..15371
        CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..15371
      EVERY 6000 HOURS SERVICE…..15372
        LUBRICATE DRIVE SHAFT…..15372
      EVERY 8000 HOURS SERVICE…..15373
        REPLACE INJECTOR NOZZLE TIP (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)…..15373
        REPLACE HIGH-PRESSURE PIPING CLAMP…..15373
        REPLACE FUEL SPRAY PREVENTION CAP…..15373
  SPECIFICATIONS…..15375
    SPECIFICATIONS…..15376
  ATTACHMENTS, OPTIONS…..15377
    HANDLING TACHOGRAPH (TCO20-90W)…..15378
      EXPLANATION OF COMPONENTS…..15378
      METHOD OF USE…..15381
  INDEX…..15385
TEN00349-00 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..15389
  COVER…..15389
  FOREWORD…..15390
    BEFORE READING THIS MANUAL…..15391
    SAFETY INFORMATION…..15392
    INTENDED USE…..15393
      USE OF MACHINE…..15393
      DIRECTIONS OF MACHINE…..15393
      VISIBILITY FROM OPERATOR&apos;S SEAT…..15393
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15394
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..15394
      EPA REGULATIONS, ENGINE NUMBER PLATE…..15394
      SERVICE METER POSITION…..15395
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15395
    CONTENTS…..15396
  SAFETY…..15400
    SAFETY…..15401
    SAFETY LABELS…..15404
      POSITION FOR ATTACHING SAFETY LABELS…..15405
      SAFETY LABELS…..15406
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..15412
      PRECAUTIONS BEFORE STARTING OPERATION…..15412
      PREPARATIONS FOR SAFE OPERATION…..15412
      FIRE PREVENTION…..15414
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..15415
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..15417
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..15417
      UNAUTHORIZED MODIFICATION…..15417
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..15418
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..15418
    PRECAUTIONS FOR OPERATION…..15419
      PRECAUTIONS FOR JOBSITE…..15419
      STARTING ENGINE…..15421
      OPERATION…..15424
      TRANSPORTATION…..15428
      TOWING…..15429
    PRECAUTIONS FOR MAINTENANCE…..15430
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..15430
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..15435
      TIRES…..15440
  OPERATION…..15442
    GENERAL VIEW…..15443
      GENERAL VIEW OF MACHINE…..15443
      GENERAL VIEW OF CONTROLS AND GAUGES…..15444
    EXPLANATION OF COMPONENTS…..15446
      MACHINE MONITOR…..15446
      OTHER FUNCTIONS OF MACHINE MONITOR…..15467
      SWITCHES…..15471
      CONTROL LEVERS AND PEDALS…..15482
      BODY PIVOT PIN…..15487
      ARTICULATE LOCK…..15487
      LOCATION OF FIRE EXTINGUISHER…..15488
      DUST INDICATOR…..15488
      CIRCUIT BREAKER…..15488
      FUSES…..15489
      CAR RADIO…..15492
      CAR STEREO…..15498
      AIR CONDITIONER…..15506
    OPERATION…..15511
      CHECK BEFORE STARTING ENGINE…..15511
      STARTING ENGINE…..15525
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..15527
      STOPPING ENGINE…..15528
      CHECKS AFTER STOPPING ENGINE…..15528
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..15529
      SHIFTING GEAR…..15534
      TRAVELING DOWNHILL…..15536
      STEERING THE MACHINE…..15542
      OPERATION USING DIFFERENTIAL LOCK…..15542
      LOADING OPERATIONS…..15545
      DUMP OPERATIONS…..15546
      CAB TILT OPERATION…..15548
      PRECAUTIONS FOR OPERATION…..15551
      PARKING MACHINE…..15552
      CHECKS AFTER COMPLETION OF WORK…..15553
      LOCKING…..15553
