GEN00041-03

ARTICULATED HM350 -2
DUMP TRUCK
SERIAL NUMBERS 2001 and up
 Contents

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 Positioning bare machine ....................................................... 3
0200 Installation of right and left mudgurds .................................... 4
0300 Installation of rear monitor ...................................................... 5
0400 Installation engine hood mirrors ............................................. 6
0500 Adjusting N2 gas of front and rear suspensions .................... 7
A0100 Installation of antenna ............................................................ 8
Appendix: Field assembly inspection report
1 Drawings of removed units

1. Bare machine

2. Engine hood mirror

Specifications of HM350-2 completed truck

Related items
Specifications
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
31,060 3,700
Self-propelled travel (Weight of machine) 11,145 3,190 (When empty)

2 Dimensions of removed units

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

1
3 Assembly procedure, necessary equipments, and schedule

Day 1st day

Hour
1 2 3 4 5 6 7 8

Assembly unit

(1) Positioning bare machine (4) Installing engine hood mirror

(2) Installation of rear monitor (5) Adjusting N2 gas of front and
(3) Installation of right and left mudguards rear suspensions

Assembly procedure No. No.0100 - 0500

Number of workers 2

Suspension gas Adjusting

pouring tool suspension gas

Meeting before work Completion of assembly

Remarks Unloading
Starting assembly

4 Necessary tools and equipments

(1) Necessary tools
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
3 Socket 19 mm Each 1 For assembling parts
4 Suspension gas pouring tool (7926-10-1000) 1 For adjusting suspension gas
(2) Necessary equipments

No. Equipment name Specifications Q'ty Remarks

1 Stepladder (Work stand) 4 steps (About 1.5 m) 1 For work

2
Assembly procedure No.
Positioning bare machine
No.0100

1. Positioning bare machine

Steering lock bar

1. Lower the bare machine from the trailer and position it on the flat ground.
2. Set the steering lock bar securely.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Before starting the work, set the steering
lock bar securely.
Others

3
Assembly procedure No.
Installation of right and left mudguards
No.0200

1. Install mudguards to the right and left fenders.

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

1. Remove the bolts and plates installed temporarily to the fenders.

2. Install mudguards mounted in the cab to the fenders.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Ring wrench (19 mm) 1 Stepladder (Work stand) 1
Others

4
Assembly procedure No.
Installation of rear monitor
No.0300

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.

Rear lamp bracket

(To be fixed together with rear monitor assembly.)

View Z

View Y

To be connected.

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

5
Assembly procedure No.
Installing engine hood mirror
No.0400

1. Installing engine hood mirror

Engine Hood
Installed to engine
hood temporarily

1
View Z
Installed to engine
2
hood temporarily

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

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.
a To adjust, see Operation and Maintenance Manual.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Socket wrench (19 mm) 1 Stepladder (Work stand) 1
Others

6
Assembly procedure No.
Adjusting N2 gas of front and rear suspensions
No.0500

1. Adjusting N2 gas of front and rear suspensions

Adjust the quantity of N2 gas (front and rear, 4 places).
N2 gas pouring valve Air bleeding valve Installing position of suspension gas pouring tool

Air bleeding hole

Front
suspension

N2 gas cylinder
Before adjusting suspension gas,
remove the cover. After adjusting install it. Suspension gas pouring tool
(7826-10-1000)
Front suspension cylinder Rear suspension cylinder
Chassis side

Chassis side
Axle side

Axle side

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)

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.)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
1. Bleed air from the cylinders.
Suspension gas pouring tool 1
2. Pour nitrogen gas in the right and left
suspension cylinders simultaneously. (7926-10-1000)
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,
Others

the piping may be broken.)

7
 Assembly procedure No.
Installation of antenna
No. A0100

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.

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 8A13-10-2100 ANTENNA. SAT 1 Separately Packed （M42-05-070）
(2) 416-56-31130 RUBBER ANTENNA 1 Separately Packed （M42-05-071）

Apply Loctite No. 262 Remove cap and

or equivalent. install antenna.

Remove vinyl and

install antenna.

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Others

8
Assembly procedure No.
Mirror adjustment procedure
Attached sheet

9
 1/3

★ Carefully read the Operation and Maintenance Manual in advance to understand safety, List of check marks for inspection results
operation, machine operations and controls, and then carry out the following inspections. : Acceptable : Unacceptable
( ) : Enter numeric values. : Uninspected
: Not applicable : No check is required
Service meter Mileo meter
Date of Inspection Inspector
Start Finish Start Finish * Check relevant items after maintenance.
When the result is acceptable, circle any of the above marks.
(Example: ・ )

No. Inspection items Judgment procedures and criteria Check Remarks

Checking oil and water levels.

Engine oil level

1 The level must be in the range between (H) and (H - 10 mm).
(Check with engine stopped.)
Transmission oil level The level must be in the range between (H) and (center between H
2
(Check with engine at low idling.) and L).

3 Hydraulic oil level The level must be within inspection window range.

Turn switch ON. (Basic items: Check lights and buzzers.)

