SEN03017-13
ARTICULATED DUMP TRUCK
HM350 -2R SERIAL NUMBERS
7001
and up
SEN03019-13
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM350-2R
Machine model
Serial number
HM350-2R
7001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
HM350-2R
1
SEN03019-13
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN03017-13
00 Index and foreword Index Foreword and general information
SEN03018-13 SEN03019-13 SEN03020-04
01 Specification Specification and technical data
SEN03021-00 SEN03022-00
10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Brake system Undercarriage and frame Hydraulic system Cab and its attachments Electrical system, Part 1 Electrical system, Part 2 Electrical system, Part 3
SEN03023-01 SEN03024-00 SEN03025-01 SEN03026-01 SEN03027-00 SEN03028-00 SEN03029-00 SEN03030-00 SEN03031-00 SEN03032-00 SEN03033-00 SEN03034-00
20 Standard value table Standard service value table 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code (Display of code), Part 1 Troubleshooting by failure code (Display of code), Part 2 Troubleshooting by failure code (Display of code), Part 3 Troubleshooting by failure code (Display of code), Part 4 Troubleshooting by failure code (Display of code), Part 5 Troubleshooting by failure code (Display of code), Part 6 Troubleshooting by failure code (Display of code), Part 7 Troubleshooting by failure code (Display of code), Part 8 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)
2
SEN03035-00 SEN03347-00 SEN03036-05 SEN03348-05 SEN03349-03 SEN03350-01 SEN03037-05 SEN03351-01 SEN03352-03 SEN03353-02 SEN03354-02 SEN03355-02 SEN03356-03 SEN03357-03 SEN03358-01 SEN03359-01 SEN03360-02 SEN03361-01 SEN03362-00 SEN03363-01
HM350-2R
00 Index and foreword
SEN03019-13
50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system (SAA6D140E-5) Engine (SAA6D140E-5) Power train, Part 1 Power train, Part 2 (Differential) Power train, Part 3 (Final drive, brake, axle) Undercarriage and frame Hydraulic system Cab and its attachments Electrical system
SEN03038-08 SEN04135-04 SEN04136-00 SEN04137-02 SEN04138-02 SEN04139-01 SEN04140-03 SEN04141-03 SEN04142-00 SEN04143-01 SEN04144-00
90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
SEN03039-03 SEN03040-00 SEN03041-03
HM350-2R
3
SEN03019-13
00 Index and foreword
Table of contents 00 Index and foreword Index SEN03019-13 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN03020-04 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 8 Explanation of terms for maintenance standard.......................................................................... 10 Handling of electric equipment and hydraulic component........................................................... 12 Handling of connectors newly used for engines .......................................................................... 21 How to read electric wire code .................................................................................................... 24 Precautions when carrying out operation .................................................................................... 27 Method of disassembling and connecting push-pull type coupler ............................................... 30 Standard tightening torque table ................................................................................................. 33 Conversion table ......................................................................................................................... 37 01 Specification Specification and technical data SEN03022-00 Specification drawings................................................................................................................. 2 Specifications .............................................................................................................................. 3 Weight table ................................................................................................................................ 6 Fuel, coolant and lubricants ........................................................................................................ 7 10 Structure, function and maintenance standard Engine and cooling system SEN03024-00 Radiator, oil cooler, aftercooler.................................................................................................... 2 Output shaft................................................................................................................................. 3 Power train, Part 1 SEN03025-01 Power train skeleton.................................................................................................................... 2 Torque converter and transmission hydraulic piping ................................................................... 6 Brake cooling oil control valve (BCV) .......................................................................................... 8 Power train pump ........................................................................................................................ 9 Torque converter ......................................................................................................................... 12 Transmission ............................................................................................................................... 18 Transmission control valve .......................................................................................................... 46 ECMV .......................................................................................................................................... 47 Main relief, torque converter relief valve ..................................................................................... 54 Power train, Part 2 SEN03026-01 Drive shaft ................................................................................................................................... 2 Axle ............................................................................................................................................. 6 Differential ................................................................................................................................... 10 Limited slip differential................................................................................................................. 24 Final drive.................................................................................................................................... 28 Steering system SEN03027-00 Steering column .......................................................................................................................... 2 Brake system SEN03028-00 Brake piping ................................................................................................................................ 2 Brake valve.................................................................................................................................. 4 Accumulator charge valve ........................................................................................................... 7 Accumulator ................................................................................................................................ 11 Slack adjuster.............................................................................................................................. 12 Brake ........................................................................................................................................... 14 Proportional reducing valve......................................................................................................... 19