      HANDLING TIRES…..15554
    DETERMINING AND MAINTAINING TRAVEL ROAD…..15555
      DETERMINING TRAVEL ROAD…..15555
      MAINTAINING TRAVEL ROAD…..15555
    TRANSPORTATION…..15556
      PRECAUTIONS WHEN TRANSPORTING…..15556
      STEPS FOR TRANSPORTATION…..15556
      METHOD OF SECURING MACHINE…..15557
      METHOD OF LIFTING MACHINE…..15558
    COLD WEATHER OPERATION…..15562
      PRECAUTIONS FOR LOW TEMPERATURE…..15562
      PRECAUTIONS AFTER COMPLETION OF WORK…..15563
      AFTER COLD WEATHER…..15564
    LONG-TERM STORAGE…..15565
      BEFORE STORAGE…..15565
      DURING STORAGE…..15565
      AFTER STORAGE…..15565
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..15565
    TROUBLESHOOTING…..15566
      AFTER RUNNING OUT OF FUEL…..15566
      IF TRANSMISSION HAS TROUBLE…..15567
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..15567
      METHOD OF TOWING MACHINE…..15568
      IF BATTERY IS DISCHARGED…..15572
      OTHER TROUBLE…..15576
  MAINTENANCE…..15582
    GUIDES TO MAINTENANCE…..15583
    OUTLINE OF SERVICE…..15585
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..15585
      OUTLINE OF ELECTRIC SYSTEM…..15589
    WEAR PARTS…..15590
      WEAR PARTS LIST…..15590
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..15591
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..15592
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..15593
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..15594
      TORQUE LIST…..15594
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..15596
      SAFETY CRITICAL PARTS…..15597
    MAINTENANCE SCHEDULE CHART…..15598
      MAINTENANCE SCHEDULE CHART…..15598
    SERVICE PROCEDURE…..15601
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..15601
      WHEN REQUIRED…..15602
      CHECK BEFORE STARTING…..15618
      EVERY 50 HOURS SERVICE…..15619
      EVERY 250 HOURS SERVICE…..15620
      EVERY 500 HOURS SERVICE…..15634
      EVERY 1000 HOURS SERVICE…..15641
      EVERY 2000 HOURS SERVICE…..15652
      EVERY 4000 HOURS SERVICE…..15659
      EVERY 6000 HOURS SERVICE…..15662
      EVERY 8000 HOURS SERVICE…..15663
  SPECIFICATIONS…..15664
    SPECIFICATIONS…..15665
  ATTACHMENTS, OPTIONS…..15666
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..15667
      EXPLANATION OF COMPONENTS…..15667
      METHOD OF OPERATION…..15668
    USE OF REAR VIEW MONITOR…..15669
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..15669
      SETTING OF REAR VIEW MONITOR…..15672
      CAUTIONS WHEN USING REAR VIEW MONITOR…..15672
    HANDLING DUMPING COUNTER…..15673
    HANDLING BATTERY DISCONNECTOR SWITCH…..15674
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..15676
      BASIC PRECAUTIONS…..15676
  INDEX…..15678
TEN00443-07 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..15682
  COVER…..15682
  FOREWORD…..15683
    BEFORE READING THIS MANUAL…..15684
    SAFETY INFORMATION…..15685
    INTENDED USE…..15686
      USE OF MACHINE…..15686
      DIRECTIONS OF MACHINE…..15686
      VISIBILITY FROM OPERATOR&apos;S SEAT…..15687
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15688
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..15688
      EPA REGULATIONS, ENGINE NUMBER PLATE…..15688
      SERVICE METER POSITION…..15689
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15689
    CONTENTS…..15690
  SAFETY…..15693
    SAFETY…..15694
    SAFETY LABELS…..15697
      POSITION FOR ATTACHING SAFETY LABELS…..15698
      SAFETY LABELS…..15699
