hm 300

00-1

SEBM024815

Machine model

HM300-1

This shop manual may contain attachments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you mayrequire. Materials and specifications are subject to change without notice.

HM300-1 mount the SAA6D125E-3 engine.For details of the engine, see the 125-3 Series Engine Shop Manual.

2012 All Rights ReservedPrinted in Japan 08-12 (02) (15)

Serial number

1001 and up

00-2 HM300-12

CONTENTS

No. of page

01 GENERAL ......................................................................................... 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

00

HM300-1 00-2-1

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(90- 23)

SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.The cautions accompanying these symbols should always be followed carefully. If any danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing. Always wear safety glasses when hitting

parts with a hammer. Always wear safety glasses when grinding

parts with a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive () terminal first.

14.When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts. When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Use the specifications given in the book with the latest date.

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

Electrical volume: Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. See the page number on the bottom of the page.

File the pages in correct order.2. Following examples show how to read the page

number.Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

When a manual is revised, an edit ion mark((1)(2)(3)....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

k Safety Special safety precautionsare necessary when per-forming the work.

a Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 WeightWeight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3 TighteningtorquePlaces that require specialattention for the tighteningtorque during assembly.

2 Coat Places to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.

} Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

k Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol

If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.k Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120 hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

4

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

k Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

l ic tank. For details, see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5

mm. Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3) Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4) Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5) When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3D

isas

sem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turnlever (4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

Con

nect

ion

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.

For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Qty Container Main applications, features

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B 790-129-9050 20 g (2 pcs.)Polyethylene

container

Used in places requiring an immediately effective, strong adhesive.Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

Features: Resistance to heat and chemicals

Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3790-129-9060

(Set of adhesive and hardening

agent)

Adhesive: 1 kg

Hardening agent: 500 g

Can

Used as adhesive or sealant for metal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylene container Used as sealant for machined holes.

Holtz MH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1735 790-129-9140 50 g

Polyethylene container

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha 201 790-129-9130 2 g


Quick hardening type adhesive Quick cure type

(max. strength after 30 minutes) Used mainly for adhesion of rubbers,

plastics and metals.

Loctite 648-50 79A-129-9110 50 cc


Resistance to heat, chemicals Used at joint portions subject to high

temperatures.

Gasket sealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5 790-129-9080 1 kg Can Used as sealant for various threads, pipe

joints, flanges. Used as sealant for tapered plugs,

elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive

case, etc.

LG-7 790-129-9070 1 kg Tube

Features: Silicon based, quick hardening type

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Three bond 1211 790-129-9090 100 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1207B 419-15-18131 100 g Tube

Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material

Used as sealing material for transfer case

FOREWORD COATING MATERIALS

00-11

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube Used to prevent seizure or scuffling of the

thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings,

etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

Used for normal temperature, light load bearing at places in contact with water or steam.

Molybdenum disulphide greaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g 10400 g 20

16 kg

Bellows typeBellows type

Can

Used for heavy load portion

Hyper White Grease G2-TG0-T (*)*: For use in

cold district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

Seizure resistance and heat resistance higher than molybdenum disulfide grease

Since this grease is white, it does not stand out against machine body.

Biogrease G2BG2-BT (*)*: For high

temperature and large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.

Primer

SUNSTAR PAINT PRIMER 580 SUPER

417-926-3910

20 ml Glass container

Adhe

sive

for c

ab g

lass

Used as primer for cab side (Using limit: 4 months)

SUNSTAR GLASS PRIMER 580 SUPER

20 ml Glass container Used as primer for glass side

(Using limit: 4 months)

SUNSTAR PAINT PRIMER 435-95

22M-54-27230 20 ml Glass container Used as primer for painted surface on

cab side (Using limit: 4 months)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240 150 ml Can Used as primer for black ceramic-

coated surface on glass side and for hard polycarbonate-coated surface(Using limit: 4 months)

SUNSTAR SASH PRIMER GP-402

22M-54-27250 20 ml Glass container Used as primer for sash (Alumite).


Adhesive

SUNSTAR PENGUINE SUPER 560

22M-54-27210 320 mlEcocart (Special

container)

Used as adhesive for glass.(Using limit: 6 months)

SUNSTAR PENGUINE SEAL 580 SUPER S or W

417-926-3910 320 ml Polyethylene container

S is used for high-temperature season (April - October) and W for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months)

Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml


Used as adhesive for glass.(Using limit: 6 months)

Caulking material

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920 320 ml Polyethylene container Used to seal joints of glass parts.