4
HM350-2R
This is the sample of the manual Click on the download link for complete manual
Download Link
00 Index and foreword
SEN03019-13
Brake system tank....................................................................................................................... 20 Parking brake .............................................................................................................................. 22 Parking brake caliper .................................................................................................................. 24 Spring cylinder ............................................................................................................................ 25 Parking brake solenoid................................................................................................................ 26 Undercarriage and frame SEN03029-00 Suspension ................................................................................................................................. 2 Suspension cylinder .................................................................................................................... 7 Oscillation hitch ........................................................................................................................... 9 Hydraulic system SEN03030-00 Steering, hoist oil hydraulic piping diagram................................................................................. 2 Dump body control ...................................................................................................................... 3 Hydraulic tank and filter............................................................................................................... 4 Flow amp valve ........................................................................................................................... 5 Steering valve ............................................................................................................................. 8 Steering cylinder ......................................................................................................................... 12 Hoist valve................................................................................................................................... 14 EPC valve ................................................................................................................................... 20 Pilot check valve ......................................................................................................................... 21 Hoist cylinder............................................................................................................................... 22 Hydraulic pump ........................................................................................................................... 23 Cab and its attachments SEN03031-00 ROPS cab ................................................................................................................................... 2 Cab tilt ......................................................................................................................................... 3 Air conditioner ............................................................................................................................. 4 Rear view monitor ....................................................................................................................... 12 Controller related......................................................................................................................... 15 Electrical system, Part 1 SEN03032-00 Machine monitor system ............................................................................................................. 2 Electrical system, Part 2 SEN03033-00 Automatic shift control system .................................................................................................... 2 Transmission controller ............................................................................................................... 5 Retarder control system .............................................................................................................. 34 Auto emergency steering system................................................................................................ 46 Dump control lever ...................................................................................................................... 47 Electrical system, Part 3 SEN03034-00 Sensors, switches ....................................................................................................................... 2 KOMTRAX terminal system (if equipped) ................................................................................... 9 20 Standard value table Standard service value table SEN03347-00 Standard value table for engine .................................................................................................. 2 Standard value table for chassis ................................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN03348-05 Precautions before work ............................................................................................................. 3 Tools for testing, adjusting, and troubleshooting ......................................................................... 4 Sketches of special tools............................................................................................................. 9 Measuring engine speed............................................................................................................. 10 Testing intake air pressure (boost pressure) ............................................................................... 11 Testing exhaust temperature....................................................................................................... 12 Testing exhaust gas color............................................................................................................ 13 Adjusting valve clearance ........................................................................................................... 14 Testing compression pressure .................................................................................................... 15 Testing blow-by pressure ............................................................................................................ 17 HM350-2R
5
SEN03019-13
00 Index and foreword