Sound must be proper in volume and must not have beat noise.
4 Function of horn
(Sensory check)
Sound must be proper in volume and must not have beat noise.
5 Function of back-up buzzer
(Sensory check)
When light switch is turned ON (1st, 2nd stage), front right and left
6 Function of clearance lamp clearance lamps and rear right, center, and left clearance lamps (3
lamps) must light up.
When light switch is turned ON (2nd stage), 2 headlamps must light
7 Check of headlamps
up.
Check of high beam High beam should turn on by operating the dimmer switch while the
8
(Function of dimmer switch) headlamps are on.
When turn signal lever is operated, front and rear turn signal lamps
9 Function of turn signal lamps
must flash on correct side.
All the right and left turn signal lamps as well as their pilot lamps
10 Function of hazard lamp (arrows) in the cab should flash when the hazard warning light switch
is set to “ON”.
When transmission shift lever is set to at R, backup lamps must light
11 Function of backup lamps
up.

The brake lamps should light up when the brake pedal is depressed.

12 Function of brake lamps 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).

Fog lamp operation check The fog lamps should light up when the fog lamp switch is set to ON.
13
（If equipped） The lamp inside switch should also light up simultaneously.

Start engine.

14 Abnormal noise from engine No abnormal noise must be generated. (Sensory check)

No exhaust leakage should be detected at any muffler and exhaust

15 Exhaust gas leakage
connections.
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
16 Operating effort of dump lever
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.
17 Function of dump lever
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

Check of potentiometer voltage. is seated)
Standard value: 0.46 – 0.54V , Measured value: ( )V
18
*Perform this check at transmission
contact No. 34603. Voltage of potentiometer at dump lever RAISE end
Standard value: 4.00 – 4.70V, Measured value: ( )V
 2/3

No. Inspection items Judgment procedures and criteria Check Remarks

There should be no harsh shock when the dump body gets seated on
Shock made when dump body is
19 the frame (sensory check).
lower to end
*Perform this check after completing the calibration.
Operate lever to RAISE position and check that it does not return
to HOLD when released.
20 Function of positioner Operate lever to RAISE position to raise dump body and check that it
automatically returns to HOLD at a point 50 – 100 mm before end of
H/T cylinder 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
Alignment of dump body on right and evenly. (Contact area must be at least 60%.)
21 The clearance at the hinge pin section should not exceed 1mm on
left
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.
Body lifting speed Engine speed: Rated speed (2,000rpm)
22
(Oil temperature: 80°C) Standard: 12.0 ± 1.5 sec, Measured value: ( ) sec
Body lowering speed
Power down (from No. 1 cylinder: Hi to No. 2 cylinder: LiL)
23 (Lever at FLOAT,Oil temperature:
Standard: 12.0±1.5 sec, Measured value:( )sec
70 – 90 °C)
Hydraulic drift in 5 minutes must be 85 mm or less. (From point where
24 Hydraulic drift of dump body cylinder No. 2 is extended by 100 mm).
Measured value: ( ) mm

Stop truck on level ground and measure.

Length must be shorter than dimension A.

Length of suspension cylinder (Front)
25 Dimension A: 153 ± 10 mm
* Measure with dump body empty.
Measured value: Left ( ) mm, Right ( ) mm
Length must be shorter than dimension A.
Length of suspension cylinder (Rear)
26 Dimension A: 104 ± 5 mm
* Measure with dump body empty.
Measured value: Left ( ) mm, Right ( ) mm

Inspect each part.

Safety pin must be inserted without obstruction in right and left

27 Function of safety pin
stopper holes.
Safety pin must be removed from, installed to, and locked at
28 Storage function of safety pin
storage position securely.

29 Inspection around engine No oil and water leakage.

30 Inspection around transmission No oil leakage.

Inspection of hydraulic oil system

31 No oil leakage.
(tank, cylinder, pump, piping)

(1) Front left: Should be retightened to the specification.

(2) Front right: Should be retightened to the specification.

Tightness of tire hub nuts

(3) Center left: Should be retightened to the specification.
32
*See the Assembling Procedure for
(4) Center right: Should be retightened to the specification.
the tightening torque specification.

(5) Rear left: Should be retightened to the specification.

(6) Rear right: Should be retightened to the specification.

Standard: Shown at left

Tire inflation pressure
Measured value: Front left ( MPa )
(When dump body is empty)
Front right ( MPa)
26.5-R25 (Standard for Japanese markets) Standard: Shown at left
Front wheels : 0.44 ± 0.01 Mpa
33 Front wheels & Rear wheels :
Measured value: Center left inside ( MPa)
0.44 ± 0.01 Mpa Center right inside ( MPa)
BS VKT (Standard for other markets than
Japan) Standard: Shown at left
Front wheels : 0.44 ± 0.01 Mpa Measured value: Rear left outside ( MPa)
Front wheels & Rear wheels : Rear right outside ( MPa)
0.44 ± 0.01 Mpa
 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.

Remarks（Reports）

･ Enter any problem found during the field inspection in this space.

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.

【Calibration procedure】
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.
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.)
7) Calibration can be considered to have been satisfactorily completed if the dump body gets seated without shock in both Steps 5) and 6).
HM350-2 ARTICULATED DUMP TRUCK

Form No GEN00041-03