‘SEBM020NA00 SIO WwW IMLAVINTUA\ Ls KOMATSU PC10-3 MACHINE MODEL SERIAL No. PC10-3 10001 and up Printed in Japan 12-83(02}0034CONTENTS No. of page 01 GENERAL 01-1 10 ENGINE 11 STRUCTURE AND FUNCTION ..........0005 1-4 12 TESTING AND ADJUSTING cee cee 12-4 13 DISASSEMBLY AND ASSEMBLY ........ eee 13-1 20 POWER TRAIN 21 STRUCTURE AND FUNCTION ........000.0005 21-4 23 DISASSEMBLY AND ASSEMBLY ..........-.....5 : 23-1 24 MAINTENANCE STANDARD .........00000000:000000 + 24-1 30 UNDERCARRIAGE 31 STRUCTURE AND FUNCTION .... oe neceesees BTA 34 MAINTENANCE STANDARD Gosanodanatmaceaiccacsecd 34-1 60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION . 61-1 62 TESTING AND ADJUSTING 62-1 63 DISASSEMBLY AND ASSEMBLY eaee set teeee er cet OS) 64 MAINTENANCE STANDARD ...........000000cceecseteeeeeeetereneee 64-1 70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION ........000cee00e ee dl 74 MAINTENANCE STANDARD .........---22200000eeeeeeetesereeeeeenns 744 80 ELECTRICAL SYSTEM 81 STRUCTURE AND FUNCTION . 81-1 00-2 PC10.3ZA\IporTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols /A\, and UN are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine, 1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing, © Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when gtinding parts with a grinder, etc. 3.1f welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two or more workers. always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the ‘machine from moving. 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In additon, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. 1 it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing, 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug ‘or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. ‘Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel oF oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In patticular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. © When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check. that the measuring tool is correctly assem- bled before taking any measurements, 24. Take care when removing or installing the tracks of track-type machines, When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD 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 judgements. 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 service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give ‘an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations, MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE ‘The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as 2 guide to carrying, ut repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series, Each issued as one volume to cover all models Electrical volume Attachments volume ‘These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, itis necessary DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any works, FILING METHOD 1, 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): 214-3 Unit number (2. Power train) Item number (1. Structure and Function) Consecutive page number for each items. Example 2 (Engine volume} 42-410 i Unit number (Engin item number (2. Testing and Adjusting! Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page ‘number. File as in the example. Example. 21-4 12-203 2-4-1 12-2081 21.4.2} — Added pases 49/793-2 21-8 12-204 00-6 REVISED EDITION MARK (D2@-—) When a manuals revised, 3 edition mark is record- ed on the bottom outside comer of the pages. REVISIONS Revised pages are shown at the (LIST OF REVISED PAGES) on the back of the title page. SYMBOLS. So that the shop manual can be of sufficient practical use, important places for safety and quality are marked with the following symbols. Symbol | Item Remarks Spocial safety precautions are ad necessary when performing the wor Safety Extra special safety precautions yp are necessary when performing i the work because itis under internal pressure. Special technical precautions or other precautions tor ke | Caution preserving standards are fecescary wen performing the work Weight of pars or systems Caution necessary when (ie) | Weight | selecting hoisting wire, or when working posture ts important, ate, ‘chen. [Places that require special S| Tighten’ | attention for the tightening 19 torque) torque during assembly. Places to be coated with Coat | adhesives and lubricants etc. Paces wher oi, water or fue Gp | oi. water|must be asae0 and tne bei Places where oll or water must Drain |be drained, and quantity to be drained,HOW TO READ THE SHOP MANUAL NETWORK (Disassembly and assembly rela- tionship drawings) In the shop manual the following network draw- ings show relationship between work items and se- quence for assembly and disassembly. : s Lu a ® 5 > Assy e ay 50001 In this network the sequence of disassembly is marked on the top right of each work item so that handling can be easily understood. For example, when taking D of the Ass'y follow the sequence A— B- D, when removing E follow the sequence A —E. [eas incates a further separate disassem- bly, sates the existance of a previous work network. For assembly the sequence is shown using the same kind of network. TROUBLESHOOTING CHART ‘As shown below, the symptoms relating to 8 par- ticular trouble are described in the line designated Problems". The probable cause of the trouble is then marked under the “Causes” column. Example Symptom: Reduced tractive power or slow raval speed cames : 2 gE 82 ii roams 3/2 Sanaa ease [oo lo aatkoee™ aig mre | | o ° MAINTENANCE STANDARD Standard size, Tolerance ‘The dimensions of finished parts each differ a little. Therefore, when determing the finished dimen- sions of parts, a dimension that will be standard is determined provisionally, then the difference allowed {rom itis indicated, The former is called the standard size, and the latter the tolerance. The way to show this is by a plus or @ minus sign with the tolerance in smaller numerals to the right of the standard size. Example: 12073938 0138 (tequals 119.874 — 119.978 mm) Moreover, when expressing the dimensions of a hole and the shaft that goes inside it, for the sake of convenience, the standard size for the hole and the shaft are usually taken as the same, and the toler- ances changed to indicate the tightness of the fit. For example, the fit of a revolving shaft is indicated as follows, and is shown in the drawing, z = 8 8 3 0.030 Shaft: 6079030 i 2 Lower tolerance: 0.076 3 i {4 50002 00-7HOW TO READ THE SHOP MANUAL Standard size This is the standard value at the time of design. Repair limit This is the limit in dimensions which the part can be used. When parts exceed the repair limit, they must be repaired or replaced as specified. Example: Units mm No. ‘Check tem ‘rivera Remedy Standard size Standard clearance This is the clearance between new parts after assembly. It is recorded as a range between minimum clearance and maximum clearance. The clearance is adjusted to this value. Clearance limit This is the maximum clearance allowed. ‘When the clearance exceeds the clearance limit, ‘the parts must be repaired or replaced as specified. Example: Unit: mm Ne ‘Check ier Criteria Remedy ‘Stendora]_ Tolerance sie | shart | Hole 00-8PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 1. PREPARATIONS BEFORE DISASSEMBLY 1. Washing before taking @ machine into the repair shop ‘Thoroughly wash the machine to remove sand, mud and dust before taking it into the shop. Taking a dirty machine into the shop will decrease work efficiency, cause damage to parts, and it crease the intrusion of dust and dirt into the ma~ chine when it is reassembled. 2. Checking the machine before disassembly Before disassembly, study the entire disassembly procedure from beginning to end in the reference materials, and carefully check and record the items listed below. This will help to save unneces- sary disassembly and parts costs. It will also gi ‘clues on how to prevent recurrence of the trouble. @ Machine model, serial number and service meter reading. ‘@ Reason for disassembly. (Symptoms, locations, and cause of trouble) ‘@ Any dirty air cleaner elements or sir leakage. @ Properties of fuel used, clogging of fuel filter ‘elements, water mixed in fuel, and leaky or con- stricted fuel pipes. @ Oil capacities, dirtiness of oils (viscosity, color, ‘and any impurities), water mixed in oil, oil leak- age, and any clogging of oil filter elements. Tension of the V-belt and tracks. ‘@ Any damaged parts or loose bolts. 