Komatsu PC01-1 (JPN) 14001-Up Shop Manual

SEN02688-01
HYDRAULIC PC01 -1A

EXCAVATOR
SERIAL NUMBERS 14001 and up
SEN02690-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC01-1A
Machine model Serial number

PC01-1A 14001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
PC01-1A 1
SEN02690-01 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02688-01
00 Index and foreword SEN02689-01

Index SEN02690-01 q
Foreword and general information SEN02691-00
01 Specification SEN02692-00
Specification and technical data SEN02693-00
10 Structure, function and maintenance standard SEN02694-00

Engine and cooling system SEN02695-00
Power train SEN02696-00
Undercarriage and frame SEN02697-00
Hydraulic system SEN02698-00
Work equipment SEN02699-00
20 Standard value table SEN02700-00

Standard service value table SEN02719-00 Q
30 Testing and adjusting SEN02701-00

Testing and adjusting SEN02720-00 Q
80 Others SEN02794-00
Engine SEN02796-00
90 Diagrams and drawings SEN02704-00

Hydraulic diagrams and drawings SEN02706-00
Electrical diagrams and drawings SEN02705-00
2 PC01-1A
Table of contents 1
00 Index and foreword
Index SEN02690-01
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 3
Foreword and general information SEN02691-00

Safety notice ............................................................................................................................... 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation.................................................................................... 26
Method of disassembling and connecting push-pull type coupler............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02693-00
Dimension and working range..................................................................................................... 2
Specification ................................................................................................................................ 3
Weight table ................................................................................................................................ 5
Table of fuel, coolant and lubricants ............................................................................................ 6
10 Structure, function and maintenance standard

Engine and cooling system SEN02695-00
PTO ............................................................................................................................................. 2
Power train SEN02696-00
Power train .................................................................................................................................. 2
Swing circle ................................................................................................................................. 3
Undercarriage and frame SEN02697-00
Track frame ................................................................................................................................. 2
Idler ............................................................................................................................................. 4
Track roller .................................................................................................................................. 5
Hydraulic system SEN02698-00
Hydraulic piping........................................................................................................................... 2
Valve control................................................................................................................................ 3
Hydraulic tank ............................................................................................................................. 4
Hydraulic pump ........................................................................................................................... 5
9-spool control valve ................................................................................................................... 6
Swing motor ................................................................................................................................ 10
Center swivel joint ....................................................................................................................... 12
Travel motor ................................................................................................................................ 14
Hydraulic cylinder........................................................................................................................ 15
Work equipment SEN02699-00
Work equipment .......................................................................................................................... 2
20 Standard value table

Standard service value table SEN02719-00
Standard service value table for engine ...................................................................................... 2
Standard service value table for chassis ..................................................................................... 3
PC01-1A 3
30 Testing and adjusting

Testing and adjusting SEN02720-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 2
Testing and adjusting hydraulic pressure .................................................................................... 3
Testing locations causing hydraulic drift of work equipment........................................................ 5
Bleeding air from cylinders .......................................................................................................... 6
80 Others
Engine SEN02796-00
General purpose engine GX120K1, GX160K1............................................................................ 0-2
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02706-00
Hydraulic circuit diagram ............................................................................................................. 3
Electrical diagrams and drawings SEN02705-00
Electrical circuit diagram ............................................................................................................. 3
4 PC01-1A
PC01-1A 5
PC01-1A Hydraulic excavator

Form No. SEN02690-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
6 PC01-1A
SEN02691-00
PC01-1A

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC01-1A 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 PC01-1A
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC01-1A 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC01-1A
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC01-1A 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 PC01-1A
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC01-1A 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC01-1A
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC01-1A 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 PC01-1A
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC01-1A 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 PC01-1A
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC01-1A 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 PC01-1A
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC01-1A 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 PC01-1A
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC01-1A 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC01-1A
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC01-1A 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 PC01-1A
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC01-1A 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC01-1A
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC01-1A 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 PC01-1A
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC01-1A 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC01-1A
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC01-1A 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 PC01-1A
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC01-1A 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 PC01-1A
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC01-1A 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 PC01-1A
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC01-1A 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 PC01-1A
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
PC01-1A 35
Conversion table 1
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: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 PC01-1A
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC01-1A 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC01-1A
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC01-1A 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC01-1A
PC01-1A 41

© 2007 KOMATSU
All Rights Reserved
42 PC01-1A
SEN02693-00
PC01-1A

01 Specification 1
Specification and technical data
Dimension and working range ........................................................................................................................ 2
Specification.................................................................................................................................................... 3
Weight table .................................................................................................................................................... 5
Table of fuel, coolant and lubricants................................................................................................................ 6
PC01-1A 1
SEN02693-00 01 Specification
Dimension and working range 1
2 PC01-1A
Specification 1
Machine model PC01-1A
Serial No. 14001 and up
Operating weight kg 300
Bucket capacity m 3
0.008
Max. digging depth mm 1,050
Max. vertical wall depth mm 780
Max. digging radius mm 2,000
Working range
Reach at ground level mm 1,925