SEKISUI SILICONE SEALANT

20Y-54-55130 333 ml Polyethylene container Used to seal front window.


GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220 333 ml Cartridge Used to seal joint of glasses.

Translucent white seal.(Using limit: 12 months)

Category Komatsu code Part No. Qty Container Main applications, features

FOREWORD STANDARD TIGHTENING TORQUE

00-12

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

101214

1013171922

11.8 14.727 3459 7498 123

153 190

1.2 1.52.8 3.5

6 7.510 12.5

15.5 19.5

1618202224

2427303236

235 285320 400455 565610 765785 980

23.5 29.533 41

46.5 5862.5 7880 100

2730333639

4146505560

1150 14401520 19101960 24502450 30402890 3630

118 147155 195200 250250 310295 370

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

1012

10131427

5.9 9.813.7 23.534.3 46.174.5 90.2

0.6 1.01.4 2.43.5 4.77.6 9.2

SAD00483

Sealing surface

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 4.949 19.6

78.5 19.6137.3 29.4176.5 29.4196.1 49245.2 49294.2 49

2.5 0.55 28 2

14 318 320 525 530 5


00-13

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

101216

141722

59 7498 123

235 285

6 7.5 10 12.5

23.5 29.5

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

0203, 0405, 0610, 12

14

1420243342

Varies depending on type of connector.

35 63 {3.5 6.5}84 132 {8.5 13.5}

128 186 {13.0 19.0}363 480 {37.0 49.0}

746 1010 {76.0 103}

44 {4.5}103 {10.5}157 {16.0}422 {43.0}883 {90.0}

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

08101214161820243033364252

08101214161820243033364252

14171922242730323236

5.88 8.82 {0.6 0.9}9.8 12.74 {1.0 1.3}14.7 19.6 {1.5 2.0}19.6 24.5 {2.0 2.5}24.5 34.3 {2.5 3.5}34.3 44.1 {3.5 4.5}44.1 53.9 {4.5 5.5}58.8 78.4 {6.0 8.0}

93.1 122.5 {9.5 12.5}107.8 147.0 {11.0 15.0}127.4 176.4 {13.0 18.0}181.3 240.1 {18.5 24.5}274.4 367.5 {28.0 37.5}

7.35 {0.75}11.27 {1.15}17.64 {1.8}22.54 {2.3}29.4 {3.0}39.2 {4.0}49.0 {5.0}68.6 {7.0}

107.8 {11.0}124.4 {13.0}151.9 {15.5}210.7 {21.5}323.4 {33.0}


00-14

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.

3) TAPERED SCREWSUse these torques for tapered screws (unit: inch) of Cummins Engine.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torque

mm Nm kgm

68

1012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22


mm Nm kgm

68

101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51


inch Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 2

12 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.202.45 0 0.413.67 0 0.516.12 0 0.92

Nominal size of hose

Width across flats

Tightening torque (Nm {kgm}) Taper seal type Face seal type

Range Target Thread size (mm)Nominal thread

size - Threads per inch, Thread series

Root diameter (mm) (Reference)

02 1934 54 {3.5 5.5} 44 {4.5} 18UN 14.3

34 63 {3.5 6.5} 44 {4.5} 14

0322 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5

24 59 98 {6.0 10.0} 78 {8.0} 18

04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6

05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4

06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2

(10) 41 177 245 {18.0 25.0} 216 {22.0} 33

(12) 46 197 294 {20.0 30.0} 245 {25.0} 36

(14) 55 246 343 {25.0 35.0} 294 {30.0} 42

916

1116

1316

316

FOREWORD ELECTRIC WIRE CODE

00-15

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wire

Cable O.D.(mm)

Current rating

(A)Applicable circuit

Number of strands

Dia. of strands(mm2)

Cross section(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-mary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR BW RW YR GW LW

Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB BY RB YB GR LR

Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL BR RY YG GY LY

Color White & Blue Black & Red Red & Yellow Yellow & GreenGreen & Yellow Blue & Yellow

5Code WG RG YL GB LB

Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black

6Code RL YW GL nColor Red & Blue Yellow & White Green & Blue n

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.

EXAMPLE Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal linefrom (A).

(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line downfrom (B).