Testing engine oil pressure.......................................................................................................... 18 Handling of fuel system devices.................................................................................................. 19 Releasing residual pressure from fuel system ............................................................................ 19 Testing fuel pressure ................................................................................................................... 20 Testing fuel return and leakage amount ...................................................................................... 21 Bleeding air from fuel circuit ........................................................................................................ 24 Testing the fuel circuit for leakage ............................................................................................... 26 Testing and adjusting fan belt tension ......................................................................................... 27 Testing and adjusting alternator belt tension ............................................................................... 28 Testing and adjusting air conditioner compressor belt tension.................................................... 29 Adjusting the shims in the body mount........................................................................................ 30 Testing and adjusting, Part 2 SEN03349-03 Testing torque converter stall speed............................................................................................ 3 Testing power train oil pressure................................................................................................... 4 Testing and adjusting of differential lock oil pressure (differential lock spec.) ............................. 12 Adjusting transmission speed sensor.......................................................................................... 17 Testing and adjusting brake oil pressure ..................................................................................... 19 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ......................................................................................................................... 23 Testing brake performance.......................................................................................................... 31 Releasing remaining pressure in brake circuit ............................................................................ 32 Bleeding air from brake circuit..................................................................................................... 33 Testing wear of wheel brake disc ................................................................................................ 34 Testing the parking brake pad wear ............................................................................................ 35 Emergency release of the parking brake..................................................................................... 36 Testing and adjusting steering circuit oil pressure....................................................................... 37 Testing and adjusting suspension cylinder .................................................................................. 39 Method of tilting cab up ............................................................................................................... 43 Testing and adjusting dump circuit oil pressure........................................................................... 45 Adjusting body positioner sensor ................................................................................................ 47 Adjusting length of spring in body heating spherical joint............................................................ 48 Adjustment of tilt lock lever of steering wheel ............................................................................. 49 Handling of voltage circuit of engine controller............................................................................ 50 Adjusting transmission controller................................................................................................. 50 Method for emergency escape at electrical system failure ......................................................... 51 Testing and adjusting, Part 3 SEN03350-01 Setting and adjusting various equipments................................................................................... 2 Special function of machine monitor ........................................................................................... 11 How to start operation of KOMTRAX terminal............................................................................. 55 Lamp display of KOMTRAX terminal........................................................................................... 60 Pm Clinic check sheet ................................................................................................................. 63 40 Troubleshooting Failure code table and fuse locations SEN03351-01 Failure codes table ...................................................................................................................... 2 Fuse locations ............................................................................................................................. 9 General information on troubleshooting SEN03352-03 Precautions before work.............................................................................................................. 2 Points to remember when performing troubleshooting................................................................ 3 How to proceed in troubleshooting.............................................................................................. 5 Check before troubleshooting ..................................................................................................... 7 Classification and procedures of troubleshooting........................................................................ 8 Information in troubleshooting table ............................................................................................ 12 Troubleshooting method for disconnecting wiring harness of pressure sensor system .............. 14 Phenomena looking like troubles and troubleshooting Nos. ....................................................... 17 Connection table for connector pin numbers............................................................................... 19 T- branch box and T- branch adapter table ................................................................................. 55
6
HM350-2R
00 Index and foreword
SEN03019-13
Troubleshooting by failure code (Display of code), Part 1 SEN03353-02 Failure code [1500L0] Detecting dual engagement .................................................................... 3 Failure code [15B0NX] Transmission oil filter: Clogging ............................................................. 4 Failure code [15F0KM] R o F gear shift abuse 1 ....................................................................... 6 Failure code [15F0MB] R o F gear shift abuse 2 ....................................................................... 6 Failure code [15F7KM] Transmission forward clutch abuse ....................................................... 7 Failure code [15G0MW] Reverse clutch system failure (Slip is detected) .................................. 8 Failure code [15G7KM] Transmission reverse clutch abuse....................................................... 10 Failure code [15H0MW] Hi clutch system failure (Slip is detected)............................................. 12 Failure code [15J0MW] Lo clutch system failure (Slip is detected)............................................. 14 Failure code [15K0MW] 1st clutch system failure (Slip is detected) ........................................... 16 Failure code [15L0MW] 2nd clutch system failure (Slip is detected)........................................... 