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..15705
      PRECAUTIONS BEFORE STARTING OPERATION…..15705
      PREPARATIONS FOR SAFE OPERATION…..15705
      FIRE PREVENTION…..15707
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..15708
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..15710
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..15710
      UNAUTHORIZED MODIFICATION…..15710
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..15711
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..15711
    PRECAUTIONS FOR OPERATION…..15712
      PRECAUTIONS FOR JOBSITE…..15712
      STARTING ENGINE…..15714
      OPERATION…..15717
      TRANSPORTATION…..15721
      TOWING…..15722
    PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..15728
    TIRES…..15733
  OPERATION…..15735
    GENERAL VIEW…..15736
      GENERAL VIEW OF MACHINE…..15736
      GENERAL VIEW OF CONTROLS AND GAUGES…..15737
    EXPLANATION OF COMPONENTS…..15739
      MACHINE MONITOR…..15739
      OTHER FUNCTIONS OF MACHINE MONITOR…..15760
      SWITCHES…..15764
      CONTROL LEVERS AND PEDALS…..15775
      BODY PIVOT PIN…..15780
      ARTICULATE LOCK…..15780
      LOCATION OF FIRE EXTINGUISHER…..15781
      DUST INDICATOR…..15781
      CIRCUIT BREAKER…..15781
      FUSES…..15782
      CAR RADIO…..15785
      CAR STEREO…..15791
      AIR CONDITIONER…..15799
    OPERATION…..15804
      CHECK BEFORE STARTING ENGINE…..15804
      STARTING ENGINE…..15819
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..15821
      STOPPING ENGINE…..15822
      CHECKS AFTER STOPPING ENGINE…..15822
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..15823
      SHIFTING GEAR…..15828
      TRAVELING DOWNHILL…..15830
      STEERING THE MACHINE…..15836
      OPERATION USING DIFFERENTIAL LOCK…..15837
      LOADING OPERATIONS…..15840
      DUMP OPERATIONS…..15841
      CAB TILT OPERATION…..15843
      PRECAUTIONS FOR OPERATION…..15846
      PARKING MACHINE…..15847
      CHECKS AFTER COMPLETION OF WORK…..15848
      LOCKING…..15848
      HANDLING TIRES…..15849
    DETERMINING AND MAINTAINING TRAVEL ROAD…..15850
      DETERMINING TRAVEL ROAD…..15850
      MAINTAINING TRAVEL ROAD…..15850
    TRANSPORTATION…..15851
      PRECAUTIONS WHEN TRANSPORTING…..15851
      STEPS FOR TRANSPORTATION…..15851
      METHOD OF SECURING MACHINE…..15852
      METHOD OF LIFTING MACHINE…..15853
    COLD WEATHER OPERATION…..15857
      PRECAUTIONS FOR LOW TEMPERATURE…..15857
      PRECAUTIONS AFTER COMPLETION OF WORK…..15858
      AFTER COLD WEATHER…..15859
    LONG-TERM STORAGE…..15860
      BEFORE STORAGE…..15860
      DURING STORAGE…..15860
      AFTER STORAGE…..15860
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..15860
    TROUBLESHOOTING…..15861
      AFTER RUNNING OUT OF FUEL…..15861
      IF TRANSMISSION HAS TROUBLE…..15862
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..15862
      METHOD OF TOWING MACHINE…..15863
      IF BATTERY IS DISCHARGED…..15867
      OTHER TROUBLE…..15871
  MAINTENANCE…..15877
    GUIDES TO MAINTENANCE…..15878
    OUTLINE OF SERVICE…..15880
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..15880
      OUTLINE OF ELECTRIC SYSTEM…..15884
    WEAR PARTS…..15885
      WEAR PARTS LIST…..15885
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..15886
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..15887
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..15889
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..15890