3. Preparation for disassembly Prepare the required facilities, tools, and space for the disassembly work and rack space for storing the disassembled parts. Make sure that they are all clean. 2, PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 1. During disassembly AIF the disassembly involves draining oil or lubricants, have containers of suitable capacity on hand. Do not spill any oil or lubricants on the floor. 2) Mark the parts clearly to prevent confusion at the time of reassembly 3) For disassembly of certain designated parts, use only the special tool prescribed for that purpose. 4) When, after removal of fastening nuts and bolts, a part still can not be removed, never force it. Instead, investigate and correct the 5) Maintain disassembled parts in good order for storage, paying special care not to confuse parts that appear similar. Tag them or mark with ink if necessary. 6) Store standard parts such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. 2. During reassembly 1) Thoroughly clean and examine all parts before reassembly. Repair any scratched or dented surfaces. + Foreign matter is especially damaging to slid- ing surfaces, and will greatly decrease their service life, 2) Clean new parts to remove any rust preventa- tive coating. Solvent: Light oil or trichloroethane 3) Carefully align any match marks provided. 4) Use a press or press-fitting tool to assemble bearings, bushings and oil seals. 3. Checks and inspections during bly/reassembly 1) During disassembly, watch carefully for e\ dence of seizing, interference, or improper con- ‘act of sliding parts. 2) Measure and record end clearances, gear backlashes, protrusions, and the like during the disassembly/reassembly. Quite often they cannot be measured afterwards. 00-9PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 3. DETERGENTS 1. Precautions for cleaning 1) Thoroughly clean disassembled parts and group them by unit for storage. Be especially sure to remove sludge from oil holes and pipes. 2) Never use dirty solvents to clean important parts. 3) Take extreme care with special chemical agents. Observe the manufacturer's handling instructions and take measures to prevent the agent from coming into contact with your skin or eyes, 2. Selection of detergents Pons Detergents Ordinary parts Kerosene, ight ol or wichoroothane Finely machined parts|_Clesn kerosene or neutral (Bearings ste) dehyarated light ot Large castings Alkaline detergent, PHIO — 12. (Cylinder nese, {immerse in 50 ~ 70°C detergent cylinder block te) | for — 10 minutes. Thon rinse thoroughly with water) 4.NUTS AND BOLTS Unless otherwise specified in the DISASSEMBLY AND ASSEMBLY, tighten all bolts to a torque of page 00-29. 1) Use bolts having the exact length required for the parts they are to join. If t00 long, the bolt presses against the bottom of the tapped hole; this pressure makes proper tightening impossible. If too short, the bolt lacks the number of threads necessary to hold the parts together. 2) Tighten each nut and bolt to the specified torque. 3) Tighten bolts evenly and in order. Tighten mutually opposing ott alternately. oC B&B Tighton from the conter outwards ans alternate Tighten at an anal. 3. Detergents for washing rubber parts (O-rings, oll seals etc) om] I | S| SE Detergents <2 a 00-10 SOOHOOGB 50003 4)The Template Method is prescribed for tightening bolts on certain specific parts of the engine. The Template Method obtains good fittings of bolts with their seats and of bearings with their races to encure uniform overall tightening. The bolts are tightened in stages, then loosened, and then tightened once more.PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 5.HANDLING LOCKING DEVICES Nuts and bolts which cannot be checked visually from the outside or which are located in vital areas must be firmly locked into position with wires, cotter pins, and lock washers. Never reuse these locking devices. 1, Lock wire Bott oosening dection Qe > OFF The tension in the reshould oppose This wir serves thebolt's ge ‘esl purpose. wrong 80008 2 ‘hie tightening in bent inthe Bena the pins Pavan ae perpen gy RS fo the bot face th a comet wrong ———rs0008 Conect ‘wrong rs0cos ‘© Bend the head and ends of the cotter pin up- wards as far as possible. Cle [os - t OBE 7 Beacm Qe oo ae wont Fs0008 4, Thread tightener 1) Wash and degrease the bolt and bolt hole with trichloroethylene and dry. Coat the bolt threads with two or three drops of thread tightener and. tighten the bolts, 2) After an hour had passed, the bolt cannot be loosened or tightened any further. If retightening becomes necessary, the bolt must be completely removed, the old thread tightener removed, and a new coat applied, 6. PRECAUTIONS FOR PRESS-FITTING ‘@ Coat the surfaces of the parts to be press-fitted, with anti-friction grease (molybdenum disulfide) — unless they are tapered. ‘© For taper spline-to-serration fittings 1) Check that the splines and serrations are free from dust, burr, dents and indentations. 2) Insert and align the splines and serrations by hand before press-fitting the shaft into the hole. 3) IF the spline-serration assembly is loose, dis- assemble and examine for wear. Replace ‘worn parts with new ones. 00-11PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 7.PRECAUTIONS FOR ASSEMBLING THE PIN AND SHAFT Before reassembling the pin and shaft, check the positions of the locking device and fastening device on the other side. This is especially impor- tant when the shaft is retracted from the inside of the hole as illustrated in the accompanying diagram. To ensure proper reassembly, make sure that the lock pin holes coincide, Line up the lock pin holes 80000 8. SERVICE TOOLS 1, Gear puller Fit the gear puller over the gear or bearing and tighten the bolt on the gear puller to remove the part from the shaft. 00-12 2. Push-pulller ‘When the screw of the push-puller does not reach the surface of the part to be pushed, insert a spacer. It is also a good idea to insert a plate to prevent the head of the screw from damaging the part. 50010 3. Bearing coupler This can be used two ways: 1) When the bottom of the hole is strong enough to withstand the 2) When the bottom, of the hole is not strong enough to withstand the f wee PS pran ort to, TTD saanor 4 ( - FS0011 FS0012,PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 4, Bearing separator 8. Hook wrench ‘A hook wrench has a claw which hooks into the turning sockets of round nuts. The wrench size is defined by the outer diameter of the round nut turned. The accompanying figure shows a hook wrench designed for use with round nuts of two different sizes. Fo001s Removal and Installation of the Sprocket Wheel 00-13PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 9.CLEARANCE ADJUSTMENTS Store each set of shims or washers so that they can be installed in their original condition at the time or reassembly. 10.LINK RODS 1) If it is necessary to change the length of the link rod in order to remove it, first record the original length so that the rod can be easily reassembled in its original condition. 2) Remove the link rod at the pins. Ros —3 FJ O] Pl aD ete 50017 11.SHIMS AND WASHERS 1) Shims are used to center the engine and adjust the action of the bevel gears. Handle very carefully as they get deformed easily 2) Record the numbers and positions to speed adjustment after reinstallation 3) Do not reuse any shims or washers that are deteriorated, damaged, bent or deformed. 4) Insert thin shims between thicker ones. 00-14 12. CENTERING Centering is very important for interfaces in the power train — for example, between the engine ‘and the transmission and between the transverse axles and the final drives, Incorrect centering only increases the stresses acting on the turning parts, so always make sure that the deviation is within the specified limits. Engine “Tranemiasion Tranamission o@ OO come: Fs0018MEASURING INSTRUCTIONS MEASURING INSTRUCTIONS PREPARATIONS BEFORE CHECKING 1. Cleaning of parts Wash parts to be checked. Special care should be paid to thoroughly remove dust and dirt from the surfaces on which measurements are to be made so that possible errors can be eliminated. 