Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04

Description

Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04 Overview

The Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04 delivers complete, workshop-level technical documentation for the Komatsu HM350-2 articulated dump truck, covering machines with serial numbers 2001 and up. Designed specifically for heavy equipment technicians, fleet service centers, and professional field mechanics, this comprehensive service publication provides exact factory specifications, mechanical clearances, hydraulic pressures, electrical wiring schematics, and detailed step-by-step disassembly and assembly instructions. Whether diagnosing electronic control modulation valve (ECMV) fault codes, overhauling the TORQFLOW 6-speed transmission, checking hydropneumatic suspension nitrogen charging, or rebuilding final drives, this Komatsu HM350-2 shop manual provides the authoritative technical foundation required for precision service and maximum machine availability.

Document & File Details

• Manual Type: Shop Manual / Workshop Service Manual
• Brand & Model: Komatsu HM350-2 Articulated Dump Truck
• Applicable Serial Numbers: 2001 and up
• Engine Model: Komatsu SAA6D140E-5 (6-Cylinder, 15.23L Turbocharged Diesel)
• Document Form Number: SEN00238-04 (Binder Set SEN00488-04 through SEN00510-02)
• Document Revision: Revision 04 (Printed in Japan 07-07)
• Language: English
• Page Count: 1,214 pages
• File Format: Portable Document Format (PDF)

Chapters & Sections Covered

• 00 Index and Foreword (SEN00487-04, SEN00488-04, SEN00489-02)
  • Composition of shop manual and table of contents
  • Safety notices, workshop preparation, and slinging safety standards
  • Maintenance standard terminology: clearances, tolerances, and interference limits
  • Handling electric wiring harnesses, waterproof connectors, and electronic controllers
  • Push-pull coupler disconnect/reconnect procedures and hydraulic system cleanliness
  • Standard tightening torque tables (metric bolts, split flanges, O-ring boss joints, hoses)
• 01 Specification (SEN00490-01, SEN00491-01)
  • Dimensional specification drawings and turning radius data
  • General machine specifications and vehicle weight distribution tables
  • Fuel, coolant, power train oil, and lubricant capacity charts

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• 10 Structure, Function and Maintenance Standard (SEN00492-01 to SEN00503-01)
  • Engine and cooling system: radiator, oil coolers, aftercooler, and flywheel output shaft
  • Power train, Part 1: skeleton diagrams, hydraulic piping, brake cooling valve (BCV), power train pumps, torque converter, TORQFLOW transmission, transmission control valve, ECMV, and main relief valves
  • Power train, Part 2: front, center, and rear drive shafts, axles, standard differentials, limited slip differentials, and planetary final drives
  • Steering system: steering column assembly and orbit-roll steering valve
  • Brake system: piping, brake valve, accumulator charge valve, nitrogen accumulators, slack adjusters, wet multi-disc brakes, retarder proportional reducing valve, and spring-applied parking brake
  • Undercarriage and frame: hydropneumatic suspension cylinders, equalizer bar, trailing arms, and oscillation hitch assembly
  • Hydraulic system: steering and hoist piping, dump body control, tank and filters, flow amplifier valve, steering cylinders, hoist valve, EPC proportional valve, pilot check valve, and gear pumps
  • Cab and attachments: ROPS cab mounting, hydraulic cab tilt, air conditioning refrigeration cycle, monitor panels, and controller arrangement
  • Electrical systems (Parts 1, 2, 3): machine monitor network, automatic shift controller, retarder control system, auto emergency steering, dump control lever, sensors, switches, and KOMTRAX system
• 20 Standard Value Table (SEN00504-00, SEN01481-00)
  • Engine and chassis standard service value tables and judgment criteria
• 30 Testing and Adjusting (SEN00505-00, SEN01482-00 to SEN01484-00)
  • Engine testing: engine speed, boost pressure, exhaust temperature/gas color, valve clearance, compression, blowby, fuel rail pressure, and belt tensions
  • Power train and chassis testing: stall speed, transmission clutch pressures, differential lock pressure, brake pressure and disc wear, suspension cylinder adjustment, dump circuit pressure, and cab tilt operation
  • Electrical and monitor testing: machine monitor special service functions and KOMTRAX commissioning
• 40 Troubleshooting (SEN00506-00, SEN01485-00 to SEN01497-00)
  • General troubleshooting procedures, connector pin layouts, and T-box adapter charts
  • Troubleshooting by failure code (Parts 1–8): transmission clutch slip, ECMV solenoid circuits, differential lock valves, sensor voltages, common rail fuel injection (CA codes), and CAN network communication
  • Electrical system troubleshooting (E-mode)
  • Hydraulic and mechanical system troubleshooting (H-mode)
  • Engine mechanical and combustion troubleshooting (S-mode)
• 50 Disassembly and Assembly (SEN00507-01, SEN01471-01 to SEN01479-01)
  • Special tools list, sketches, and recommended thread lockers/adhesives
  • Removal and installation of engine assembly, cylinder head, fuel injection pump, and injectors
  • Power train overhaul: output shaft, torque converter, transmission, differentials, final drives, and axles
  • Undercarriage overhaul: suspension cylinders, equalizer bar, oscillation hitch, and dump body
  • Hydraulic component overhaul: steering valve, flow amp valve, hoist valve, and hydraulic cylinders
  • Cab components and electronic controller replacement
• 90 Diagrams and Drawings (SEN00508-02, SEN00509-01, SEN00510-02)
  • Hydraulic circuit diagrams: power train, steering, hoist, service brake, brake cooling, and differential locks
  • Electrical circuit schematics: cab interior and chassis wiring for serial numbers 2001–2092 and 2093 and up

As a complete technical reference, the Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04 provides technicians with exact engineering criteria rather than generalized guidance. Service personnel gain immediate access to component tolerances, pressure test values, electrical harness terminal pinouts, and detailed hydraulic oil routing, allowing every inspection, rebuild, or troubleshooting task to be conducted accurately in accordance with original manufacturer service standards.