(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting frommillimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

(A)

(B)

(C)


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176.37

198.42

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178.57

200.62

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180.78

202.83

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182.98

205.03

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185.19

207.24

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187.39

209.44

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189.60

211.64

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191.80

213.85

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194.01

216.05

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196.21

218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.200

4.399

6.599

8.799

10.998

13.198

15.398

17.598

19.797

0.220

2.420

4.619

6.819

9.019

11.281

13.418

15.618

17.818

20.017

0.440

2.640

4.839

7.039

9.239

11.438

13.638

15.838

18.037

20.237

0.660

2.860

5.059

7.259

9.459

11.658

13.858

16.058

18.257

20.457

0.880

3.080

5.279

7.479

9.679

11.878

14.078

16.278

18.477

20.677

1.100

3.300

5.499

7.969

9.899

12.098

14.298

16.498

18.697

20.897

1.320

3.520

5.719

7.919

10.119

12.318

14.518

16.718

18.917

21.117

1.540

3.740

5.939

8.139

10.339

12.528

14.738

16.938

19.137

21.337

1.760

3.950

6.159

8.359

10.559

12.758

14.958

17.158

19.357

21.557

1.980

4.179

6.379

8.579

10.778

12.978

15.178

17.378

19.577

21.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

1084.9

1157.3

1129.6

1301.9

1374.3

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

1092.2

1164.5

1236.8

1309.2

1381.5

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

1099.4

1171.7

1244.1

1316.4

1388.7

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

1106.6

1179.0

1251.3

1323.6

1396.0

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

1113.9

1186.2

1258.5

1330.9

1403.2

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

1121.1

1193.4

1265.8

1338.1

1410.4

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

1128.3

1200.7

1273.0

1345.3

1417.7

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

1135.6

1207.9

1280.1

1352.6

1424.9

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

1142.8

1215.1

1287.5

1359.8

1432.1

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

1150.0

1222.4

1294.7

1367.0

1439.4


00-20

kg/cm2 to lb/in21kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399

3542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F

C F C F C F C F

40.437.234.431.728.9

28.327.827.226.726.1

25.625.024.423.923.3

22.822.221.721.120.6

20.019.418.918.317.8

17.216.716.115.615.0

14.413.913.312.812.2

4035302520

1918171615

1413121110

9 8 7 6 5

4 3 2 1 0

1 2 3 4 5

6 7 8 9 10

40.031.022.013.0 4.0

2.2 0.4 1.4 3.2 5.0

6.8 8.6 10.4 12.2 14.0

15.8 17.6 19.4 21.2 23.0

24.8 26.6 28.4 30.2 32.0

33.8 35.6 37.4 39.2 41.0

42.8 44.6 46.4 48.2 50.0

11.711.110.610.0 9.4

8.9 8.3 7.8 7.2 6.7

6.1 5.6 5.0 4.4 3.9

3.3 2.8 2.2 1.7 1.1

0.6 0

0.6 1.1 1.7

2.2 2.8 3.3 3.9 4.4

5.0 5.6 6.1 6.7 7.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.8 53.6 55.4 57.2 59.0

60.8 62.6 64.4 66.2 68.0

69.8 71.6 73.4 75.2 77.0

78.8 80.6 82.4 84.2 86.0

87.8 89.6 91.4 93.2 95.0

96.8 98.6100.4102.2104.0

105.8107.6109.4111.2113.0

7.8 8.3 8.9 9.410.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859 0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

81 82 83 84 85

86 87 88 89 90

91 92 93 94 95

96 97 98 99100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22 04-05

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:N {kg}Nm {kgm}MPa {kg/cm2}kPa {mmH2O}kPa {mmHg}kW/rpm {HP/rpm}g/kWh {g/HPh}

GENERAL

HM300-1 01-1

01 GENERAL

Specification drawings................................................................................................................................... 01-2Specifications ................................................................................................................................................ 01-3Weight table................................................................................................................................................... 01-6Fuel, coolant and lubricants........................................................................................................................... 01-7

GENERAL SPECIFICATION DRAWINGS

01-2 HM300-1

SPECIFICATION DRAWINGS

GENERAL SPECIFICATIONS

HM300-1 01-3

SPECIFICATIONS

Machine model HM300-1 HM300-1 E-SPEC

Serial Numbers 1001 and up 1001 and up

Wei

ght

Unloaded

Max. payload

Overall weight

kg

kg

kg

23,545

27,300

50,920

Weight

Unloaded (front wheel)

