-
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
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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
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(90- 23)
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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.
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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
Polyethylene container
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
Polyethylene container
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).
(Using limit: 4 months)
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
Polyethylene container
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.
(Using limit: 4 months)
SEKISUI SILICONE SEALANT
20Y-54-55130 333 ml Polyethylene container Used to seal front
window.
(Using limit: 6 months)
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
-
FOREWORD STANDARD TIGHTENING TORQUE
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}
-
FOREWORD STANDARD TIGHTENING TORQUE
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
Thread diameter Tightening torque
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
Thread diameter Tightening torque
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)
-
FOREWORD CONVERSION TABLE
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
-
FOREWORD CONVERSION TABLE
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
-
FOREWORD CONVERSION TABLE
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
-
FOREWORD CONVERSION TABLE
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
-
FOREWORD CONVERSION TABLE
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)
-
GENERAL SPECIFICATIONS
01-4 HM300-1
Machine model HM300-1 HM300-1 E-SPEC
Serial Numbers 1001 and up 1001 and up
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
-
GENERAL SPECIFICATIONS
HM300-1 01-5
Machine model HM300-1 HM300-1 E-SPEC
Serial Numbers 1001 and up 1001 and up
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
Discharge amount (l /min)(when engine is at rated speed of 2000
rpm)
For transmission, brake coolingType
Discharge amount (l /min) (when engine is at rated speed of 2000
rpm)
For brake coolingType
Discharge amount (l /min)(when engine is at rated speed of 2000
rpm)
For brake Type
Discharge amount (l /min)(when engine is at rated speed of 2000
rpm)
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
Machine model HM300-1 HM300-1 E-SPEC
Serial Numbers 1001 and up 1001 and up
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)
-
GENERAL FUEL, COOLANT AND LUBRICANTS
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)
-
GENERAL FUEL, COOLANT AND LUBRICANTS
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
(11)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-8 HM300-1
TORQUE CONVERTER AND TRANSMISSIONHYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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
No. Check item Criteria Remedy
2 Clearance between PTO gear and bearing
Standardsize
Tolerance Standardclearance
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)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE
CONVERTER
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)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE
CONVERTER
10-12 HM300-1
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE
CONVERTER
HM300-1 10-13
Unit: mm
No. Check item Criteria Remedy
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
(9)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE
CONVERTER
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)
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE
CONVERTER
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
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
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
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
10-18 HM300-1
-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
HM300-1 10-19
No. Check item Criteria Remedy
1 Clearance (F) between FL, R clutch bearing and case
Standardsize
Tolerance Standardclearance
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