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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'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'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'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'S CAB…..1991
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…..1996
DISASSEMBLY AND ASSEMBLY OF OPERATOR'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
<A>…..2358
<B>…..2358
<C>…..2358
<D>…..2358
<E>…..2358
<F>…..2358
<G>…..2358
<H>…..2358
<I>…..2358
<L>…..2358
<M>…..2358
<O>…..2358
<P>…..2359
<R>…..2359
<S>…..2359
<T>…..2359
<W>…..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
<A>…..2606
<C>…..2606
<D>…..2606
<E>…..2606
<F>…..2606
<G>…..2606
<H>…..2606
<I>…..2606
<L>…..2606
<M>…..2606
<O>…..2606
<P>…..2606
<S>…..2607
<T>…..2607
<U>…..2607
<W>…..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'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
<A>…..2938
<B>…..2938
<C>…..2938
<D>…..2938
<E>…..2938
<F>…..2938
<G>…..2938
<H>…..2938
<I>…..2938
<L>…..2938
<M>…..2939
<O>…..2939
<P>…..2939
<R>…..2939
<S>…..2939
<T>…..2939
<U>…..2939
<W>…..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
<A>…..3186
<B>…..3186
<C>…..3186
<D>…..3186
<E>…..3186
<F>…..3186
<I>…..3186
<L>…..3186
<M>…..3186
<O>…..3186
<P>…..3186
<S>…..3187
<T>…..3187
<U>…..3187
<V>…..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
<A>…..3484
<B>…..3484
<C>…..3484
<D>…..3484
<E>…..3484
<F>…..3484
<I>…..3484
<L>…..3484
<M>…..3484
<O>…..3484
<P>…..3485
<R>…..3485
<S>…..3485
<T>…..3485
<U>…..3485
<V>…..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
<A>…..3824
<B>…..3824
<C>…..3824
<D>…..3824
<E>…..3824
<F>…..3824
<I>…..3824
<L>…..3824
<M>…..3824
<O>…..3825
<P>…..3825
<R>…..3825
<S>…..3825
<T>…..3825
<U>…..3825
<V>…..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
<A>…..4156
<B>…..4156
<C>…..4156
<D>…..4156
<E>…..4156
<F>…..4156
<I>…..4156
<L>…..4156
<M>…..4156
<O>…..4157
<P>…..4157
<R>…..4157
<S>…..4157
<T>…..4157
<U>…..4157
<V>…..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'S COMPARTMENT…..4241
ALWAYS APPLY LOCK LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..4247
EMERGENCY ESCAPE FROM OPERATOR'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'S COMPARTMENT…..4800
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..4806
EMERGENCY ESCAPE FROM OPERATOR'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'S COMPARTMENT…..5089
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..5095
EMERGENCY ESCAPE FROM OPERATOR'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'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'S COMPARTMENT…..5963
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..5969
EMERGENCY ESCAPE FROM OPERATOR'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'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'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'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'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'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'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'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'S COMPARTMENT…..14539
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..14545
EMERGENCY ESCAPE FROM OPERATOR'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'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'S COMPARTMENT…..15133
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'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'S SIGNALS AND SIGNS…..15139
EMERGENCY ESCAPE FROM OPERATOR'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'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'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'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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