(center wheel)

(rear wheel)

Fully loaded (front wheel)

(center wheel)

(rear wheel)

kg

kg

kg

kg

kg

kg

13,125

5,345

5,075

15,220

18,125

17,575

Per

form

ance

Dump body capacityStruck

Heaped (2:1)

m3

m312.9

16.6

Max. travel speed

Gradeability (sin )

Min. turning radius

Dumping angle (angle to ground)

km/h

mm

deg

59

0.45

8,110

70

Dim

ensi

ons

Overall length

Overall width

Overall height

Wheelbase (front wheel - center wheel)

Wheelbase (center wheel - rear wheel)

mm

mm

mm

mm

mm

10,095

3,195

3,500

4,100

1,710

Tread

Front tires

Center tires

Rear tires

mm

mm

mm

2,435

2,435

2,435

Ground Clearance mm 510

Eng

ine

Model

Type

No. of cylinders - Bore x stroke

Piston displacement

Flywheel horsepower

Max. torque

Fuel consumption (rated)

Starting motor

Alternator

Battery

mm

l {cc}kW/rpm{HP/rpm}

Nm/rpm{kgm/rpm}

g/kWh{g/HPh}

Komatsu SAA6D125E-3

4-cycle, water-cooled, in-line 6 cylinder, direct injection, with turbocharger and air-cooled

after-cooler

6-125 x 150

11.04{11,040}

238/2,000 {319/2,000}

1,569/1,400 {160/1,400}

194 {145}

7.5kW

24V 50A

12V 112Ah x 2

4(9)


01-4 HM300-1



Pow

er tr

ain

Torque converterType

Lock-up clutch

3-element, 1-stage, 2-phase

Hydraulically-actuated, wet-type, single-disc clutch

TransmissionType

No. of speeds

TORQFLOW multiple-axle transmission, fully automatic, electrically-hydraulically actuated,

force-feed type pump lubrication type

F6, R2

Reduction gear

Type

Reduction ratio

Differential type

Spiral bevel gear, splash lubrication

3.154

Straight bevel gear, splash lubrication

Final driveType

Reduction ratio

Planetary gear, splash lubrication

4.667

Trav

el s

yste

m

Type Fully hydraulic

Sus

pens

ion Axle type

Front axle

Center axle

Rear axle

Full floating suspension (De Dion type)

Full floating suspension

Full floating suspension

Suspension methodFront axle

Rear axle

Hydropneumatic type

Hydropneumatic type

Tire

s

Size and no.

Front tire

Center tire

Rear tire

23.5 R25 x 2

23.5 R25 x 2

23.5 R25 x 2

Tire inflation pressurekPa

{kg/cm2}440 {4.5}

Bra

kes

Main brakeFront wheel

Center wheel

Independent front and center system brake, sealed, wet- type, multiple disc, hydraulically operated type

Independent front and center system brake, sealed, wet- type, multiple disc, hydraulically operated type

Parking brake Spring-boosted, caliper disc type

Retarder

Independent front and center system brake,

sealed, wet- type, multi-ple disc, hydraulically

operated type

4


HM300-1 01-5



Hyd

raul

ic s

yste

m

Hyd

raul

ic p

ump,

mot

or

For steering, hoistType

Discharge amount (l /min)(when engine is at rated speed of 2000 rpm)

For hoist controlType


For transmission, brake coolingType

Discharge amount (l /min) (when engine is at rated speed of 2000 rpm)

For brake coolingType


For brake Type


Gear pump137 + 137

Gear pump14.1

Gear pump204

Gear pump180

Gear pump40

Cyl

inde

rs

Hoist cylinderType

No. - bore (1st-2nd) x strokeSteering cylinder

TypeNo. - bore x stroke

2-stage piston type(only 2nd stage double-acting)

2-(140mm-100mm) x 2,897mm

Piston type, double acting2-110mm x 420mm

4(9)

GENERAL WEIGHT TABLE

01-6 HM300-1

WEIGHT TABLE This weight table is a guide for use when transporting or handling components.

