Komatsu ecot3 HM350-2 User manual

ARTICULATED
DUMP TRUCK
Field Assembly Instruction
GEN00041-03
HM350-2
SERIAL NUMBERS 2001 and up

1 Drawings of removed units ..............................................................
.
1
2 Dimensions of removed units ..........................................................
.
1
3 Assembly procedure, necessary equipments, and schedule .......
.
2
4 Necessary tools and equipments ....................................................
.
2
5 Assembly procedure No. ..................................................................
.
3
0100 Positionin
g
bare machine ......................................................
.
3
0200 Installation of ri
g
ht and left mud
g
urds .................................... 4
0300 Installation of rear monitor .....................................................
.
5
0400 Installation en
g
ine hood mirrors ............................................. 6
0500 Ad
j
ustin
g
N2
g
as of front and rear suspensions .................... 7
A0100 Installation of antenna ............................................................ 8
Appendix: Field assembly inspection report
Contents

1
1 Drawings of removed units
Specifications of HM350-2 completed truck
2 Dimensions of removed units
1. Bare machine
2. Engine hood mirror
Specifications Related items
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
Self-propelled travel 31,060
(Weight of machine) 11,145 3,190 3,700 (When empty)
No. Unit name Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
1 Bare machine 31,057 11,145 3,190 3,700
2 Engine hood mirror 3 500 340 450

2
3 Assembly procedure, necessary equipments, and schedule
4 Necessary tools and equipments
(1) Necessary tools
(2) Necessary equipments
241
Day
Hour
1st day
36857
Assembly unit
Assembly procedure No.
No.0100 - 0500
Remarks
Meeting before work
Unloading
Starting assembly
Completion of assembly
Suspension gas
pouring tool
Adjusting
suspension gas
Number of workers 2
(4) Installing engine hood mirror
(5) Adjusting N2 gas of front and
rear suspensions
(1) Positioning bare machine
(2) Installation of rear monitor
(3) Installation of right and left mudguards
No. Tool name Specifications Q'ty Remarks
1 Ring wrench 19 mm
Each 1 For assembling parts
2 Impact wrench GTP-800P/GTP-60VP or equivalent
Each 1 For assembling parts
3Socket 19mm
Each 1 For assembling parts
4 Suspension gas pouring tool (7926-10-1000) 1 For adjusting suspension gas
No. Equipment name Specifications Q'ty Remarks
1 Stepladder (Work stand) 4 steps (About 1.5 m) 1 For work

3
1. Positioning bare machine
1. Lower the bare machine from the trailer and position it on the flat ground.
2. Set the steering lock bar securely.
Assembly procedure No.
Positioning bare machine
No.0100
Precautions Necessary tools Necessary equipment
Before starting the work, set the steering
lock bar securely.
Name Q’ty Name Q’ty
Others
Steering lock bar

4
1. Install mudguards to the right and left fenders.
1. Remove the bolts and plates installed temporarily to the fenders.
2. Install mudguards mounted in the cab to the fenders.
Assembly procedure No.
Installation of right and left mudguards
No.0200
Part No. Part name Q'ty State of parts
(1) 56D-54-22950 GUARD, L.H. 1 Mounted in cab
(2) 56D-54-22960 GUARD, R.H. 1 Mounted in cab
(3) 56D-54-22970 PLATE 2 Temporarily installed to fender
(4) 01024-81025 BOLT, SEMS 4 Temporarily installed to fender
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Ring wrench (19 mm) 1 Stepladder (Work stand) 1
Others

5
Assembly procedure No.
Installation of rear monitor
No.0300
Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-86-8310A REAR MONITOR ASS'Y 1 Separately packed (M352-06-050)
(2) 01024-81020 BOLT 4 Temporarily installed to rear lamp bracket
(3) 04434-50810 CLIP 1 Temporarily installed to rear lamp bracket
(4) 04434-51410 CLIP 1 Temporarily installed to rear lamp bracket
(5) 01024-81030 BOLT 1 Temporarily installed to rear lamp bracket
(6) 424-54-14380 COLLAR 1 Temporarily installed to rear lamp bracket
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Others
Rear lamp bracket
View Z
(To be fixed together with rear monitor assembly.)
View Y
To be connected.
1. Install the rear monitor assembly as shown in view Z.
2. Connect the rear monitor cable.
3. Fix the rear monitor cable as shown in view Y.