2. Minor repair of part surfaces Remove scratches, dents and rust from parts to be checked. f the surface are rough, the measure- ments will be inaccurate. When smoothing any surface, be careful not to use an oilstone or sand paper coarser than the finished surface. 3, Preparation of measuring tools Clean the tools and thoroughly remove dust and dirt from the surfaces which contact parts. Check the tools for proper function and zero-point adjustment. Remedy any abnormality. 4, Maintenance of measuring tools Handle all tools with sufficient care and do not subject them to unreasonable force or shocks which can affect their delicate construction, Peri- odically check the tools for accuracy and, if necessary, calibrate them. Put the tools back into their cases and return them to their fixed storage locations whenever not in use. It is recommended, to assign 2 person to be responsible for the proper storage of measuring tools. MEASURING TOOLS ‘2 Repeat each measurement two or three times to eliminate possible errors. Further repetition wil be necessary, if there is a large variation in the readings, ‘¢ When measuring the inside or outside diameter of a cylindrical object, take two readings with the measuring device put in two directions at right angles to each other. Repeat this at several points, along the overall length of the object. ‘Along eye-measurement below the unit of a scale may be used for making a comparison between, ‘two approximately equal measurements, the accu- racy of scuh eye-measurements should not be considered as reliable. © At the start of each measurement, select a ‘measuring device having an accuracy appropriate for judging whether the measurement reaches its allowable limit. BLOCK GAUGES ‘@ To bring two blocks into contact, wash each block with benzene to remove rust-preventing oil and wipe with a clean cotton cloth. Put one block on the other, causing a sliding or twisting movement between the two. @ If the contact between two blocks feels rough, apply a fine-grade oilstone to’ the blocks along their edges. (Do not try to rub the contact surface of the blocks!) ‘¢ Do not leave the blocks in contact for a long time. Long-time contact will make the blocks difficult to separate or cause black rust to appear on the con- tact surfaces. ‘® When separating two blocks, slide or twist them, Do not try to pull them apart, by force or strike them with a mallet. © When storing a block gauge, wipe off moistur dirt and fingerprints, coat with a rust-preventing lubricant such as vaseline, and put the gauge back inits case, VERNIER CALIPERS At the start of measurement, close the jaws and ccheck that there is no clearance (due to wear) be- tween the jaws and that the “zero” point of the ‘graduation is in exact alignment with the “zero” point of the vernier scale. ‘¢ Measuring an outer diameter comect ‘Wrong wrong Comect Fs0019 00-15MEASURING INSTRUCTIONS ‘@ Measuring an inner diameter ho wrong correct 4 50020 © Measuring a depth \\\! it | \ jj Comact Wro MICROMETERS '@ Put the anvil onto an object at a right angle and tur in the spindle until it comes into contact with, the object. Rotate the ratcher stop until there are two or three idle rotations, then read the ‘measurement. ‘¢ When reading a measurement, keep your eyes at a right angle to the graduation on the sleeve. To turn back the spindle, rotate the thimble with ‘your fingers. Ore@r edo Comect rs0022 © When storing a micrometer, leave a slight clear- ance between the anvil and the spindle. 00-16 DIAL GAUGES Carefully put the gauge contact-point on a surtace to be measured to protect the delicate gauge against shock. «Set the zero-point of the gauge with care to keep the movement of the contact-point within its stroke during measurement, Careless setting of the zero-point may cause the spindle to retract or extend to its limit, thus ‘making measurement impossible. ‘2 The measurements of the dial gauge are accompanied by relatively large errors because minute variations of the contact-point (and accompanying errors) are indicated by the dial pointer through an expanding mechanism using, gears, The reliability of eye measurements can not bbe assured below the minimum unit on the scale. ¢ Measuring protrusions, depressions or steps Set the zero-point so that vertical movement of the probe does not exceed its stroke limits, and slide the base of the gauge on a flat surface. Contact: Spindle pont © Measuring bending Read the Total Indicator Reading (T.LR) while moving the object back and forth or vertically. Turn the object one complete rotation and read the difference between the maximum and minimum indications of the gauge pointer.MEASURING INSTRUCTIONS ‘® Measuring end play, looseness or deviation 50028 Read the TLR. while moving the object back and forth or vertically. ‘@ Measuring face runout o radi Racial unout 50026 1) Read runout at six or more positions during one complete rotation of the object 2) At the start of each measurement, set the zero- point at the middle of the assumable range of, the spindle movement. Be careful not to con- fuse positive and negative readings of runout. Face | Radial runout | runout When the pointeris |" 4. S tothe right of “0” When the pointeris [ + tothe left of 0" 3) When measuring face runout, place the contact-point on the object along a circle 2 or 3 ‘mm smaller in diameter than the outside diame- ter of the object, ‘¢ Measuring gear backlash Lover and fulrum type il gauge 1) Fully mesh one of two gears and place the dial gauge contact-point on a tooth of the other gear. Swing the free gear within the limits of its play in the rotational directions, and read the TAR. 2) Use of the lever and fulcrum type dial gauge is recommended for this purpose as the contact- point placed on the gear is moved tangentially to the gear pitch circle. 3) The lever and fulcrum type dial gauge is suitable for use in a narrow space or for a special measurement which requires placing the contact-point on an object at an angle to the spindle of the gauge. Since the contact-point of this type of gauge has 8 very narrow measuring range (usually 3 mm or less), the contact-point should be care~ fully checked for contact with the object during measurement. CYLINDER GAUGES @ Install a contact-point having @ length approxi mately equal to the cylinder bore to the measured ‘on the cylinder gauge, Set the zero-point of the test indicator to the bore diameter of the standard cylinder measured with a reference ring gauge or a micrometer. Test indicator Contact-point Measuring point Fs0028 00-17PARTS CHECKING INSTRUCTIONS ‘@ Insert the gauge into the bore to be measured and read the minimum indication of the test indicator while giving swings to the gauge about the tip of the detachable rod used as the fulorum. @ When the minimum reading is obtained on the right side of the zero point of the test indicator, and the reading to the standard value to which the zero points set, When the minimum reading is obtained on the left side of the zero point, subtract the reading from the standard value. PARTS CHECKING INSTRUCTIONS ‘@ Check disassembled parts to see if they are reusa- ble or need repair. If the part failed due to an exter- nal source, determine the cause and correct before assembly. 1. GENERAL PRECAUTIONS @ Visually inspect parts for cracks, pitting, cor- rosion, scoring, ridging etc. To ensure proper inspection, every part should be clean before inspection. «If the cause of the defect can be found, it will be a great help to analyze the part condition; whether the defect will progress or not, and the possibility of future trouble. Knowing the cause of the defect, the service man can give good advice to the customer to prevent him from having the same trouble again, ‘Visual inspection can not find minute or hidden damage. Other methods of inspection are as follows: a) Water-pressure or air-pressure test b) Cold check or magnetic damage test 2. CRACKS ‘e If the part is found to be cracked by visual inspection, it should be replaced or repaired. If the length or depth of crack exceeds 1/3 of the thickness of the part, it should be replaced instead of repaired. ‘® Apart having an internal crack should be replaced. 