Unit: kg



Engine assembly

Output shaft assembly

Cooling assembly

Fuel tank (individual part)

Torque converter assembly

Transmission assembly

Drive shaft assembly

Front axle assembly

Differential

Final drive

Center axle assembly

Differential

Final drive

Rear axle assembly

Differential

Final drive

Front suspension cylinder

Rear suspension cylinder

Oscillation hitch assembly

Front frame

Rear frame

ROPS cab (including platform, interior components)

Operators seat

Steering cylinder (one side)

Hoist cylinder (one side)

Flow amp valve

Hoist valve

Hydraulic tank

Hydraulic pump (SAR(3) 63 + 63 + (1)6)

Hydraulic pump (SAR(3)90)

Hydraulic pump (SAR(3)80+(1)18)

Hydraulic pump (SBL(1)26)

Emergency steering motor

Body assembly

1,200

65

229

205

112

935

178

1,139

302

779

1,394

300

813

894

194

423

70.1

54.2

634

1,362

1,596

1,300

56.1

56.2

182

29

33.6

185

38.6

17.2

24.8

7.9

13

3,454

(12)

GENERAL FUEL, COOLANT AND LUBRICANTS

HM300-1 01-7

FUEL, COOLANT AND LUBRICANTS

ASTM: American Society of Testing and Material

(11)


01-8 HM300-1

NOTICEUse only diesel fuel.The engine mounted on this machine employs electronic control and a high-pressure fuel injectiondevice to obtain good fuel consumption and good exhaust gas characteristics. For this reason, itrequires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricatingability is used, there will be a big drop in durability.

Note 1: HTHS (High-Temperature High-Shear Viscosity 150C), specified by ASTM D4741 must be equal to orhigher than 3.5 m Pa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.

Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.

Note 3: When the ambient temperature is higher than 45C (113F) and the machine operation hour is longerthan 12 hours/day, then the use of TO50 instead of AXO80 is recommended.Squealing of the brakes may occur with TO50, but there is no problem with the brake performance ordurability.

Note 4: Hyper grease (G2-T, G2-TE) has a high performance.When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking ofpins and bushings, the use of G2-T or G2-TE is recommended.

Note 5: Supercoolant (AF-NAC)1) The coolant has the important function of preventing corrosion as well as preventing freezing.

Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC)has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or4000 hours.Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.

2) For details of the ratio when diluting super coolant with water, see "Mixing rate water and antifreeze".When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Super-coolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10C (14F). (neverdilute with water)

3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercool-ant between 30% and 68%.

Reservoir

Capacity

Engine oilpan

Transmission case

(Incl. brake oil tank)

Hydraulic tank

Front suspension

(each)

Rear suspension

(each)

Front differential

Case

Specified Liters 45 165 171 3 2.2 14

Refill Liters 35 77.5 120 3 2.2 14

Reservoir

Capacity

Front final drive case

(each)

Centerdifferential

case

Center final drive case

(each)

Rear differential

case

Rear final drive case

(each)Fuel tank Cooling system

Specified Liters 4.5 25 4.0 25 5.0 386 57

Refill Liters 4.0 24.5 3.5 25 4.5 51

(11)