18 Failure code [15M0MW] 3rd clutch system failure (Slip is detected) .......................................... 20 Failure code [15SBL1] Reverse clutch pressure control valve failure ...................................... 22 Failure code [15SBMA] Reverse clutch pressure control valve failure .................................... 25 Failure code [15SCL1] Hi clutch pressure control valve failure ................................................ 26 Failure code [15SCMA] Hi clutch pressure control valve failure .............................................. 29 Failure code [15SDL1] Lo clutch pressure control valve failure ............................................... 30 Failure code [15SDMA] Lo clutch pressure control valve failure ............................................. 33 Troubleshooting by failure code (Display of code), Part 2 SEN03354-02 Failure code [15SEL1] 1st clutch pressure control valve failure ............................................... 4 Failure code [15SEMA] 1st clutch pressure control valve failure ............................................. 7 Failure code [15SFL1] 2nd clutch pressure control valve failure .............................................. 8 Failure code [15SFMA] 2nd clutch pressure control valve failure ............................................ 11 Failure code [15SGL1] 3rd clutch pressure control valve failure .............................................. 12 Failure code [15SGMA] 3rd clutch pressure control valve failure ............................................ 15 Failure code [15SJMA] Lockup clutch pressure control valve failure ...................................... 16 Failure code [15SKMA] Interaxle differential lock clutch pressure control valve failure ........... 18 Failure code [2A62L1] Front wheel differential lock pressure control valve failure .................. 20 Failure code [2A62LH] Front wheel differential lock pressure control valve failure .................. 22 Failure code [2B62L1] Rear wheel differential lock pressure control valve failure .................. 24 Failure code [2B62LH] Rear wheel differential lock pressure control valve failure ................... 26 Failure code [2C4MNX] Retarder cooling oil filter clogging......................................................... 28 Failure code [2F00KM] Dragging of parking brake ..................................................................... 30 Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ......................................... 32 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) .......................................... 32 Failure code [989A00] Engine overrun prevention activated ...................................................... 33 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) ................ 33 Failure code [A570NX] Engine oil filter clogging ......................................................................... 34 Failure code [AA10NX] Air cleaner clogging ............................................................................... 36 Failure code [AB00MA] Battery charge circuit failure.................................................................. 38 Failure code [B@BAZG] Lowering of engine oil pressure........................................................... 39 Failure code [B@BAZK] Lowering of engine oil level.................................................................. 40 Failure code [B@BCNS] Engine overheat .................................................................................. 41 Failure code [B@BCZK] Lowering of coolant level ..................................................................... 42 Failure code [B@C6NS] Overheat of brake cooling oil temperature (front) ................................ 44 Failure code [B@C8NS] Overheat of brake cooling oil temperature (center) ............................. 44 Failure code [B@CENS] Overheat of torque converter oil temperature ..................................... 45 Failure code [B@JANS] Overheat of steering oil temperature.................................................... 45 Troubleshooting by failure code (Display of code), Part 3 SEN03355-02 Failure code [CA111] Abnormality in engine controller................................................................ 4 Failure code [CA115] Engine Ne or Bkup speed sensor error .................................................... 6 Failure code [CA122] Charge (boost) pressure sensor high error .............................................. 8 Failure code [CA123] Charge (boost) pressure sensor low error................................................ 10 Failure code [CA131] Throttle sensor high error ......................................................................... 12 Failure code [CA132] Throttle sensor low error .......................................................................... 14 Failure code [CA135] Engine oil pressure sensor high error ...................................................... 16
HM350-2R
7
SEN03019-13
00 Index and foreword
Failure code [CA141] Engine oil pressure sensor low error ........................................................ 18 Failure code [CA144] Coolant temperature sensor high error..................................................... 20 Failure code [CA145] Coolant temperature sensor low error ...................................................... 22 Failure code [CA153] Charge (boost) temperature sensor high error ......................................... 24 Failure code [CA154] Charge (boost) temperature sensor low error .......................................... 26 Failure code [CA187] Sensor power supply 2 low error .............................................................. 28 Failure code [CA221] Atmospheric pressure sensor high error................................................... 30 Failure code [CA222] Atmospheric pressure sensor low error .................................................... 32 Failure code [CA227] Sensor power supply 2 high error............................................................. 34 Failure code [CA234] Engine overspeed..................................................................................... 35 Failure code [CA238] Ne speed sensor power supply error........................................................ 36 Failure code [CA263] Fuel Temperature Sensor High Error........................................................ 38 Failure code [CA265] Fuel Temperature Sensor Low Error ........................................................ 40 Failure code [CA271] PCV1 Short circuit .................................................................................... 42 Failure code [CA272] PCV1 Disconnection................................................................................. 43 Failure code [CA273] PCV2 Short circuit .................................................................................... 44 Failure code [CA274] PCV2 Disconnection................................................................................. 45 Failure code [CA322] Injector #1 open/short error ...................................................................... 46 Failure code [CA323] Injector #5 open/short error ...................................................................... 48 Failure code [CA324] Injector #3 open/short error ...................................................................... 