00-18 3. PITTING 1) Pitting by cavitation In most cases, cavitation is accompanied by chemical corrosion. After removing rust or scale, carefully inspect the depth of pitting, ‘© When the pitting can not be repaired within the allowable limit, replace the part. © If pitting is not deep, resurface the part after removing the rust and scale. 2) Pitting due to removal of surface ‘¢ If ball bearing is pitted, replace it. ‘¢ If mote than 1/3 of the contact face is pitted, the part should be replaced. ‘¢ If pitting is not serious, resurface the partTHE PARTS HANDLING THE PARTS HANDLING 1.01L SEALS 1. Direction Be careful to install the oil seal with its lips facing in the proper direction, as shown in the figure below. oi presauce side l ©) E a Main ip Bust ip 30028 2. Inspection prior to installation 1) Keep the oil seals free from dust, rust and scratches. Take special care to prevent rust or scratches con the lips. 2) To check the oil seal lip for smoothness, gently slide a wire across its surface. If the wire catches, replace the oil seal with a new one. % Make sure that the wire used for this test does not scratch the lip surface. 3) Do not use the oil seal on a shaft where it would come into contact with rust or scratches on the shaft surface. 4) When removing the oil seal, take care not to damage the housing or shaft surfaces. installing the oil seat 1) Coat the surface to which the oil seal is to be applied with a lubricant or grease. + If the lip should double over as the oil seal is being fitted over the shaft, return it to its proper place by rotating the shaft and pulling the oil seal slightly backwards. 2) When installing an oil seal on a shaft machined with a keyway, splines, or threads, use a suitable jig to protect the lip. a _-Lip protect 50030 3) Use a suitable press to press fit the oil seal into the housing. ‘© When installing the oil seal flush with the housing surface i sea nominal outsive 1} Giameter 415 10lmm Press ja 80031 ¢ When installing the oil seal inside the housing it eal nominal outside diameter Oi seat nominal outside diametor + (0.5 ~ 10mm os ~ Lolmm sate seat nominal outside dlameter t ] “OS = 1.0mm eal Fscoxe fs003e 4) After press-fitting the oil seal, check that it has not been installed at an angle to the housing, Max. parmisibe ol cea slant ti Hyr2 1400 Fs000 00-19THE PARTS HANDLING 4. Applying grease to the lips Before instaling an oil, seal, coat it with grease according to the following procedure to prevent friction from burning the seal surfaces while the machine is being started. 1) Single-tp oil seal Place a flat, uniform coating of grease on the surface away from the sealing surface. ‘Greate 80098 2) Double-lip oil seal Coat the entire surface between the two lips with grease in the manner shown in the accom- panying figures. ‘Take special care when applying adhesives, to the ‘outer surface of oil seals. Adhesive on the surface Of the lip or shaft leads to oll leakage. % Since any adhesives on the surface of the press jig will soon transfer to the oil seal lips, clean the jig before use. 00-20 2. FLOATING SEALS 1. Handling floating seals 1) Keep each pair of floating seals bundled together with tape to avoid mix-ups when they are reinstalled. 2) Discard the old O-rings. Always use new ones when installing the floating seals. 3) Replace a floating seal if its contact surface is rusted. 2. Installing floating seals 1) Remove all rust and dust from the mounting surfaces of the seal. Use sandpaper to remove any rust that might come into contact with the O-ring, 2) When installing the floating seal, coat the mounting surfaces with oil. Then install the O-ring, taking care not to twist it ‘% Do not coat the O-ring with ol. + The floating seal has been correctly installed if the seal ring rotates. 3) After installing the O-ring and seal rings in both housings, mate the two together. => <= o-ring : Housing Seal ring F30037 4) An installer is recommended for inserting the O-rings. + Using a screwdriver or other pointed object risks scarring the O-ring. '5) Attempting to mate the two housings together without the O-rings and seal rings in place can ‘damage the O-rings and lead to oil leakage. ag tems SeteingTHE PARTS HANDLING 3.0-RINGS 1. Handling 1) Discard any O-ring that has been in storage too ong or has hardened. 2) Use only the O-rings prescribed for the part in the PARTS BOOK. This is especially important for those rings used with high-temperature engine parts, where heat-resistant and durable materials such as silicon are required. 3) ALWAYS USE NEW O-RINGS, 2. O-ring types KOMATSU O-rings are marked with colored dots ‘as shown in the accompanying chart. Marking | PartNumber] —Materat | Applicaton One blue spat | 07000-0.~-] Nitrterabbee | TO esse For Two bluespets | 07000-1-~| Nine rubbor high-pressure For ve green spot | 07000-9.~-| Fuoine rubber] FO sreasure ‘Two green spots| 0700-2] Florine rubber} FF oreen ap Wworinewdber) high-pressure For Onered spot | 07000.4.--| Niviteruober | low-pressure In cold weather For Twored spots | 0700-5. Ntrterubber | high-pressure incokd weather For Orange spot | 07000-6.--|siicon subber | low-pressure innot weather Inserting O-rings After coating the O-ring with oil, insert carefully 80 as not to damage it. Silicon rubber O-rings require special care since they tear easily. 4.GASKETS Handling gaskets 1) Always replace packings, gaskets and copper packings with new ones. 2) Make sure that there are no scratches or burr (on the contact surfaces of the gasket. 2. Installing gaskets 1) Make sure that the holes in the gasket match those in the mating part. 2) Apply liquid gasket for the joints so specified in the SHOP MANUAL. 3, Precautions for using liquid gasket 1) Remove all scratches, dirt, paint, grease and old liquid gasket before applying a new coat. 2) Coat the specified area evenly and let dry for several minutes. 3) Assemble the mating parts when the liquid ‘gasket is sticky to the touch, 5. BEARINGS 1, Handling bearings 1) Shiled the bearings from dust and dirt; even the tiniest speck rapidly accelerates wear. %* Leave the bearings in their protective packaging until just before they are to be installed, 2) Protect 2 bearing from excessive force and shocks. %* Never dry a bearing with compressed air after cleaning, 2, Installing bearings 1) Never drive a bearing onto a shaft by pounding fon the outer race or into an opening by Pounding on the inner race. Such pounding produces dents in the tracks in the races. 2) When a bearing must be fitted onto @ shaft with some interference, press-fit the inner race with the jig shown in the accompanying figure. Jia PZASSSSSSSSSSS: Neves te N et N N i N PASSE f 00-21THE PARTS HANDLING 3) If the shaft of opening has considerable inter- ference, heat the bearing before installing, % Do not heat above 120°C 4) When 2 non-separable bearing must be fitted with interference for both races, press-fit with the lig shown in the accompanying figure. Ja £ Press fit 80080 5) Thoroughly coat the bearing with oil before installing, 6) Install the bearing, spacer or washer with its ‘chamfered surface facing the step on the shaft. correct ‘wrong 50081 00-22 6. PRESS-FITTING BUSHINGS Do not drive in a bushing directly with a hammer. Use a press so that pressure is uniform over the entire circumference. 1) If no press is available, hammer in the bushing using a driving tool so that the force is distributed evenly, Fs0082 2) If the bushing has an oil hole, bring the hole into, exact alignment with the oil hole in the housing. Rear 900 of Bushing Hinde dock QH le To injection pump V 8008s '3) When a bushing has been removed, remove all burrs and foreign matter from the mounting hole, and then clean. 