6
1. Installing engine hood mirror
1. Remove the bolts and washers installed to the engine hood temporarily.
2. Take the engine hood mirror out of the cab and install it to the engine hood.
3. Adjust the angle of the mirror.
aTo adjust, see Operation and Maintenance Manual.
Assembly procedure No.
Installing engine hood mirror
No.0400
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Socket wrench (19 mm) 1 Stepladder (Work stand) 1
Others
Installed to engine
hood temporarily
Installed to engine
hood temporarily
Z
View Z
Engine Hood
2
2
1
Part No. Part name Q'ty State of parts
(1) 56B-54-2152A MIRROR, R.H. 1 Mounted in cab
(2) 01024-81225 BOLT 4 Installed to engine hood temporarily

7
1. Adjusting N2 gas of front and rear suspensions
Adjust the quantity of N2 gas (front and rear, 4 places).
1. Loosen the air bleeding valves of the right and left front suspension cylinders and bleed air thoroughly. (Check that air does not come
out any more (and only oil flows out) and tighten the valves again. Tightening torque: 39.2 – 49.0 Nm {4 – 5 kgm})
2. Check that the valves are closed and install the suspension gas pouring tool to the gas cylinder.
3. Connect the hoses of the suspension gas pouring tool to the nitrogen gas pouring valves. (Since there are 2 hoses, connect them to
the right and left suspension cylinders and pour the nitrogen gas simultaneously so that pressure will be applied to both cylinders even-
ly.)
4. Open the valve of the suspension gas pouring tool gradually.
5. When the suspension cylinders rise to the specified level shown above, close the valve. (Pour the gas to the front suspension cylinders
until they rise to the level indicated by the decalcomania. Pour the gas to the rear suspension cylinders until they rise to the level shown
in the above figure.)
6. Remove the hoses from the nitrogen gas pouring valves and move the machine forward and in reverse to fit the suspension cylinders,
and then stop without applying the brake. (Finally, stop the machine without applying the brake to prevent an uneven load caused by
braking.)
7. Apply the parking brake and check the length of the suspension cylinders.
8. If the length of the suspension cylinders is out of the standard range, repeat steps 3 - 7. (Usually, adjustment is completed by repeating
those steps 3 - 4 times.)
Assembly procedure No.
Adjusting N2 gas of front and rear suspensions
No.0500
Dimension A (Front side) Dimension A (Rear side)
When cylinder is retracted fully: MIN (32 ± 1 mm) When cylinder is retracted fully: MIN (26 ± 1 mm)
Specified quantity of filled oil: OIL 53 ± 3 mm Specified quantity of filled oil: OIL 66 ± 3 mm
When empty: EMPTY (153 ± 10 mm) When empty: EMPTY (96 ± 5 mm)
When cylinder is extracted fully: MAX (209 ± 1 mm) When cylinder is extracted fully: MAX (116 ± 1 mm)
Precautions Necessary tools Necessary equipment
1. Bleed air from the cylinders.
2. Pour nitrogen gas in the right and left
suspension cylinders simultaneously.
3. Do not extend the suspension cylinders
to the stroke end.
4. After moving the machine forward and in
reverse, stop it without applying the
brake.
5. Do not steer the machine before
finishing this adjustment. (If it is steered,
the piping may be broken.)
Name Q’ty Name Q’ty
Suspension gas pouring tool 1
(7926-10-1000)
Others
Front
suspension
Before adjusting suspension gas,
remove the cover. After adjusting install it.
Air bleeding valve
Air bleeding hole
N2 gas pouring valve Installing position of suspension gas pouring tool
N2 gas cylinder
Suspension gas pouring tool
(7826-10-1000)
i
Chassis side
Front suspension cylinder Rear suspension cylinder
Axle side
o
i
Chassis side
Axle side
o

1. Install antenna to top of cab.
1. KOMTRAX antenna ：Install antenna to top of cab.
2. Radio antenna ：Install antenna to left top of cab.
Q'ty Name Q'ty
Necessary equipmentNecessary toolsPrecautions
Others
Name
Assembly procedure No.
Installation of antenna
No. A0100
②
①
Remove cap and
install antenna.
A
pply Loctite No. 262
or equivalent.
Remove vinyl and
install antenna.
Q'ty State of parts (Parts list No.)
(1) 1 Separately Packed （M42-05-070）
(2) 1 Separately Packed （M42-05-071）
Part No. Part name
8A13-10-2100 ANTENNA. SAT
416-56-31130 RUBBER ANTENNA
8