50 Failure code [CA325] Injector #6 open/short error ...................................................................... 52 Failure code [CA331] Injector #2 open/short error ...................................................................... 54 Failure code [CA332] Injector #4 open/short error ...................................................................... 56 Failure code [CA342] Calibration code inconsistency ................................................................. 58 Failure code [CA351] Injectors drive circuit error ........................................................................ 59 Failure code [CA352] Sensor power supply 1 low error .............................................................. 60 Failure code [CA386] Sensor power supply 1 high error............................................................. 62 Troubleshooting by failure code (Display of code), Part 4 SEN03356-03 Failure code [CA431] Idle validation switch error ........................................................................ 3 Failure code [CA432] Idle validation action error ........................................................................ 6 Failure code [CA441] Battery voltage low error........................................................................... 9 Failure code [CA442] Battery voltage high error ......................................................................... 10 Failure code [CA449] Common rail pressure high error 2........................................................... 11 Failure code [CA451] Common rail pressure sensor high error .................................................. 12 Failure code [CA452] Common rail pressure sensor low error ................................................... 14 Failure code [CA553] Common rail pressure high error 1........................................................... 16 Failure code [CA554] Common rail pressure sensor in range error............................................ 17 Failure code [CA559] Supply pump pressure very low error 1.................................................... 18 Failure code [CA689] Engine Ne speed sensor error.................................................................. 22 Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 24 Failure code [CA757] All continuous data lost error .................................................................... 25 Failure code [CA778] Engine Bkup speed sensor error .............................................................. 26 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 28 Failure code [CA2185] Throttle sensor power supply voltage high error .................................... 30 Failure code [CA2186] Throttle sensor power supply voltage low error ...................................... 32 Failure code [CA2249] Supply pump pressure very low error 2.................................................. 34 Failure code [CA2555] Intake air heater relay open circuit error................................................. 36 Failure code [CA2556] Intake air heater relay short circuit error................................................. 38 Troubleshooting by failure code (Display of code), Part 5 SEN03357-03 Failure code [DAF9KM] Wrong connection of connector ............................................................ 4 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication..................................................................................................... 5 Failure code [DAQ0KK] Lowering of source voltage ................................................................... 6 Failure code [DAQ0KT] Trouble in non-volatile memory ............................................................. 8 Failure code [DAQ2KK] Trouble in solenoid power supply system ............................................. 10 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)................. 12 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication..................................................................................................... 14
8
HM350-2R
00 Index and foreword
SEN03019-13
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ................... 19 Failure code [DB10KT] Trouble in non-volatile memory.............................................................. 19 Failure code [DB12KK] Trouble in solenoid power supply system.............................................. 20 Failure code [DB13KK] Lowering of battery direct voltage.......................................................... 22 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 24 Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ........................... 25 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled .... 26 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled...... 30 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal ................... 36 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve .................................................. 38 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve................................................... 39 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve ................................................. 40 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve ................................................ 41 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve ................................................ 42 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve .......................................... 43 Failure code [DF10KA] Input of no lever signals ......................................................................... 44 Failure code [DF10KB] Input of multiple lever signals ................................................................ 48 Failure code [DGF1KX] Transmission oil temperature out of range............................................ 52 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) .......................... 54 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) ........................ 56 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) ............................. 58 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................... 60 Failure code [DGR6KX] Steering oil temperature out of range ................................................... 62 Troubleshooting by failure code (Display of code), Part 6 SEN03358-01 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system ........... 4 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system ....................................................................................................... 6 Failure code [DHT5L6] Torque converter oil pressure sensor failure .......................................... 8 Failure code [DHU2KX] Accumulator oil pressure sensor (front) system failure ......................... 10 Failure code [DHU3KX] Accumulator oil pressure sensor (rear) system failure.......................... 12 Failure code [DJF1KA] Disconnection in fuel level sensor system ............................................. 14 Failure code [DK51L5] Manual retarder potentiometer and RVS failure ..................................... 16 Failure code [DK52KX] Dump lever potentiometer 1 failure ....................................................... 18 Failure code [DK53L8] Dump lever potentiometer 2 failure ........................................................ 