7.REMOVING SNAP RINGS 1) Use snap ring pliers to remove or install snap rings. Do not overexpand them —especially the smaller ones. 2) After installing, check to make sure that the ‘snap ring is firmly in place within its groove.THE PARTS HANDLING 8. HYDRAULIC PIPING A Precautions for servicing the work equip- ment hydraulic system 1) Lower the work equipment to the ground and tum off the engine. 2) Loosen the oil filler cap to relieve pressure in the hydraulic oil tank. 3) Operate the control levers 2 or 3 times to eliminate hydraulic pressure remaining in the piping to be disassembled. 4) Support the work equipment on a stand to Prevent it from falling when the piping is removed and the hydraulic pressure is released. 1. Removing the hydra ing 1) Disconnect hydraulic tubes from hoses or other tubes by holding the nut on the spigot (the male side of the joint) with a wrench while loosening the one on the socket (the female side) J 2) Seal the ends of the disconnected tubes and hoses and the oil ports to the hydraulic equipment with blind plugs to keep out foreign ‘matter. For the same reason, seal the ports of the hydraulic tank with adhesive tape. 3) Have appropriately-sized containers under- neath to catch the hydraulic fluid that will flow ‘out when the piping is disconnected. Clean up all spills immediately 4) When working under the machine, position yourself out of the way of the oil shower. 5) Tag the ends of all piping removed as well as the ports to which they were attached. 2. Installing the hydraulic piping 1) Thoroughly clean each piece of piping with 3 suitable detergent (for example, light oil, kerosene, trichloroethane) and remove all traces of detergent with compressed air. 2) Repair the sealing faces or, if the scratches and dents are too large, replace. 3) Do not use liquid gasket for hydraulic piping! 4) Install the piping so that all the identification tags match 5) When a pipe must be joined at both ends, tightening only one end at a time may make it 00 short. First fit both ends by hand and then tighten the ends by turns. (See figure) aS Tighton gradually nd alternately the both ends. Fs0088 6) To ensure tight-fitting seals, tighten the nuts to 80% of the specified torque, loosen 90°, and then tighten to the full torque. 7) After completing all connections, run the engine at idling speed and operate all the control levers of the hydraulic attachments, Then check the oil level in the hydraulic tank and add oil as necessary. 00-23THE PARTS HANDLING 3. Handling high-pressure hoses 1) Do not try to shorten the hose. A hose shorter than the specified length is subject to the defects shown in the accompanying figures. Shonting under pressure increases the tension, Fs0046 ‘Too sharp 2 bend damages the hose. 50087 2) Make sure the hose is not twisted after its installed. “The ltters printed onthe hose soon revel any twists Fs004e Irnproper connection caus the pine move the hove to twist 8 Fs0080 4) The last figures on this page are examples of poor connections. 77 The hose must have sufficient play to.allowit to contract undor pressure ‘without eimping, 80081 eae Rubbing 00-24THE PARTS HANDLING 4, Handling hoses with self-seal couplings 1) Do not attempt to connect or disconnect or coupling without first relieving the internal hydraulic pressure, 2 The gushing hydraulic fluid will not only soil the surroundings, but the high flow rate may also damage the O-ring of coupling 2) Never use @ hammer to tighten or loosen a coupling, + Such sharp blows can deform the coupling, leading to oil leakage or cracking of the coupling 3) Protect the disconnected piping from the intrusion of dust and dirt! If it is to remain 1 disconnected for some time, seal by con- necting to another coupling or by fitting a dust ap or a blind plug to each end. Fs005a 50085 5. Handling split flanges 1) Follow the bolt tightening sequence given in the figure. 50056 2) Press the two halves completely together and tighten them uniformly. If they are not held tightly together, they will separate by @ distance equivalent to the clearance between the fastening bolts and their holes, forming a pathway for oilleakage, 80087 6. Using sealing tape 1)To prevent oil leakage, wind sealing tape around the tapered thread before inserting the plug into the plug hole. 2) Wrap all but the first 1.5 threads at the tip and. then force the tape into the threads with a fingernail. Wind the tape in the same direction as the threads Seating tape Leave 1.5 threads bare Fs0088 00-25THE PARTS HANDLING 9.SPRING WASHERS Judging suitability 1) Discard the spring washer if the overlapping portion is worn or damaged. ir Miesing d 50089 2) Discard if the distance P is more than 2/3. + peas T he Washer 80060 10. SPRING (ROLL) PINS Handling spimng pins 1). A spring pin performs somewhat better when the split is placed facing the load instead of at a right angle to the load. SS +) 50061 00-26 11, PUMP 1) After assembly and before installation, fill the pump with oil through the intake port to provide initial lubrication. 2) Before installing the pump, turn the drive shaft by hand to make sure that it turns ‘smoothly without any catching. 50082 3) Test run the installed pump and check for Unusual noises and leakage. 12. SEAL RINGS. 1) Seal rings are very delicate, so handle and store carefully. 2) Do not reuse rubber seal rings. 3) Avoid excessive stretching when fitting a seal ring over a shaft; it decreases the ring’s performance. 4) Remove all sharp edges before fitting 2 seal ring into a slot on an abutment. Check for sharp edges and sertches, f Shatt s Sealing 30062HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AY Heavy parts (25 kg or more) must be ifted with 2 hoist ete, in the Disassembly and As- sembly section, every part weighing 25 kg,or more is indicated clearly with the symbol m=") 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts. ‘® Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S” twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 2 14 125 16 14. 22 16 28 18 36 20 44 22.4 58 30 10.0 40 180 60 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, ‘and a serious accident can result. Hooks have ‘maximum strength at the middle portion. 100% 9% = 1% AH Fs0084 2) Do not sling @ heavy load with one rope alone, but sling with two or more ropes symmertically wound on to the load. AN Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a ‘wide hanging angle from the hook. ‘When hoisting a load with two or more ropes, the force subjected to each rope will incresse with the hanging angles. The table below shows the variation of allowable load (kg) when. hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes ‘make @ 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load ata lifting angle of 150°. Load capacity g Liting angle :HOISTING INSTRUCTIONS 5 ‘© Approximate reduction of allowable load for wire ropes at various hanging angles. Hanging angle Reductionin 30° orless 10% 31 = 60" 2036 ete — 90° 30% a1 = 120" 50% A Hanging angles should not exceed 150° 5) When hoisting several parts as a unit, be careful not to allow any part of the unit to fall Use a suitable container when hoisting many small parts at a time. 6) Select the most suitable sling device when hoisting a specially-shaped object. yinder ead. Fs0086 7) When using a hoist to tun over a heavy part, ‘observe the following instructions: @ Clear as much of the area surrounding the part as possible. ‘@ When turning the part over, take special care to prevent he ropes from slackening and the part from slipping when the center of gravity changes, © Gradually slacken the wire ropes after making sure that the part is completely tured over. Slackening the ropes before complete turning of the part may cause the part to fall back to its original position. 