      TORQUE LIST…..15890
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..15892
      SAFETY CRITICAL PARTS…..15893
    MAINTENANCE SCHEDULE CHART…..15894
      MAINTENANCE SCHEDULE CHART…..15894
    SERVICE PROCEDURE…..15897
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..15897
      WHEN REQUIRED…..15898
      CHECK BEFORE STARTING…..15915
      EVERY 50 HOURS SERVICE…..15916
      EVERY 250 HOURS SERVICE…..15917
      EVERY 500 HOURS SERVICE…..15931
      EVERY 1000 HOURS SERVICE…..15938
      EVERY 2000 HOURS SERVICE…..15957
      EVERY 4000 HOURS SERVICE…..15964
      EVERY 6000 HOURS SERVICE…..15967
      EVERY 8000 HOURS SERVICE…..15968
  SPECIFICATIONS…..15969
    SPECIFICATIONS…..15972
  ATTACHMENTS, OPTIONS…..15973
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..15974
      EXPLANATION OF COMPONENTS…..15974
      METHOD OF OPERATION…..15975
    USE OF REAR VIEW MONITOR…..15976
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..15976
      SETTING OF REAR VIEW MONITOR…..15979
      CAUTIONS WHEN USING REAR VIEW MONITOR…..15979
    HANDLING DUMPING COUNTER…..15980
    HANDLING BATTERY DISCONNECTOR SWITCH…..15981
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..15983
      BASIC PRECAUTIONS…..15983
  INDEX…..15985
TEN00443-11 – Articulated Dump Truck HM350-2 Operation & Maintenance Manual…..15989
  COVER…..15989
  FOREWORD…..15990
    BEFORE READING THIS MANUAL…..15991
    SAFETY INFORMATION…..15992
    INTENDED USE…..15993
      USE OF MACHINE…..15993
      DIRECTIONS OF MACHINE…..15993
      VISIBILITY FROM OPERATOR&apos;S SEAT…..15994
    LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15995
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..15995
      EPA REGULATIONS, ENGINE NUMBER PLATE…..15995
      SERVICE METER POSITION…..15996
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..15996
    CONTENTS…..15997
  SAFETY…..16000
    SAFETY…..16001
    SAFETY LABELS…..16004
      POSITION FOR ATTACHING SAFETY LABELS…..16005
      SAFETY LABELS…..16006
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..16012
      PRECAUTIONS BEFORE STARTING OPERATION…..16012
      PREPARATIONS FOR SAFE OPERATION…..16012
      FIRE PREVENTION…..16014
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..16015
      DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…..16017
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..16017
      UNAUTHORIZED MODIFICATION…..16017
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..16018
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..16018
    PRECAUTIONS FOR OPERATION…..16019
      PRECAUTIONS FOR JOBSITE…..16019
      STARTING ENGINE…..16021
      OPERATION…..16024
      TRANSPORTATION…..16028
      TOWING…..16029
    PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..16035
    TIRES…..16040
  OPERATION…..16042
    GENERAL VIEW…..16043
      GENERAL VIEW OF MACHINE…..16043
      GENERAL VIEW OF CONTROLS AND GAUGES…..16044
    EXPLANATION OF COMPONENTS…..16046
      MACHINE MONITOR…..16046
      OTHER FUNCTIONS OF MACHINE MONITOR…..16067
      SWITCHES…..16071
      CONTROL LEVERS AND PEDALS…..16082
      BODY PIVOT PIN…..16087
      ARTICULATE LOCK…..16087
      LOCATION OF FIRE EXTINGUISHER…..16088
      DUST INDICATOR…..16088
      CIRCUIT BREAKER…..16088
      FUSES…..16089
      CAR RADIO…..16092
      CAR STEREO…..16098
      AIR CONDITIONER…..16106
    OPERATION…..16111
      CHECK BEFORE STARTING ENGINE…..16111