Assembly procedure No.
Mirror adjustment procedure
Attached sheet
9

1/3
No. Inspection items Judgment procedures and criteria Check Remarks
Checking oil and water levels.
1Engine oil level
(Check with engine stopped.) The level must be in the range between (H) and (H - 10 mm).
2Transmission oil level
(Check with engine at low idling.)
The level must be in the range between (H) and (center between H
and L).
3 Hydraulic oil level The level must be within inspection window range.
Turn switch ON. (Basic items: Check lights and buzzers.)
4 Function of horn Sound must be proper in volume and must not have beat noise.
(Sensory check)
5 Function of back-up buzzer Sound must be proper in volume and must not have beat noise.
(Sensory check)
6 Function of clearance lamp
When light switch is turned ON (1st, 2nd stage), front right and left
clearance lamps and rear right, center, and left clearance lamps (3
lamps) must light up.
7 Check of headlamps When light switch is turned ON (2nd stage), 2 headlamps must light
up.
8Check of high beam
(Function of dimmer switch)
High beam should turn on by operating the dimmer switch while the
headlamps are on.
9 Function of turn signal lamps When turn signal lever is operated, front and rear turn signal lamps
must flash on correct side.
10 Function of hazard lamp
All the right and left turn signal lamps as well as their pilot lamps
(arrows) in the cab should flash when the hazard warning light switch
is set to “ON”.
11 Function of backup lamps When transmission shift lever is set to at R, backup lamps must light
up.
The brake lamps should light up when the brake pedal is depressed.
The brake lamps should light up when the retarder lever is pulled.
When light switch is ON and brake is turned ON, brightness of brake
lamp must change (become brighter).
13 Fog lamp operation check
（If equipped）
The fog lamps should light up when the fog lamp switch is set to ON.
The lamp inside switch should also light up simultaneously.
14 Abnormal noise from engine No abnormal noise must be generated. (Sensory check)
15 Exhaust gas leakage No exhaust leakage should be detected at any muffler and exhaust
connections.
16 Operating effort of dump lever
The force necessary for moving the lever into every position should be
proper (HOLD to UP: 3.0 kg; FLOAT to HOLD: 3.0kg; FLOAT to
DOWN: 3.0 kg). Operation of the lever should not involve any snagging
movements.
1) Check that order of operation from top is RAISE →HOLD →FLOAT
→LOWER.
2) Check that dump body can be stopped at desired position when
lever is at HOLD.
3) Operate lever to LOWER position and check that it returns to
FLOAT when released.
4) Pressure must be adjusted at RAISE and LOWER positions.
Voltage of potentiometer at dump lever LOWER end (dump body
is seated)
Standard value: 0.46 – 0.54V , Measured value: ( ) V
Voltage of potentiometer at dump lever RAISE end
Standard value: 4.00 – 4.70V, Measured value: ( ) V
12 Function of brake lamps
Start engine.
17 Function of dump lever
18
Check of potentiometer voltage.
*Perform this check at transmission
contact No. 34603.
★Carefully read the Operation and Maintenance Manual in advance to understand safety,
operation, machine operations and controls, and then carry out the following inspections.
: Acceptable : Unacceptable
(
)
: Enter numeric values. : Uninspected
: Not applicable : No check is required
* Check relevant items after maintenance.
When the result is acceptable, circle any of the above marks.
(
Exam
p
le: ・
)
List of check marks for inspection results
Date of Inspection Inspector
Service meter
Start Finish
Mileo meter
Start Finish