00-28 3, Hanging bolts é Fs0087 Partnumber | a | pitcn | | Mest@ele 04530-0815] @ | 125 | 18 80 o4sgo-1018| 10 | 15 | 18 150 04530-1222} 12 | 1.75 | 22 220 04530-1628] 16 | 20 | 28 450 04590-2030] 20 | 25 | 30 | 630 04530-2498] 24 | 30 | 38 | 950 04530-2048] 30 | 30 | 45 | 1500 04530-3655] 36 | 30 | 86 | 2300 04530-4625] 46 | 30 | 26 | 3400 o4sa0-4870| 48 | 30 | 70 | 4500 + The allowable load in the table means the maximum static load which the bolt can withstand. The values of allowable load given in the table should be reduced, taking the necessary safety factors into consideration, as these bolts will be subjected to shocks during actual hoisting operation. The allowable loads in the table are applicable to the bolts slung vertically from a hoistSTANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ‘The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of assembly and Assembly”, Thread dometer wiath @ ‘rbot across at (mm) (mm) ‘om Wim 6 10 1.954015 13214 @ 13 a2eo3 214429 10 17 6.7207 05.7468 12 19 118210 112498 14 2 180220 177419 16 24 2a520 279429 18 27 axe 39329 20 30 sez6 549258 22 22 7028 14578 2 36 94.5210 92798 27 a 135215 13200140 20 a6 17520 1720190 33 50 228225 22102240 38 56 22020 2750:+290 39 60 395295 22802240 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are {to be used, or which require to tighten to otherwise specified torque. 4 Nm (newton meter): 1Nm & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt, (com) across flat (com) 12 16 7 11541 22 285+3 65.7468 112298 279429 00-29STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS AT FLARED _ Saal surface Oman Saas =... Use these torques for nut part of flared Thread diameter | Width across flat Tightening torque ‘oF nut part ‘of nut part (com) mm) kgm Nm 14 19 25205 2454.9 18 24 6x2 494196 22 27 B42 785196 24 32 1443 13734294 30 36 1823 176.5294 33 a 20+5 196.1449 36 46 2525 245,249 42 55 305 294.249 a COATING MATERIALS ‘The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu code ‘Applications uta Used to apply rubber pads, rubber gaskets, nd cork plugs ‘Used to apply resin rubber, metalic and ue ‘nonsmetaie pars when fast, strong sea is needed. Adhesives p a ura Preventing bolts, pls and plugs from loosening and leking ol Provides an airtight, eletiealy insulating seal rs) (Used fr aluminum surtoces tet ‘Used with gaskets and packings to increase sealing effect. tsa Hear-resiatant gasket for precombustion chambers and exhaust piping. Liquid gasket ise i ‘Used by fell on mounting surfaces on the final drive and wrensmission cases a ‘Thickness ster ghtenng: 0.07 ~ 0.08 mm) , ‘Used by eet to asl grease Stings, tapered screw tings and tapered serew ts Fitngs in hydraute circus of lees than 80 mm in iamotr. ‘Antinetion composition “Applied to bearings ond aper shatis to focitate press-fiting and 10 (utsieant incuding ra prevent sticking, Burning or ustng smolysdenu disulde) ‘Grease “Applied to bearings, aking paris ond ol seas for lubrication, rust (Citi erease) eee prevention and faclitation of assemeting work, Vaseline = sod for protecting battery electrode terminals from corosion LT-2is also called LOCTITE in the shop manuals. 00-30ELECTRIC WIRE CODE ELECTRIC WIRE CODE ac H Le 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: O5WB indicates a cable having a norminal number 05 and white coating with black sprite. CLASSIFICATION BY THICKNESS Copper wire Nominal copper catieo.0, | current rating ‘Applicable circuit number ‘Mumbor | Oia of stands | Grose section | mm) ww Stands tr te a u 032 os 2a 2 Starting, igting, signal ete 2 28 032 208 a4 20 Lighting, signal et. 05 65 092 523 46 7 Charging and signal 15 ea os 1336 790 69 Starting (Glow plug) 40 88 080 4273 4 135 Staring 60 127 080 6384 136 178 Starting 100 a7 | ose 1091 176 230 Starting CLASSIFICATION BY COLOR AND CODE Circuits Priority Staring | Charging | Lighting Signet | Instument Other Ctessitieatior — ‘Code ® w ® @ Y v 1 | Primary 7 olor Bleck White ea Green Yellow Bie Code ow we aw ow YR Ww 2 —|_~_ Color | Bock& white | White Red | Reds white [Green & white | Yellow & Red | Blue & Whi Code ev we Fe oR ve a 3 - Color | Black & Yetow | white & Black | Rea Black | Green 2 Red |Yetow® Black | Glued Rea ‘Auxitary Code eR we RY cr Ye wv a Color | BlackeRed | white & Give | Red & Yetlow [Green & Yetiow [Yellow & Green | Blue & Yellow Coxe 5 wr RG ce w ie 6 Color = [white 2 Yetow | Red & Groen aBiack | Yetowa Bue | Blue Code = we RL a vw 6 Color 5 White & Green | Red& Give | Greene Blue |Yelow & White 00-3701 GENERAL PC10-3 General views ce ‘Assembly drawing ... Specifications ... En Weight table il and coolant capacities . . assembly drawing .. 01-1GENERAL GENERAL VIEWS GENERAL VIEWS 41, Bucket 7. Sprocket 2. Buckot eylindor 8 Track frame 3. Arm 9. tale 4. Arm eylinder 10, Track shoe 5, Boom 11. Front blade 6. Boom eylinder 01-2 PC10.3GENERAL ASSEMBLY DRAWING ASSEMBLY DRAWING Min swing radius 2095, {When boom suing T8a0) 3260 io i a ey a > SIE al PC10.3 01-3GENERAL, SPECIFICATIONS. SPECIFICATIONS Moctine mode Peis sera numbers 10001 and vp Bucket capacity tw) 009 Operating wah Aho) 2120 ox axing depth (om) 2310 Sax, vera wal depth (rom) 1500 8 | ox cing reach tom 4038 & | max. digging roach ot grade tevet Aron) 3,900 g | = | Mex cisna bean (oom 3260 : | © | max. duping nis oom) 2.208 E |_| posta otra fom {Boom sin ana sch de 87:5") Bucket dain force ta) 1540 Swing sed trom " | swing max, slope aie a) 2 | Teme speed (eon 17 Gradenity (a0 20 Ground prossure ith 250 mm STD shoe) (halen?) oz Over enth(rnsport trom) 2.986 ver wih trom) 1.300 vec with track see trom) 1.300 Over ight transport) tomy 2496 Cverl hight to tp of ab trom) 2496 2 | Ground clesranes of eounterioht (rom) 585 2 | min. ground clearance (om) 295 & | rat wing rac tox) 1.195 in, ving rads of work eaipment (om 2098 Comer aatance betwen eer ane orockot (rm) 1325 Lana of tack on round (oe) 1818 Track aoe (om) 1.080 Blade (with fons (om) 1280 x 300 Note 1) Includes full fel tank, lubricants, coolant, hydroulie oll end equipments, 3,760 mm Boom, 1,760 mm Arm, (0152 m backhoe Bucket and Operator, 01-4 PC10.3SPECIFICATIONS, GENERAL pcos 10001 and up Model 307518 Tee 4eyele, watercooled, nine, vertical turbulence chamber No, of evinders — bore x stoke 375% 94 Paton caplacement (ee) 1126 Firing oder 3-1-2 Fiyneel horsoponer (Piro) 1972:200 & | Max. core Ceamirpnt 601,200 Max, eed at no lod (rom 2400 Min. speed at no tood trom) 900 Mia, fel consumption ‘oyHe.n) 185 Ateermator 2av, 208 starting motor 2a, 21K eatery 12vi70An <1 B | Upper ste piate 2on each side 3 | rmetrter een 3 | rock anos ‘Assombiyype, double grouser eve, ing, work equipment Bld, sing BE] type x ro. Gear type x 2 Geer type x 1 2°) pavery (ejmin | 18+ 18 1 2200r9m) 20 at 2200 rom) Sm pressure (gfe?) 175 at 180) 185 lo 202i.) Type x no. Control method “Travel motor » no. Swing motor % 90, 62p001 «1, 2sp001 1 Direct Piston type (with counterbalance valve) x 2 Orbit type (with brake volve) x 4 Hydraulic eytinder Hydraulic tank Hydeuliefiter Reciprocating piston Box-sheped, open type ‘Tonk return side PC10.3 01-5GENERAL ENGINE ASSEMBLY DRAWING t i I i 20n201 F20nno08 01-6 son ENGINE ASSEMBLY DRAWING PCl0.3GENERAL WEIGHT TABLE WEIGHT TABLE ots ka Machine model Pct03, Machine mode! Poros ‘Serial number 10001 end up Serial number 10001 and vp Engine atsombly (ine. 7.0) 198 Boom oe Engine (ine. P70) 168 Aim 30 Pump for blade 38 Bucket essombly ans Tandem pump 8 Boom cylinder sembly 16 Reckator asombly 7 ‘Arm eylinger assembly 7 Hydraulic tank (ext. hydraulic oi) a Bucket cylinder ssembly 138 Fuel tank (excluding fuel) 4 ‘Boom suing bracket 2 “Track shoe assembly (esch) 140 Blade 70 evolving frame 25 Ble einer ° cab assombiy 160 Swving motor tne. brake valve) 146 {p00 contro valve Swing brake valve counterbelance ole (ach) | 18 eet vete a ‘center swivel ausembiy 6 “rack frame assembly 240 + Track frame 213 + Track rolier (eh) 6 + tle (eh side) 28 + Recoil spring assembly (each side) 96 + Sprocket 85 “Trove moto each side) 38 ‘Swing circle asembly 48 Swing machinery 10 Pcl0.3 01-7GENERAL, OIL AND COOLANT CAPACITIES lL AND COOLANT CAPACITIES Machine model Pc103 Remarks Serial number 10001 and up Engine cooling water 42 Wier Fost onk ” ‘Above 10°C: ASTM D875 No. 2 a Below —10°C: ASTM D975 No. 1 {API Service Clsification CD Engine lubricant a2 ‘Above 0°C: SAE3O Below 10°C: SAE 10W ‘Swing machinery case 03 [API Service Clasitication CD, SAE3O Travel motor (one side) 08 Hydraulic oil (hydraulic tank) es [API SarvicaClasitiction CD, SAETOW (23) “Track roller (each) 40 [API Service Clasification CD, SAE3O tater roller (each 2 1 (de Refill pacity 2) API: American Petroleum Institute 01-8 3) SAE: Society of Automative Engineers PC10.3ENGINE 41 STRUCTURE AND FUNCTION PC10-3 11-1STRUCTURE AND FUNCTION ENGINE MOUNT ENGINE MOUNT __| f * 5, Chasse side bracket 11-2 PC10.3STRUCTURE AND FUNCTION POWER TAKE-OFF (P.7.0) POWER TAKE-OFF (P.T.O) 20NF206 {Coupling assembly 2, Cover “Tender gear pume for travel, ‘wing, boom arm and bucket (SAR‘003 + os} ‘Gear pump for biade and boom, swing (Sar'008) PC10.3 11-3STRUCTURE AND FUNCTION RADIATOR Radiator core: Corrugate type RADIATOR 2ONF2070 Fler cap Inet hove Radiator Outlet hose Drain cock PC10.3STRUCTURE AND FUNCTION FUEL TANK AND PIPING Filer cap Strain Fuel tank PCl0.3 FUEL TANK AND PIPING Section A ~ A. 5, Water saporator 6. Feed pump 7. Fuel filer Thermostat tankSTRUCTURE AND FUNCTION ENGINE CONTROL ENGINE CONTROL 11-6 PC10-3ENGINE Ke 12 TESTING AND ADJUSTING Testing and adjusting data eo 12-2 Tools for testing and adjusting ..... 