      STARTING ENGINE…..16126
      OPERATIONS, CHECKS AFTER STARTING ENGINE…..16128
      STOPPING ENGINE…..16129
      CHECKS AFTER STOPPING ENGINE…..16129
      MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…..16130
      SHIFTING GEAR…..16135
      TRAVELING DOWNHILL…..16137
      STEERING THE MACHINE…..16143
      OPERATION USING DIFFERENTIAL LOCK…..16144
      LOADING OPERATIONS…..16147
      DUMP OPERATIONS…..16148
      CAB TILT OPERATION…..16150
      PRECAUTIONS FOR OPERATION…..16153
      PARKING MACHINE…..16154
      CHECKS AFTER COMPLETION OF WORK…..16155
      LOCKING…..16155
      HANDLING TIRES…..16156
    DETERMINING AND MAINTAINING TRAVEL ROAD…..16157
      DETERMINING TRAVEL ROAD…..16157
      MAINTAINING TRAVEL ROAD…..16157
    TRANSPORTATION…..16158
      PRECAUTIONS WHEN TRANSPORTING…..16158
      STEPS FOR TRANSPORTATION…..16158
      METHOD OF SECURING MACHINE…..16159
      METHOD OF LIFTING MACHINE…..16160
    COLD WEATHER OPERATION…..16164
      PRECAUTIONS FOR LOW TEMPERATURE…..16164
      PRECAUTIONS AFTER COMPLETION OF WORK…..16165
      AFTER COLD WEATHER…..16166
    LONG-TERM STORAGE…..16167
      BEFORE STORAGE…..16167
      DURING STORAGE…..16167
      AFTER STORAGE…..16167
      PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…..16167
    TROUBLESHOOTING…..16168
      AFTER RUNNING OUT OF FUEL…..16168
      IF TRANSMISSION HAS TROUBLE…..16169
      METHOD OF LOWERING DUMP BODY IN EMERGENCY…..16169
      METHOD OF TOWING MACHINE…..16170
      IF BATTERY IS DISCHARGED…..16174
      OTHER TROUBLE…..16178
  MAINTENANCE…..16184
    GUIDES TO MAINTENANCE…..16185
    OUTLINE OF SERVICE…..16187
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..16187
      OUTLINE OF ELECTRIC SYSTEM…..16191
    WEAR PARTS…..16192
      WEAR PARTS LIST…..16192
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..16193
      USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..16194
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..16196
    STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..16197
      TORQUE LIST…..16197
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..16199
      SAFETY CRITICAL PARTS…..16200
    MAINTENANCE SCHEDULE CHART…..16201
      MAINTENANCE SCHEDULE CHART…..16201
    SERVICE PROCEDURE…..16204
      INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…..16204
      WHEN REQUIRED…..16205
      CHECK BEFORE STARTING…..16222
      EVERY 50 HOURS SERVICE…..16223
      EVERY 250 HOURS SERVICE…..16224
      EVERY 500 HOURS SERVICE…..16238
      EVERY 1000 HOURS SERVICE…..16245
      EVERY 2000 HOURS SERVICE…..16264
      EVERY 4000 HOURS SERVICE…..16271
      EVERY 6000 HOURS SERVICE…..16274
      EVERY 8000 HOURS SERVICE…..16275
  SPECIFICATIONS…..16276
    SPECIFICATIONS…..16279
  ATTACHMENTS, OPTIONS…..16280
    HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…..16281
      EXPLANATION OF COMPONENTS…..16281
      METHOD OF OPERATION…..16282
    USE OF REAR VIEW MONITOR…..16283
      NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…..16283
      SETTING OF REAR VIEW MONITOR…..16286
      CAUTIONS WHEN USING REAR VIEW MONITOR…..16286
    HANDLING DUMPING COUNTER…..16287
    HANDLING BATTERY DISCONNECTOR SWITCH…..16288
    HANDLING MACHINES EQUIPPED WITH KOMTRAX…..16290
      BASIC PRECAUTIONS…..16290
  INDEX…..16292

Komatsu Articulated Dump Truck HM350 Repair Service Manuals

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