20 Failure code [DK54KX] Body positioner sensor failure ............................................................... 22 Failure code [DKH0KX] Pitch angle sensor signal out of range.................................................. 24 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system........... 26 Failure code [DLF1LC] Transmission input shaft speed sensor failure....................................... 27 Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system...................................................................................................................... 28 Failure code [DLF2LC] Transmission intermediate shaft speed sensor failure ........................... 29 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system........... 30 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system......... 31 Failure code [DV00KB] Short circuit in buzzer output circuit....................................................... 32 Failure code [DW72KZ] Kick-out solenoid output system failure (disconnection or ground fault) ............................................................................................ 34 Failure code [DW73KZ] Dump selector valve output system failure ........................................... 36 Failure code [DW78KZ] Rear wheel BCV command output system failure ................................ 38 Failure code [DW79KZ] Front wheel BCV command output system failure................................ 40 Failure code [DX11K4] Rear wheel proportional solenoid pressure reducing valve failure 1...... 42 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve....................................................................................................... 44 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve....................................................................................................... 46 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve....................................................................................................... 48 Failure code [DX11MA] Rear wheel proportional solenoid pressure reducing valve failure 2..... 50 Failure code [DX12K4] Front wheel proportional solenoid pressure reducing valve failure 1 ..... 52 HM350-2R
9
SEN03019-13
00 Index and foreword
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve ....................................................................................................... 54 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve ....................................................................................................... 56 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve ....................................................................................................... 58 Failure code [DX12MA] Front wheel proportional solenoid pressure reducing valve failure 2 .... 60 Troubleshooting by failure code (Display of code), Part 7 SEN03359-01 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve ............................... 4 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve .................................. 6 Failure code [DX13KY] Hot short in output circuit of dump EPC valve ....................................... 8 Failure code [DX14KZ] Rear wheel differential lock command output system failure ................. 10 Failure code [DX15KZ] Front wheel differential lock command output system failure ................ 12 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid ..................................................................................................................... 14 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid ..................................................................................................................... 16 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid .. 18 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid ...................... 20 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid ......................... 22 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid .............................. 24 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch ECMV solenoid.................. 26 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid..................... 28 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid.......................... 30 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch ECMV solenoid ................. 32 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid .................... 34 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid ......................... 36 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch ECMV solenoid ................ 38 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid ................... 40 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid ........................ 42 Troubleshooting by failure code (Display of code), Part 8 SEN03360-02 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid ............... 2 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid .................. 4 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid ....................... 6 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid ................ 8 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid................... 10 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid ........................ 12 Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid........ 14 Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid........... 16 Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid................ 18 Troubleshooting of electrical system (E-mode) SEN03361-01 Before troubleshooting for electrical system ............................................................................... 3 Information in troubleshooting table ............................................................................................ 9 E-1 Engine does not start............................................................................................................ 10 E-2 Auto preheater does not operate .......................................................................................... 15 E-3 When starting switch is turned ON, machine monitor displays nothing ................................ 18 E-4 When starting switch is turned OFF, machine monitor cannot be operated ......................... 20 E-5 Alarm buzzer does not sound ............................................................................................... 22 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section............................................................................................... 24 E-7 Display of character display section cannot be changed...................................................... 25 E-8 Power mode selection function does not operate normally .................................................. 28 E-9 AISS function does not operate normally.............................................................................. 30 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) ........................................................................................ 32 E-11 Interaxle differential lock-up function does not operate normally ........................................ 36 E-12 Display of seat belt caution lamp is abnormal .................................................................... 38