12-3 PC10.3 12-1TESTING AND ADJUSTING TESTING AND ADJUSTING DATA TESTING AND ADJUSTING DATA 307544 Suman trom Condition use fF cation Standard tnsake unten and Intake and exheustvae om . exhaust | Volvo lerance (omen engine 8 01d) Gy « 01 emperatue: gine | Compression pressure | more than 60°C kale? min. 38 30 body Engine speed: 260 cpm ne Emon seed: 1.200 rm i temperature 5 aa nin cation | Lubrication pressure n gamperaare kale 18 1s system SAE30 01 Fuel injection pressure | Nozzle ester alom? 160 185, Fuel _ Fuslinjction timing | 87.0.0 oaree ry . Vatve opening temperature °c cast0725 | 69510725 Litre ‘Tomo, win fully open *c 88 Lite when fully open mm . 8 Sera’ | raamorprane | cog ore : system | ive faneion {aitferonce pressure) a Co ce Fan bat tosion {eerneen storntor mm 18 51010 {© on puley) 12-2 PC10-3TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING No, Chock item Too! Port number Remarks 1 Enaine specs Tachometer 789-202-5000 Digital splay 260 t0 8,000 rpm 2] 5.6. or battery electolyie 1.100 t0 1.200 Specific gravity 795-500-1000 3] Cootent freeing temperature 810 80°C Wioter, oi and intake | Woter, oi on 0 t0200°¢ “Thermistor kit 790-500-1300 5 | exnoust temperature 0 101,000 6 | Lubricant prossure 0 4010 kalem 7 | uct pressure 0 %020 kglem? 8 | Intake, exhaust pressures Engine prossure test kit -799.200-2000 001,800 mmtig 2 | Blowby pressure (0 01,000 mm, 0 10 | torake resistance =1,000 +0 0 aml, 0 11 | Compression pressure Compression gauge ‘Yw124086.92960 12 | Biomby pressure Bloveby checker 798-201-1802, (0 t0.500 mmH, 0 a Fealer gauge 799-201-9000 0.18 Discoloration 0 to 70% stands 14 | Exhaust color ‘smoke tester Commercially avaiable | color (Discoloration % ® A/10 % Bosch index) Viator content 0.1%, OF standard 18 | water, fue in ol Diesel engine oitehecker | 799-201-6000 pees Fuel inection presure Nozzle tester Commercially avaiable | 0 40300 kalem? 1° | ozze spray condition a 17 | Quatty of coolant Winter toster "798.202.7001 PH nitrous acid ion density 1g | Pressure valve Function Fdiator cop tester 7902029000 | 0102 ka/em* Leakage from cooing sytem 19 | Cloning of racivor ‘Acarnoeter 7992022001 | tr040m/s 20| eveewie crt Tester Commerc avaible Caren, votes, sinonce When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, apply the safety pins and chocks.. When working in groups, use agreed signals and do not allow unauthorized persons near the machine, When checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while the water is hot, Boiling water may spurt out, > PBR BP Be careful not to get caught in rotating parts, PCI0-3 12-3ENGINE 13 DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY Dismounting .......-. Mounting .. 13-2 + 13-5 ‘When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: 1, Start engine and run at low idling. 2, Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke end, 3. Next, operate cylinder 3 to 4 times to stroke end, 4, After doing this, run engine at normal speed. * ‘After repair or long storage, follow the same procedure. PC10-3 13-1DISASSEMBLY AND ASSEMBLY ENGINE DISMOUNTING ENGINE ASSEMBLY 1 Bumper (cig side) Radiator ay Torsion bor Thergegare asin " foie mathe Hydroutie So} enaine ey 2002508, 1. Bumper (right side) Remove bumper (1). 2, Torsion bar Remove torsion bar (2).DISASSEMBLY AND ASSEMBLY MOUNTING ENGINE ASSEMBLY ecios Hydraulic 1. Engine assembly * » 2) 3) ay Install the cushion so that the surface painted white is outside Install the rear cushion to the revolving frame Install the front cushion to the engine, Sling engine assembly (27) and set it in the correct position Tigthen the set bolts for the bracket of the front mount and the nuts on the cushion of the rear mount. PC10-3 20NF251ADISASSEMBLY AND ASSEMBLY. 2. Pump piping for blade and boom swing 1) Install an O-ring, then connect outlet tube (26) to ‘the pump. 2) Install an O-ring, then connect inlet tube (25) to ‘the pump and install clamp (24), 3. Piping of tandem (work equipment) pump Install the O-rings, then connect inlet tube (23) and outlet tubes (21) and (22) to the pump. 4, Ground eable and wiring 1) Connect engine oil pressure switch wiring (20), starting motor wiring (19), engine ground cable (18), thermostart wiring (17), alternator wiring (16), and water temperature gauge wiring (15). 2) Connect ground cable (14). 5, Inlet hose of fuel injection pump. Connect hose (13). 6, Thormostart tank drain hose Connect hose (12). 7. Fuel control cable Connect fuel control cable (11). Bend the cotter pin securely. 8. Radiator assembly 1). Set radiator assembly (10) in position, then tighten set bolts (9) for the bracket, 2) Connect outlet hose (8) and inlet hose (7) to the radiator, and tighten drain plug (6). 13-6 PC10-3DISASSEMBLY AND ASSEMBLY 9. Hood 1) Sot hood (3) in position, and tighten set bolts (5). 2), Sling the hood and connect stay (4). When installing ‘the hood, take care not to dammage the radiator fins. 10. Torsion bar Install torsion bar (2). 11. Bumper (right side} Install bumper (1). 12, Add water and oil add 1) Confirm that the drain plug is tightened, then add ‘water through water filler (23) up to the specified level. 2), Add engine oil through lic tank up to the specifi FEF tvrautc tank: Approx. 29 # Start the engine to circulate the cooling water and ‘the oil, then check their levels again. I filler (24) of the hydrau- level PC10-3 ENGINEPOWER TRAIN \ 21 STRUCTURE AND FUNCTION OC! Powertrain 2.2... see 21-2 ‘Swing circle ‘ see 21-3 ‘Swing machinery ........ ce 21-4 PC10-3 21-1STRUCTURE AND FUNCTION POWER TRAIN 13 1 ‘The mechanical power from the engine (2) is changed to hydraulic power by three hydraulic pumps. This hydraulic power is distributed according to the use by control valve (5), (6). 21-2 POWER TRAIN ume for blade and sving Engine Tondem pump Lefe travel motor 6-sp00! control valve 2-spool contol valve Ialee ‘Center swivel joint Fight travel motor 10, Sprocket 11. Swing circle outer race 12, Swing etc bearing 13, Swing eiele inner race 14, Swing motor " F2ONAG06 Iv is then changed back to mechanical power by hydraul- lie motor (4), (8) and (18) and by the hydraulic evlin- ders into mechanical power to actuated machine travel, suing oF work equipment. PC10.3STRUCTURE AND FUNCTION SWING CIRCLE SWING CIRCLE “ ee Front chassis SA A ier Ts ena rece fitting Section A — A (Three marks) owen 1, Swing crcule outer race 2 Seal 3, Swing crcule inner race PC10.3 21-3STRUCTURE AND FUNCTION SWING MACHINERY SWING MACHINERY Reduction ratio: Rated speed of upper structure: 11 rpm Lubricant capacity: 0.3 £ (SAE3O, API Service classification: CD) Oittovel gouge ou fier Cove Coupling Pinion [shaft Roller besring coller cage Roller bearing 21-4 Pcl0.3POWER TRAIN 23 DISASSEMBLY AND ASSEMBLY SWING CIRCLE ASSEMBLY Dismounting . Mounting .......... ‘SWING MACHINERY ASSEMBLY Dismounting ‘Mounting Disassembly . Assembly 23-2 23- 6 23-10 23-10 23-11 23-11 When operating the hydraulic eylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: Start engine and run at low idling. Operate hydraulic cylinder 4 to 6 times, stopping 100 mm from stroke end. Next, operate cylinder 3 to 4 times to stroke end. ‘After doing this, eun engine at normal speed. + sone ‘After repair or long storage, follow the same procedure. PC10.3 23-1 OoDISASSEMBLY AND ASSEMBLY SWING CIRCLE DISMOUNTING SWING CIRCLE ASSEMBLY Work equip- mont 3 Operators ebasy u 2 pone Revolving ‘Swing circle Hydraulic Operator's frame asey [av Baxter 6 Drain tube | fRubber cover Plate 1 Hore aonaoo? NS Shorten the bucket and arm cylinder piston rods to their stroke end, lower the work equipment to the ground, and stop the engine. Move the control lever, ‘tvo oF three times to release the residual pressure in ‘the piping. Slowly loosen the cap of the hydraulic ‘tank to release the pressure in the tank. 1. Work equipment assembly 1) Sling boom eylinder assembly (1), remove connect- ing pin (2), and lower the boom cylinder to the block (Height: Approx. 