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10001 and up • This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
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Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
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SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi- nal places. 11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts. hydraulic pressure measuring plugs, loosen •...
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FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judge- ments.
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DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be Symbol Item Remarks sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Special safety precautions ¤ Safety are necessary when per- forming the work.
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FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING Slinging near the edge of the hook may cause ¤ the rope to slip off the hook during hoisting, and H eavy parts (25 kg or more) must be lifted a serious accident can result. Hooks have max- with a hoist, etc.
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER ¤ B efore carrying out the following work, release Type 1 the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type 2 Type 3 1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre- vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of the hexagonal portion at the male end.
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# The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. # For coating materials not listed below, use the equivalent of products shown in this list. Category Komatsu code Part No. Q'ty Container Main applications, featuresr •...
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FOREWORD COATING MATERIALS Category Komatsu code Part No. Q'ty Container Main applications, featuresr • Ftures: Silicon based, quick hard- ening type LG-7 790-129-9070 Tube • Used as sealant for flywheel housing, intake manifold, oil an, Adhesives thermostat housing, etc. •...
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FOREWORD STANDARD TIGHTENING TORQUE 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. Thread diameter Width across of bolt...
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FOREWORD STANDARD TIGHTENING TORQUE 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. Thread diameter Width across flat Tightening torque 65.7 11.5...
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FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter Tightening torque 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22 2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
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FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In 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 Copper wire Current...
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FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE •...
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FOREWORD CONVERSION TABLE Temperature Fahrenheit-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.
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FOREWORD UNITS 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/cm kPa {mmH kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}...
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Inspection and adjustment of hydraulic pressure in work equipment, swing and travel circuits... 20-113 Identification of spot causing work equipment hydraulic drift ............... 20-116 Measurement of oil leak amount inside work equipment cylinder ............20-117 Bleeding air from hydraulic circuits....................... 20-117 Pressurizing hydraulic tank........................20-118 20-101 PC09-1...
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0 – 294 N {0 – 30 kg} Operating effort 79A-264-0091 Push-pull scale 0 – 490 N {0 – 50 kg} Commercially Stroke, hydraulic drift Scale available Commercially Work equipment speed Stopwatch available Commercially Voltage resistance Tester available Sensor, wiring harness 799-601-7400 T-adapter KIT 20-101-1 PC09-1...
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3. Install clamp [1] of multi-tachometer A to fuel injection piping (2). With 2D68E engines, the No. 1 cylinder is located on the flywheel side. The clamp may be installed to either of the No. 1 and No.2 cylin- ders. 20-102 PC09-1...
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Since the DT 8-pole and 12-pole heavy duty wire connec- tors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female conector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c 20-207 PC09-1...
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Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. After completely drying the connector, blow it with contact restorer and reassemble. 20-208 PC09-1...
07371-30400 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 30-4 PC09-1...
Hydraulic oil : 9 (EO10-CD) Pressurize the hydraulic tank, referring to the section of "PRESSURIZING HYDRAULIC TANK" in INSPECTION AND ADJUSTMENT. 30-6 PC09-1...