HM300-1 01-9

Mixing rate of water and antifreeze

Min. atmospherictemperature

C -10 -15 -20 -25 -30

F 14 5 -4 -13 -22

Amount of antifreeze Liters 15.3 18.4 21.0 23.5 25.5

Amount of water Liters 35.7 32.6 30.0 27.5 25.5

Volume ratio % 30 36 41 46 50

(11)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HM300-1 10-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RADIATOR, OIL COOLER, AFTERCOOLER ............................................................................................. 10-2POWER TRAIN SKELETON ....................................................................................................................... 10-4OUTPUT SHAFT ......................................................................................................................................... 10-6TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING ...................................................... 10-8TORQUE CONVERTER ............................................................................................................................ 10-10TRANSMISSION ....................................................................................................................................... 10-16TRANSMISSION VALVE ........................................................................................................................... 10-36ECMV (Electronic Control Modulation Valve) ............................................................................................ 10-37MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE ........................................................................ 10-44DRIVE SHAFT .......................................................................................................................................... 10-46AXLE ......................................................................................................................................................... 10-47DIFFERENTIAL ......................................................................................................................................... 10-50LIMITED SLIP DIFFERENTIAL ................................................................................................................. 10-56FINAL DRIVE ............................................................................................................................................ 10-62STEERING COLUMN ................................................................................................................................ 10-67BRAKE PIPING ......................................................................................................................................... 10-68BRAKE VALVE ......................................................................................................................................... 10-70ACCUMULATOR CHARGE VALVE .......................................................................................................... 10-73ACCUMULATOR ....................................................................................................................................... 10-77SLACK ADJUSTER ................................................................................................................................... 10-78BRAKE ...................................................................................................................................................... 10-80PROPORTIONAL REDUCING VALVE ..................................................................................................... 10-85BRAKE SYSTEM TANK ............................................................................................................................ 10-86PARKING BRAKE ..................................................................................................................................... 10-88PARKING BRAKE CALIPER ..................................................................................................................... 10-90SPRING CYLINDER .................................................................................................................................. 10-91PARKING BRAKE SOLENOID .................................................................................................................. 10-92SUSPENSION ........................................................................................................................................... 10-94SUSPENSION CYLINDER ...................................................................................................................... 10-100OSCILLATION HITCH ............................................................................................................................. 10-102STEERING, HOIST OIL PRESSURE PIPING DIAGRAM ....................................................................... 10-106DUMP BODY CONTROL ........................................................................................................................ 10-107HYDRAULIC TANK AND FILTER ........................................................................................................... 10-108FLOW AMP VALVE ................................................................................................................................. 10-109STEERING VALVE .................................................................................................................................. 10-112STEERING CYLINDER ........................................................................................................................... 10-116HOIST VALVE ......................................................................................................................................... 10-118EPC VALVE ............................................................................................................................................. 10-124PILOT CHECK VALVE ...........................................................................................................................10-124-1HOIST CYLINDER .................................................................................................................................. 10-125HYDRAULIC PUMP ................................................................................................................................ 10-126CAB TILT ................................................................................................................................................. 10-130AIR CONDITIONER ................................................................................................................................ 10-131HEATER ................................................................................................................................................ 10-135-1MACHINE MONITOR SYSTEM .............................................................................................................. 10-136AUTOMATIC SHIFT CONTROL SYSTEM .............................................................................................. 10-149TRANSMISSION CONTROLLER ............................................................................................................ 10-151AUTO EMERGENCY STEERING SYSTEM ........................................................................................... 10-157SENSORS, SWITCHES .......................................................................................................................... 10-158RETARDER CONTROL SYSTEM .......................................................................................................... 10-166BRAKE CONTROL SYSTEM (E-SPEC) ................................................................................................10-175-1DUMP CONTROL LEVER ........................................................................................................................ 10-176

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10-2 HM300-1

RADIATOR, OIL COOLER,AFTERCOOLER

RADIATOR, OIL COOLER, AFTERCOOLER

1. Reservoir tank2. Radiator3. Aftercooler4. Torque converter oil cooler 5. Steering oil cooler6. Upper tank7. Lower tankA. To intake manifoldB. From turbochargerC. From thermostatD. To water pump

Specifications Radiator Core type: CF4-4 Total heat dissipation area: 50.61m2Torque converter oil cooler Core type: PTO-LS Total heat dissipation area: 4.065m2Steering oil cooler Core type: PTO-LS Total heat dissipation area: 0.497m2

(9)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON

10-4 HM300-1

POWER TRAIN SKELETON

4(9)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON

HM300-1 10-5

1. Engine2. Output shaft3. Front drive shaft4. Brake cooling and brake system pump (SAR(3)80+(1)18)5. Torque converter, transmission, front brake cooling pump (SAR(3)90)6. PTO7. Torque converter8. Steering, hoist control pump (SAR(3)63+63+(1)6)9. Transmission10. Front drive shaft11. Oscillation hitch12. Center drive shaft13. Front differential14. Front limited slip differential15. Front drive shaft16. Tire17. Final drive (front)18. Brake (front)19. Rear drive shaft (front)20. Center differential21. Center limited slip differential22. Tire23. Final drive (center)24. Brake (center)25. Rear drive shaft (rear)26. Rear differential27. Rear limited slip differential28. Tire29. Final drive (rear)30. Interaxle differential lock

4(9)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT

10-6 HM300-1

OUTPUT SHAFT

1. Rubber cushion2. Outer body3. Inner body4. Breather5. Coupling shaft6. Flange7. Cover

FUNCTIONThe output shaft is installed to the engine fly-wheel,and absorbs the twisting vibration caused bychanges in the engine torque.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT

HM300-1 10-7

Unit: mm

No. Check item Criteria Remedy

1 Clearance between bearingand inner body

Standardsize

Tolerance Standardclearance

Clearancelimit

Replace

Shaft Hole

85 +0.025+0.0030

-0.020-0.045 -0.013

2 Clearance between bearingand flange 1300

-0.018-0.020-0.045

-0.045 -0.002

3 Clearance between retainerand flange 130+0.006-0.034

+0.060+0.020

-0.014 -0.094

4 Wear of shaft and oil seal con-tact surface

Standard size Tolerance Repair limit

70 0-0.074 -0.12

5 Backlash at splineportionStandard backlash Clearance limit

0.071 0.177 0.35

6 Deterioration and cracks inrubber

Standard clearance Clearance limit

70 At min. width: Min. 63 mmThere must be no cracks

7 Deterioration and cracks inrubber 50At min. width: Min. 48 mmThere must be no cracks

(9)


10-8 HM300-1

TORQUE CONVERTER AND TRANSMISSIONHYDRAULIC PIPING

TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING


HM300-1 10-9

TORQUE CONVERTER AND TRANSMIS-SION HYDRAULIC PIPING

1. Engine2. Oil cooler3. Rear brake cooling and brake system pump (SAR(3)80+(1)18)4. Torque converter5. Transmission6. Hydraulic tank7. Brake system tank8. Torque converter, transmission, front brake cooling pump (SAR(3)90)9. Transmission line filter

4(9)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER

10-10 HM300-1

TORQUE CONVERTER

1. PTO gear (No. of teeth: 66)Unit: mm

SPECIFICATIONSType: 3 element, 1-stage, 2-phase

with modulation and lock-upclutch

Lock-up clutch: Multiple-disc clutchHydraulic control(with modulation valve)

Stall torque ratio: 2.46


2 Clearance between PTO gear and bearing

Standardsize


Clearancelimit

Replace

Shaft Hole

50 +0.018+0.0020

-0.012-0.030 -0.002

3 Clearance between bearing and case 900

-0.015+0.016-0.006

-0.006 0.031

(9)


HM300-1 10-11

1. Coupling2. Input shaft

(No. of teeth: 78)3. Case4. Drive case5. Turbine6. Race7. Pump

8. Stator shaft9. One way clutch10. Stator11. Disc12. Piston13. Clutch housing14. Retainer

(9)


10-12 HM300-1


HM300-1 10-13

Unit: mm


1 Outside diameter of coupling and oil seal sliding portion

Standard size Tolerance Repair limit

Replace

95 0-0.087 94.8

2Inside diameter of seal ring sliding portion of input shaft sliding portion

35 +0.0250 35.1

3 Inside diameter of seal ring sliding portion of clutch housing 365+0.089

0 365.5

4 Inside diameter of seal ring sliding portion of clutch piston 260+0.081

0 260.1

5 Inside diameter of seal ring sliding portion of pump housing 140+0.040

0 140.5

6 Inside diameter of seal ring sliding portion of input shaft 60+0.030

0 60.1

7 Wear of clutch housing seal ringWidth 5 -0.01-0.04 4.5

Thickness 6 0.15 5.85

8 Wear of stator shaft seal ringWidth 4.45 0-0.1 4.05

Thickness 5.2 0.1 4.7

9Inside diameter of outer race one-way clutch transmission surface

102.555 0.008 102.585

10Outside diameter of inner race one-way clutch transmission surface

83.6 + 0.004- 0.009 83.57

11 Inside diameter of sliding por-tion of bushing 83.71+0.015

0 83.79

12 Thickness of sliding portion of bushing 6 0.05 5.5

13 Thickness of clutch disc 5 0.1 4.4

14 Backlash between input shaft and PTO gear 0.18 0.46

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10-14 HM300-1

PATH FOR TRANSMISSION OF POWER

1. When lock-up clutch is disengagedWhen the lock-up clutch is disengaged, drivecase (1) and turbine (2) are separated, and thetorque converter functions as normal.The power generated by the engine goes fromthe damper through the drive shaft, is transmit-ted to coupling (3), input shaft (4) and clutchhousing (5), and rotates drive case (1) and pump(6) as one unit.The power from pump (6) uses oil as a medium,rotates turbine (2), and is transmitted from tur-bine (2) to transmission input shaft (7).