600 mm). 2aowrer? 23-2 PC10-3DISASSEMBLY AND ASSEMBLY 2) Disconnect boom cylinder hose (3) and (4). 3) Disconnect 4 arm and bucket cylinder hoses (5). 4) Sling work equipment assembly, remove connect- ing pin (6). 5) _Lift off work equipment assembly (7). CHE] Work equipment assembly: 189 kg 2. Boom cylinder assembly Pull out pin (8), and lift off boom cylinder assembly (9). PC10.3 SWING CIRCLE 2ovri010DISASSEMBLY AND ASSEMBLY 3 5. Operator's cab assembly 1). Remove floor mat (9A) and swing lock pin (98). 2) Remove floor plate (9C). 3) Remove plate (90). 4) Disconnect wiring connector (9E). 5) Lift off operator’s cab (10). [iE] Operator's cb assembly: 160 kg Operator's seat Remove operator's seat assembly. Battery Remove battery. Disconnect the battery cable from the negative terminal. Drain tube Remove drain tube (14). Hose Remove hose (15), (16), (17), (18), (18) and (20). Rubber cover Remove the plate and rubber cover (21). SWING CIRCLE PC10.3DISASSEMBLY AND ASSEMBLY. SWING CIRCLE 9, Plate Remove plate (22). 10. Swing motor assembly Disconnect tube (23), (24) and remove swing motor assembly (26). 11, Revolving frame assembly ¢ 1) Rotate revolving frame assembly and remove ‘mounting bolts (26). 4 If all the mounting bolts are removed, the revolving frame will fall off, 0 leave one bolt installed on both side. 2). Sling revolving frame assembly (27), remove the rest ‘of the sot bolts, and remove the revolving frame, care not to hit it against the center swivel joint. [iE] Rovolvng frame assembly: 760 kg aonProre 12, Swing circle assembly 1) Remove mountinb bolt (28). 2) By using sling (1) , lift swing circle assembly (29) to remove. iE} Swing circle assembly: 45 kg PC10.3 23-5DISASSEMBLY AND ASSEMBLY. SWING CIRCLE MOUNTING SWING CIRCLE ASSEMBLY 1 a 8 Hines Suing cree Sina motor Hyarautic FSi sy — s Operators w Operaors obey F20NAO27 1. Swing circle assembly 1). Sling swing circle assembly (29) and install it to the track frame using sling ‘# Set the swing circle s0 that the soft zones (stamp- ed S) of both inner and outer rings will be at the right. 2) Install set bolts (28). ATLAS Set bolt: Adhesive (LT-2) GE Setbolt: 11.52 1.0 kgm & After installing the swing circle, apply grease to its inner teeth, 23-6 Pcl0.3DISASSEMBLY AND ASSEMBLY 2. 4a 2 Revolving frame assembly 1). Sling revolving frame assembly (27) and install it, ‘meshing the machinery pinion and the inner teeth (of the swing circle, Take care not to hit the revolv- ing frame against the center swivel joint. + Tighten two or three set bolts of the revolving frame. 2) Rotate revol ing bolts (26). {frame assembly and tighten mount- GD Mounting bolts: 11.54 1.0 kam Swing motor assembly Install swing motor assembly (25), then connect tube (24), (23). Plate Install plate (22). Rubber cover Install rubber cover (21). Hose Connect hoses (20), (19), (18), (17), (16) and (15). Drain tube Connect drain tube (14). PC10.3 SWING CIRCLE 2a0ner019DISASSEMBLY AND ASSEMBLY SWING CIRCLE 8 Battery Install battery, % Connect the battery cable to positive terminal. 9, Operator's seat Install operator's seat assembly. 10, Operator's cab assembly 1) Sling operator's cab assembly (10) and install it to ‘the revolving frame assembly. 2) Connect wiring connector (9E). 3) Install plate (9D). 4) Install floor plate (9C).. 5) Install swing lock pin (9B) and floor mat (9A). 11. Boom eylinder assembly Align boom cylinder assembly with its mounting post- ‘tion and install connecting pin (8). 23-8 PC10.3DISASSEMBLY AND ASSEMBLY SWING CIRCLE 12, Work equipment assembly 1) Sting work equipment assembly (7) and set it in position. 200P010 2). Install cone plate. 3) Connect four arm and bucket cylinder hoses (5). pin (6) and fix the lock 4) Connect boom cylinder hoses (3) and (4). 8}. Sling boom cylinder assembly (1), start the engine, ‘extend the piston rod, and install connecting pin 2). 2onri20 Pcl0.3 23-9DISASSEMBLY AND ASSEMBLY SWING MACHINERY DISMOUNTING SWING MACHINERY ASSEMBLY 1, Remove swing motor assembly. For details, see DIS- MOUNTING SWING CIRCLE ASSEMBLY. 2, Remove mounting bolt (1), then remove swing machin- ery (2). MOUNTING SWING MACHINERY ASSEMBLY 1. Set swing machinery (2) in position, and tighten set bolts (1) 2, Install swing motor assembly. For details, see MOUNT- ING SWING CIRCLE ASSEMBLY. 23-10 Pc10.3DISASSEMBLY AND ASSEMBLY SWING MACHINERY DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1. Remove cage (1) and (2). 2. Remove coupling (3). 3, Remove snap ring (4), then extract shaft (6). 4, Remove bearing (6) and collar (7). i co ASSEMBLY OF SWING MACHINERY ie ASSEMBLY 4 1, Install oil seal (8) to the cage, q 2, Install shaft (5) to the cage. Install bearing (6) and -—@ ‘collar (7) and fix them with snap ring (4). 3, Assemble coupling (3). 4, Install cage (2) and (1). 20nF 188 PC103 23-11POWER TRAIN [4 24 MAINTENANCE STANDARD On ‘Swing circle cee sees 242 ‘Swing machinery ee 24-3 PC10-3 24-1MAINTENANCE STANDARD SWING CIRCLE SWING CIRCLE Section A — A (Three # marks) zonenna Unit: mm No, (Check itor Criteria Remedy ‘Standerdclesrance Clearance limit 1 | lesrence of basing in aia on 0.05 00.2 oa 2 | Tahennn trae of oer race eros Tighten 3 | Tahening torus of ine race eT 24-2 PC10.3MAINTENANCE STANDARD SWING MACHINERY SWING MACHINERY ones Units mm, No, Check tern onioria Remedy ‘Standard elesrance ‘Clearance limit Bsctish betwoon ourput sie 1 | inion and svang ccle ee 0.12100.78 14 piece Clearance in diretion of rotation 2 | Beton coupling nd eines pork 0.053 100.180 028 ‘Standard clearance ‘Clearance limit Repair hard Wear of surface of output shaft 23 | colle in contact with cil sal ° chrome eating 648 S050 a8 rreploce “Tightening torque of mounting bolt AO ton 4 | ofurputshate cage ooo om PCI0.3 24-3UNDERCARRIAGE 31 STRUCTURE AND FUNCTION Ss ‘Track frame and recoil spring ........ peeeaie2 Idler eae ren sted) Track roller seen ea i-4) Trak She oe seeses sees 31-5 PC10-3 31-1STRUCTURE AND FUNCTION TRACK FRAME AND RECOIL SPRING TRACK FRAME AND RECOIL SPRING 1, tater 2. Tank frame 3, Recoil spring 4, Track roller PC10.3STRUCTURE AND FUNCTION IDLER IDLER a TO yr o PC10.3 31-3STRUCTURE AND FUNCTION TRACK ROLLER TRACK ROLLER 2ONFT84, 1. Collar 6. Mounting bot 2. Flosting sal 7. Snap ring 3, Track roller 8. Oring 4. Bushing 8. Collar 5. Track roller shaft 31-4 PC10.3STRUCTURE AND FUNCTION TRACK SHOE TRACK SHOE PC10-3 31-5UNDERCARRIAGE 34 MAINTENANCE STANDARD ‘Track frame and recoil spring Track roller. . Track shoe PC10.3 34-1MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING TRACK FRAME AND RECOIL SPRING wo] Check tm sera Remedy Sander ae Repair ‘ta 41 | Topbottom width of ‘Trak frame GC) az ae lau enor : Ad metal or Trek tame tet - deta a | deg tn of on ‘Ad meta or oo 10 : mow Sandia sic eva tit Fim | temaied | tanansa | Ree | Insane «| ect sping veces | "cme? | Tau | secon | B80 | pepice zea | 77 | s4oonn | 20058 | 1190K9 34-2 PC10-3MAINTENANCE STANDARD TRACK ROLLER TRACK ROLLER ( onei22 nits mm Wo. checker ceria Fomeay ‘Storderd see Repair imi 1 | 0.0. oF range - 110 102 ‘Add mot 2 | oD.oF ess 90 5 orrepace 2 | wieth of rood 2 2 4 | wide of tanee 105 18 T Tolerance ] standard | standard | Clearance Clearance between track see shat wore | Stnvance | lm 5 | roltershat and bushing t —+— ° 10183 | 0.14010 cad -0.013 40,144 0.196 Mes olerance epice ‘Standard Tok ‘Stondard | Interference | bushing ae T inerterence | it «5 | Interorence berween wack Shaft Hole roller ona busing = = 19.073 | 10.039 | 0.000 32 0,048 oO 0.073 heal Standard size Repair ii 7 | Axel pay of wack ter os 2 PC10.3, 34-3