10
HM350-2R
00 Index and foreword
SEN03019-13
E-13 Both turn signal lamps and hazard lamps do not operate normally.................................... 40 E-14 Night lighting is abnormal ................................................................................................... 45 E-15 Backup lamp and backup buzzer operate abnormally........................................................ 52 E-16 Emergency steering system does not operate ................................................................... 56 E-17 Indication of the fuel gauge is abnormal............................................................................. 60 E-18 Dump lever does not operate normally............................................................................... 62 E-19 KOMTRAX system does not operate normally................................................................... 64 E-20 Electric priming pump does not operate or does not stop automatically ............................ 68 E-21 Air conditioner does not operate narmally .......................................................................... 70 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03362-00 Information in troubleshooting table ............................................................................................ 3 H-1 Machine does not start ......................................................................................................... 4 H-2 Travel is not smooth (Machine hunts) .................................................................................. 6 H-3 Lockup is not reset ............................................................................................................... 6 H-4 Start shock and gear shift shock are abnormally large ........................................................ 7 H-5 Gear is not shifted up ........................................................................................................... 8 H-6 Travel speed or power is low................................................................................................ 10 H-7 Start and gearshift time lag is large...................................................................................... 14 H-8 Torque converter oil temperature is high .............................................................................. 16 H-9 Torque converter oil temperature is low ............................................................................... 17 H-10 Front brake does not work fully .......................................................................................... 18 H-11 Center brake does not work fully ........................................................................................ 19 H-12 Rear brake does not work fully........................................................................................... 20 H-13 Steering wheel is heavy ..................................................................................................... 21 H-14 Steering wheel does not move ........................................................................................... 22 H-15 Steering wheel waggle ....................................................................................................... 23 H-16 Dump body raising speed is low......................................................................................... 24 H-17 Dump body does not move ................................................................................................ 25 H-18 Hydraulic drift of dump body is large .................................................................................. 26 Troubleshooting of engine (S-mode) SEN03363-01 Method of using troubleshooting chart ........................................................................................ 3 S-1 Starting performance of engine is poor ................................................................................ 6 S-2 Engine does not start............................................................................................................ 7 S-3 Engine does not pick up smoothly........................................................................................ 10 S-4 Engine stops during operation.............................................................................................. 11 S-5 Engine does not rotate smoothly .......................................................................................... 12 S-6 Engine lack output (or lacks power) ..................................................................................... 13 S-7 Exhaust gas is black (incomplete combustion)..................................................................... 14 S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 15 S-9 Oil becomes dirty quickly ...................................................................................................... 16 S-10 Fuel consumption is excessive ........................................................................................... 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18 S-12 Oil pressure drops .............................................................................................................. 19 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 20 S-14 Coolant temperature becomes too high (Overheating) ...................................................... 21 S-15 Abnormal noise is made ..................................................................................................... 22 S-16 Vibration is excessive ......................................................................................................... 23 S-17 Air cannot be bled from fuel circuit ..................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly SEN04135-04 Precautions before work ............................................................................................................. 2 How to read this manual ............................................................................................................. 3 Coating materials list................................................................................................................... 5 8 Special tool list ............................................................................................................................ Sketches of special tools............................................................................................................. 13
HM350-2R
11
SEN03019-13
00 Index and foreword
