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Komatsu PC09-1 Shop Manual
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Komatsu PC09-1 Shop Manual

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MACHINE MODEL
PC09-1
• 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.
• PC09-1 mount the 2D68E-N3C engine.
For details of the engine, see the 68E-88E Series Engine Shop Manual.
© 2003
All Rights Reserved
Printed in Japan 03-03(02)
SERIAL NUMBER
10001 and up
SEBM026102
00-1
(2)

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Summary of Contents for Komatsu PC09-1

  • Page 1 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.
  • Page 3 01-8 10-41 20-211 20-414 90-9 20-212 20-415 10-1 20-1 20-213 10-2 20-2 20-215 30-1 10-3 20-3 20-216 30-3 10-4 20-4 20-217 30-4 10-5 20-5 20-218 30-5 10-6 20-6 20-219 30-5-1 10-7 20-7 20-220 30-6 10-8 20-8 20-221 30-7 00-2-1 PC09-1...
  • Page 4 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.
  • Page 5 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 •...
  • Page 6 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.
  • Page 7 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.
  • Page 8 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 # 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 •...
  • Page 12 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. •...
  • Page 13 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...
  • Page 14 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...
  • Page 15 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.
  • Page 16 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...
  • Page 17 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 •...
  • Page 18 FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 19 FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1 l = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925...
  • Page 20 FOREWORD CONVERSION TABLE kgm to ft. lb 1 kgm = 7.233 ft. lb 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
  • Page 21 FOREWORD CONVERSION TABLE kg/cm to lb/in 1kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 384.0 398.3 412.5 284.5 298.7 312.9 327.1 341.4 355.6 369.8 426.7 440.9 455.1 469.4...
  • Page 22 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.
  • Page 23 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}...
  • Page 84 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...
  • Page 85 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...
  • Page 86 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...
  • Page 109 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...
  • Page 110 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...

  • Page 159: Table Of Contents

    Removal ........... 30-13 Installation ..........30-14 SWING CIRCLE Removal and Installation......30-15 IDLER Assembly..........30-16 TRACK ROLLER Assembly..........30-17 RUBBER SHOE Removal and Installation......30-17 CONTROL VALVE Assembly..........30-18 HYDRAULIC CYLINDER Assembly..........30-19 HYDRAULIC BREAKER Disassembly..........30-23 Assembly..........30-26 30-1 PC09-1...

  • Page 162: Disassembly And Assembly

    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...

  • Page 164: Special Tool List

    3 796-170-2130 Shaft Press fitting of thisel Disassembly, assembly hydraulic oil breaker 4 796-170-2140 Shaft Press fitting of dust seal assembly 5 796-170-2150 Shaft Removal of bushing 6 796-170-2160 Handle Removal of cover 7 796-170-2170 Valve Charging nitrogen gas 30-5-1 PC09-1...

  • Page 165: Swing Motor

    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...
  • Page 195 ELECTRICAL CIRCUIT DIAGRAM STANDERD SPECIFICATION 90-6 PC09-1...
  • Page 196 90-7 PC09-1...
  • Page 197 TRAVEL ALARM SPECIFICATION (If equipped) 90-8 PC09-1...
  • Page 198 90-9 PC09-1...