Engine & Cooling System Technical Coverage

The manual provides detailed structural and maintenance data for the Komatsu SAA6D140E-5 diesel engine, an in-line 6-cylinder, direct-injection power plant displacing 15.23 liters (140 mm bore x 165 mm stroke) producing a rated flywheel output of 304 kW (408 HP) at 2,000 rpm and peak torque of 1,990 Nm at 1,400 rpm. Technicians are provided with complete specifications for the cooling package, including the CF4-5 core radiator with a total heat dissipation area of 90.68 m², the PTO-LS torque converter oil cooler (4.0655 m²), and the PTO-OL steering oil cooler (0.896 m²). Maintenance criteria for the engine output shaft assembly provide critical tolerances for the rubber cushion blocks (standard width 75 mm, replacement limit 67 mm), spline backlash limits (standard 0.099–0.202 mm, repair limit 0.4 mm), and coupling oil seal journal wear limits.

TORQFLOW Transmission & Drive Train Architecture

Detailed cutaway drawings and oil circuit descriptions explain the operation of the Komatsu HM350-2 drive line. The power train utilizes a 3-element, 1-stage, 2-phase torque converter equipped with a hydraulically actuated, wet single-disc lockup clutch delivering a 2.63 stall torque ratio. The counter-shaft TORQFLOW transmission provides 6 forward and 2 reverse speeds via electro-hydraulic clutch actuation. The manual defines exact clutch pack disc and plate configurations:

• FL Clutch: 12 plates, 11 discs
• R Clutch: 12 plates, 11 discs
• FH Clutch: 10 plates, 9 discs
• 1st Clutch: 12 plates, 11 discs
• 2nd Clutch: 14 plates, 13 discs
• 3rd Clutch: 8 plates, 7 discs

The documentation details reduction ratios across all gear ranges (from 6.061 in Forward 1st to 0.714 in Forward 6th, and 5.851 in Reverse 1st to 2.484 in Reverse 2nd). Full overhaul sections detail standard clearances, wave spring loads (1,270 N at 3.8 mm test height; replacement limit 1,090 N), and wear limits for shaft bushings, clutch carrier seal rings, straight bevel gear differentials (3.231 reduction ratio; 0.36–0.54 mm backlash), and planetary final drives (4.941 reduction ratio; 0.19–0.43 mm planet-to-sun gear backlash).

Hydraulic System, Steering & Wet Disc Brakes

Complete hydraulic operational logic is documented for the dual-circuit gear pump system. Pump discharge volumes are detailed at 2,000 rpm engine speed, including 175 + 175 l/min for steering and hoist circuits, 18.5 l/min for hoist pilot control, 180 l/min for transmission and brake cooling, and 41 l/min for service brake actuation. The hydraulic sections provide functional walk-throughs and cross-sectional diagrams of the flow amplifier valve, orbit-roll steering control valve, 2-stage hoist cylinders (150 mm / 110 mm bore x 3,063 mm stroke), and the hoist EPC valve. The service braking system features independent front and center wet multiple-disc brakes, hydraulic accumulators charged with nitrogen to 4.4 MPa (45 kg/cm²), and slack adjusters designed to maintain constant braking response as friction plates wear.

Electronic Control Modulation Valves (ECMV) & Self-Diagnostics

A central feature of the Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04 is its deep coverage of the electronic management systems. Individual ECMV proportional solenoids and fill switches control hydraulic clutch pressure engagement profiles to eliminate driveline shift shock. The manual outlines fill signal timing, pressure regulation stages, and trigger compensation calibration values. Comprehensive troubleshooting procedures guide the technician through the machine monitor service menus, real-time sensor monitoring (speeds, temperatures, pressures, and voltages), and systematic fault tracing for hundreds of failure codes, including:

• Transmission & Powertrain Codes: 1500L0 (double engagement), 15B0NX (oil filter clogged), 15G0MW through 15M0MW (clutch slip), and 15SBL1 through 15SGMA (clutch pressure control valve faults).
• Engine Control (CA Codes): CA111 (engine controller fault), CA115/CA689 (Ne/Bkup speed sensor faults), CA122/CA123 (boost pressure), CA271–CA274 (PCV solenoid valves), CA322–CA332 (injector circuit faults), and CA451/CA559 (common rail fuel pressure faults).
• Brake & Differential Lock Codes: 2A62L1/2B62LH (differential lock pressure valves), 2C4MNX (retarder cooling filter), 2F00KM (parking brake drag), and 2G42ZG/2G43ZG (accumulator pressure drop).
• Network & Controller Codes: DAF9KM through DB2RKR (CAN communication and controller matching errors).
• Mechanical & Engine Symptom Charts: Structured E-mode (electrical), H-mode (hydraulic/mechanical), and S-mode (engine performance, exhaust smoke, low power, oil contamination) diagnostic tables.

Professional Workshop Utility & Instant PDF Delivery

The Komatsu HM350-2 Articulated Dump Truck Shop Manual SEN00238-04 provides professional mechanics with the exact procedures, testing sequences, and torque specifications necessary to execute heavy haul truck repairs safely, correctly, and efficiently. Performing maintenance using genuine technical documentation protects costly powertrain components, eliminates guesswork during electrical and hydraulic troubleshooting, and ensures that overhauled assemblies meet factory tolerances. Delivered as an instant, high-resolution PDF download immediately upon checkout, this shop manual is completely free of shipping delays and can be accessed immediately on workshop computers, field laptops, or mobile tablets, or printed out for direct benchtop reference during major repairs.