Engine and cooling system (SAA6D140E-5) SEN04136-00 Removal and installation of engine assembly ............................................................................. 2 Removal and installation of radiator assembly............................................................................ 11 Removal and installation of cooling assembly............................................................................. 15 Removal and installation of aftercooler assembly ....................................................................... 19 Removal and installation of output shaft assembly ..................................................................... 22 Disassembly and assembly of output shaft assembly................................................................. 27 Engine (SAA6D140E-5) SEN04137-02 Removal and installation of fuel supply pump assembly............................................................. 2 Removal and installation of cylinder head assembly................................................................... 7 Removal and installation of fuel injector assembly...................................................................... 23 Removal and installation of engine front seal.............................................................................. 27 Removal and installation of engine rear seal .............................................................................. 29 Replacement procedure of exhaust pipe fire prevention cover ................................................... 33 Power train, Part 1 SEN04138-02 Removal and installation of transmission and front differential assembly ................................... 2 Disconnection and coupling of front differential and transmission .............................................. 9 Disassembly and assembly of torque converter assembly ......................................................... 10 Disassembly and assembly of transmission assembly ............................................................... 18 Power train, Part 2 (Differential) SEN04139-01 Disassembly and assembly of front differential assembly ........................................................... 2 Removal and installation of center differential assembly ............................................................ 19 Disassembly and assembly of center differential assembly ........................................................ 22 Removal and installation of rear differential assembly ................................................................ 37 Disassembly and assembly of rear differential assembly............................................................ 39 Power train, Part 3 (Final drive, brake, axle) SEN04140-03 Removal and installation of front final drive and brake assembly ............................................... 2 Disassembly and assembly of front final drive and brake assembly ........................................... 5 Removal and installation of center final drive and brake assembly............................................. 21 Disassembly and assembly of center final drive and plate assembly ......................................... 23 Removal and installation of rear final drive assembly ................................................................. 35 Disassembly and assembly of rear final drive assembly ............................................................. 37 Removal and installation of center axle assembly ...................................................................... 44 Removal and installation of rear axle assembly .......................................................................... 47 Undercarriage and frame SEN04141-03 Removal and installation of front suspension cylinder assembly ................................................ 2 Removal and installation of rear suspension cylinder assembly ................................................. 4 Removal and installation of equalizer bar assembly ................................................................... 6 Removal and installation of front wheel assembly ...................................................................... 8 Removal and installation of rear front wheel assembly ............................................................... 9 Removal and installation of rear rear wheel assembly................................................................ 9 Removal and installation of hitch frame assembly ...................................................................... 10 Disassembly and assembly of hitch frame .................................................................................. 18 Removal and installation of body assembly ................................................................................ 23 Hydraulic system SEN04142-00 Disassembly and assembly of steering valve.............................................................................. 2 Removal and installation of flow amplifier valve assembly.......................................................... 12 Removal and installation of hoist valve assembly ....................................................................... 14 Disassembly and assembly of hoist valve assembly................................................................... 16 Disassembly and assembly of steering cylinder assembly ......................................................... 18 Disassembly and assembly of hoist cylinder assembly............................................................... 24 Cab and its attachments SEN04143-01 Removal and installation of operator's cab ................................................................................. 2 Removal and installation of operator's cab glass (Stuck glass) .................................................. 7 Disassembly and assembly of operator's seat assembly (If equipped)....................................... 14
12
HM350-2R
00 Index and foreword
SEN03019-13
Electrical system SEN04144-00 Removal and installation of air conditioner unit assembly .......................................................... 2 Removal and installation of engine controller ............................................................................. 7 Removal and installation of retarder controller............................................................................ 10 Removal and installation of transmission controller assembly.................................................... 12 90 Diagrams and drawings Hydraulic diagrams and drawings SEN03040-00 Power train hydraulic circuit diagram .......................................................................................... 3 Steering and hoist hydraulic circuit diagram ............................................................................... 5 Brake hydraulic circuit diagram ................................................................................................... 6 Brake cooling hydraulic circuit diagram....................................................................................... 7 Differential lock hydraulic circuit diagram .................................................................................... 8 Electrical diagrams and drawings SEN03041-03 Electrical circuit diagram for inside cab (1/4) .............................................................................. 3 Electrical circuit diagram for inside cab (2/4) .............................................................................. 5 Electrical circuit diagram for inside cab (3/4) .............................................................................. 7 Electrical circuit diagram for inside cab (4/4) .............................................................................. 9 Electrical circuit diagram for outside cab (1/3) ............................................................................ 11 Electrical circuit diagram for outside cab (2/3) ............................................................................ 13 Electrical circuit diagram for outside cab (3/3) ............................................................................ 15 Connectors table and arrangement drawing ............................................................................... 17
HM350-2R
13