2/3
No. Inspection items Judgment procedures and criteria Check Remarks
19 Shock made when dump body is
lower to end
There should be no harsh shock when the dump body gets seated on
the frame (sensory check).
*Perform this check after completing the calibration.
Operate lever to RAISE position and check that it does not return
to HOLD when released.
Operate lever to RAISE position to raise dump body and check that i
t
automatically returns to HOLD at a point 50 – 100 mm before end of
H/T c
y
linder stroke.
When dump body is raised fully, it must not sway to right or left.
When dump body is lower fully, it must come in contact with mount
evenly. (Contact area must be at least 60%.)
The clearance at the hinge pin section should not exceed 1mm on
one side. (Perform this check for both the clearances on the right and
left sides.
)
The clearance at the deflection stopper should be 1 to 2 mm on one
side when the dump body is in the lower end position.
22 Body lifting speed
(Oil temperature: 80°C)
Engine speed: Rated speed (2,000rpm)
Standard: 12.0 ± 1.5 sec, Measured value: ( ) sec
23
Body lowering speed
(Lever at FLOAT,Oil temperature:
70 – 90 °C)
Power down (from No. 1 cylinder: Hi to No. 2 cylinder: LiL)
Standard: 12.0±1.5 sec, Measured value:( )sec
24 Hydraulic drift of dump body
Hydraulic drift in 5 minutes must be 85 mm or less. (From point where
cylinder No. 2 is extended by 100 mm).
Measured value: ( ) mm
Stop truck on level ground and measure.
25 Length of suspension cylinder (Front)
* Measure with dump body empty.
Length must be shorter than dimension A.
Dimension A: 153 ± 10 mm
Measured value: Left
(
)
mm, Ri
g
ht
(
)
mm
26 Length of suspension cylinder (Rear)
* Measure with dump body empty.
Length must be shorter than dimension A.
Dimension A: 104 ± 5 mm
Measured value: Left
(
)
mm, Ri
g
ht
(
)
mm
27 Function of safety pin Safety pin must be inserted without obstruction in right and left
stopper holes.
28 Storage function of safety pin Safety pin must be removed from, installed to, and locked at
storage position securely.
29 Inspection around engine No oil and water leakage.
30 Inspection around transmission No oil leakage.
31 Inspection of hydraulic oil system
(tank, cylinder, pump, piping) No oil leakage.
(1) Front left: Should be retightened to the specification.
(2) Front right: Should be retightened to the specification.
(3) Center left: Should be retightened to the specification.
(4) Center right: Should be retightened to the specification.
(5) Rear left: Should be retightened to the specification.
(6) Rear right: Should be retightened to the specification.
Tire inflation pressure
(When dump body is empty)
Standard: Shown at left
Measured value: Front left ( MPa )
Front right ( MPa)
26.5-R25 (Standard for Japanese markets)
Front wheels : 0.44 ±0.01 Mpa
Front wheels & Rear wheels :
0.44 ±0.01 Mpa
Standard: Shown at left
Measured value: Center left inside ( MPa)
Center right inside ( MPa)
BS VKT (Standard for other markets than
Japan)
Front wheels : 0.44 ± 0.01 Mpa
Front wheels & Rear wheels :
0.44 ± 0.01 Mpa
Standard: Shown at left
Measured value: Rear left outside ( MPa)
Rear right outside ( MPa)
Inspect each part.
33
20 Function of positioner
21 Alignment of dump body on right and
left
32
Tightness of tire hub nuts
*See the Assembling Procedure for
the tightening torque specification.

3/3
No. Inspection items Judgment procedures and criteria Check Remarks
34 Flaw of tires (6 wheels) Tires must be free from flaw and tear.
35 Hoist cylinders (Both sides) Plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.
･Enter any problem found during the field inspection in this space.
【Calibration procedure】
Calibration of dump body system
Note: Before starting the calibration, make sure all adjustments of the dump body system and potentiometer have been satisfactorily completed.
Remarks（Reports）
1) Start the engine and let it operate to warm the hydraulic oil to 80 to 90°C.
2) With the dump body in the seated position (dump body caution light OFF), keep the dump lever in the FLOAT position for at least 5 seconds.
3) With the dump body raised to the end of stroke, keep the dump lever in the UP position for at least 5 seconds.
4) Bring the dump body to the seated position.
7) Calibration can be considered to have been satisfactorily completed if the dump body gets seated without shock in both Steps 5) and 6).
5) With the engine running at a low idle, move the dump lever to the UP and FLOAT positions several times.
(* Move the lever to the end of stroke both when placing it into the UP position and the FLOAT position.)
6) With the engine running at a high idle, move the dump lever to the UP and FLOAT positions several times.
(* Move the lever to the end of stroke both when placing it into the UP position and FLOAT position.)

HM350-2 ARTICULATED DUMP TRUCK
Form No GEN00041-03