2. When lock-up clutch is engagedWhen the lock-up clutch is engaged, drive case(1) and turbine (2) are engaged and form oneunit. Stator (8) is rotated by the rotation of pump(6) and turbine (2).The power generated by the engine goes fromthe damper through the drive shaft, is transmit-ted to coupling (3), input shaft (4) and clutchhousing (5), and rotates drive case (1) and pump(6) as one unit.In addition, drive case (1) and turbine (2) are en-gaged by the clutch, so the power is transmitteddirectly from turbine (2) to transmission inputshaft (7) without using oil as a medium.

(9)


HM300-1 10-15

FLOW OF OIL

The oil passes through the main relief valve, is ad-justed by the torque converter relief valve to a pres-sure less than the set pressure, and enters inlet portA. It then passes through the oil passage in statorshaft (1) and flows from between pump (2) and sta-tor (3) to pump (2). The oil is given centrifugal forceby pump (2), enters turbine (4), and transmits the en-ergy of the oil to the turbine.The oil from turbine (4) is sent to stator (3), and en-ters the pump again. However, part of the oil passesbetween turbine (4) and stator (3) and is sent fromoutlet port B to the oil cooler to be cooled. It is thenused to lubricate the transmission.

(9)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION

10-16 HM300-1

TRANSMISSION

1. Transmission case (front)2. Transmission case (rear)3. Oil filler pipe mount4. Transmission control valve5. Main relief, torque converter relief valve


HM300-1 10-17

1. R clutch2. Idler gear (No. of teeth: 53)3. 1st clutch4. 2nd clutch5. Differential lock clutch6. Rear output shaft7. Rear coupling8. Front output shaft

9. Lower shaft10. 3rd clutch11. Upper shaft12. FH clutch13. Input shaft14. FL clutch15. Torque converter


10-18 HM300-1


HM300-1 10-19


1 Clearance (F) between FL, R clutch bearing and case

Standardsize


Clearancelimit

Replace

Shaft Hole

130 0-0.018+0.026-0.014

-0.014 0.044

2 Clearance (R) between FL, R clutch bearing and case 1300

-0.018-0.012-0.052

-0.052 0.006

3 Clearance (F) between FH, 1st clutch bearing and case 1300

-0.018+0.026-0.014

-0.014 0.044

4 Clearance (R) between FH, 1st clutch bearing and case 1300

-0.018-0.012-0.052

-0.052 0.006

5 Clearance (R) between FH. 1st clutch bearing and upper shaft 60+0.054+0.044

0-0.015

-0.069 0.044

6 Clearance (F) between 2nd, 3rd clutch bearing and case 1200

-0.015-0.010-0.045

-0.045 0.005

7 Clearance (R) between 2nd, 3rd clutch bearing and case 1250

-0.018-0.012-0.052

-0.052 0.006

8 Clearance (F) between differential lock clutch bearing and case 2300

-0.030-0.014-0.060

-0.060 0.016

9 Clearance (R) between differential lock clutch bearing and case 205.583+0.025

0+ 0.013-0.033

-0.058 -0.013

10

Width of input shaft seal ring grooveStandard size Tolerance Repair limit

2.5 +0.18+0.10 2.7

Wear of input shaft seal ring

Width 2.4 0.05 2.2

Thickness 1.7 0-0.10 1.5

11

Width of input shaft seal ring groove 3.2 +0.0760 3.5

Wear of input shaft seal ring

Width 3.1 0- 0.05 2.8

Thickness 2.05 0.10 1.8

12

Inside diameter of seal ring sliding portions of input and upper shafts (Rear side)

60 +0.0500 60.1

Width of seal ring grooves of input and upper shafts (Rear side) 3.2

+0.0760 3.5

Wear of seal ring grooves of input and upper shafts (Rear side)

Width 3.1 0-0.05 2.8

Thickness 2.05 0.10 1.8

13

Inside diameter of seal ring sliding portion of lower shaft (Rear side) 50

+0.0500 50.1

Width of seal ring groove of lower shaft (Rear side) 3.2

+0.0760 3.5

Wear of seal ring groove of lower shaft (Rear side)

Width 3.1 0-0.05 2.8

Thickness 2.05 0.10 1.8

14

Inside diameter of seal ring sliding portion of front output shaft 80

+0.0300 80.1

hm 300

Documents

series engine shop manual

added addq page

list of revised pages15q

tothe list

use of thefollowing

optional equipment

maintenance standard

serial number1001