Max. digging height mm 1,850
Max. dumping height mm 1,300
Performance
Bucket offset mm Left: 335, Right: 285

Max. blade lifting height mm 135
Max. blade lowering depth mm 115
Max. digging force kN {kg} 4.0 {410}
Swing speed rpm 7.0
Max. slope angle for swing deg. 25
Travel speed km/h 1.4
Gradeability deg. 25
Ground pressure (Standard shoe width) kPa {kg/cm } 2 16.7 {0.17} (130 mm)
Overall length (For transportation) mm 2,100
Overall width mm 580
Overall height (For transportation) mm 1,100
Ground clearance of counterweight mm 290
Minimum ground clearance mm 100
Dimensions
Tail swing radius mm 650

Swing radius of work equipment mm 850
Height of work equipment at min. swing radius mm 1,475
Distance between tumbler centers
mm 650
(Length of track on ground)
Track gauge mm 450
Blade width x height mm 580 x 150
PC01-1A 3

Name GX160K1-SKM (HONDA)
Type 4-cycle engine, air-cooled, OHV
Number of cylinders – Bore x Stroke mm 1 – 68 x 45
Total displacement l {cc} 0.163 {163}
kW/rpm
Rated output 2.6/3,000 {3.5/3,000}
{HP/rpm}
Engine
Max. torque kgm/rpm 1.1/2,500

Max. speed at no load rpm 3,200
Min. speed at no load rpm 1,400
Min. fuel consumption {g/HPh} 340 {254}
Starting motor 12V, 0.2kW
Alternator 12V, 2.3A
Battery 12V, 18Ah
Undercarriage
Track roller 1 piece on each side
Track shoe Unit-type rubber shoe
FBR(00)1.6 + 1.6
Type/Quantity
Hydraulic pump
Gear-type double pump, 1 piece

Delivery l/min 5x2
Set pressure for travel/work equipment MPa {kg/cm }2 14.7 {150}
Set pressure for swing MPa {kg/cm }2 4.4 {45}
Hydraulic motor Control valve
Type/Quantity 9-spool type, 1 piece

Hydraulic system
Control method Direct control
Travel motor Orbit type, 2 pieces (S-160B62V3-K)
Swing motor Orbit type, 1 piece (S-050A82V8-K)
Hydraulic cylinder Double acting piston type

Hydraulic tank Enclosed box type
Hydraulic oil filter Return side of tank
4 PC01-1A
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine assembly 31
• Engine 18
• PTO 0.3
• Hydraulic pump 1.5
• Hydraulic tank 11.2
Revolving frame 29.7
Operator's seat 5.0
Fuel tank 0.6
9-spool control valve 10.5
Swing circle 7.4
Swing motor 6.8
Center swivel joint 5
Track frame assembly 109
• Track frame 28.2
• Idler 4x2
• Track roller 2.5 x 2
• Sprocket 3.4 x 2
• Track shoe 11 x 2
Travel motor 9
Swing bracket assembly 6.8
Boom assembly 12.1
Arm assembly 6.9
Bucket assembly 6.9
Blade assembly 11.2
Boom cylinder assembly 3.7
Arm cylinder assembly 3.7
Bucket cylinder assembly 3.7
Swing cylinder assembly 3.7
Blade cylinder assembly 2.6
PC01-1A 5
Table of fuel, coolant and lubricants 1

a For details, see "Operation and maintenance manual".
Engine oil Hydraulic

Fuel tank
pan system
Specified
liter 0.6 5.7 4.5
capacity
Refill
liter 0.6 4.8 —
capafity
Note1: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking
of pins and bushings, the use of G2-T or G2-TE is recommended.
6 PC01-1A
PC01-1A 7

© 2007 KOMATSU
All Rights Reserved
8 PC01-1A
SEN02695-00
HYDRAULIC EXCAVATOR
PC01-1A

10 Structure, function and

maintenance standard 1
Engine and cooling system
PTO................................................................................................................................................................. 2
PC01-1A 1
SEN02695-00 10 Structure, function and maintenance standard
PTO 1
1. Hydraulic tank
2. Hydraulic pump
3. Coupling
4. Joint
5. Engine
2 PC01-1A
PC01-1A 3

© 2007 KOMATSU
All Rights Reserved
4 PC01-1A
SEN02696-00
HYDRAULIC EXCAVATOR
PC01-1A


Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
PC01-1A 1
Power train 1
1. Idler A: Swing
2. Center swivel joint B: Control valve
3. Swing motor
4. Travel motor
5. Engine
6. Hydraulic pump
7. 9-spool control valve
8. Swing circle
2 PC01-1A
Swing circle 1
1. Swing circle inner race F: Front of machine

2. Swing circle outer race S: Outside circle soft zone
3. Ball bearing T: Inside circle soft zone
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
4 Axial clearance of bearing
0.05 – 0.25 0.6
Replace
Backlash between swing pinion
5 0.035 – 0.630 1.6
and swing circle
PC01-1A 3

© 2007 KOMATSU
All Rights Reserved
4 PC01-1A
SEN02697-00
HYDRAULIC EXCAVATOR
PC01-1A


Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Idler ................................................................................................................................................................. 4
Track roller ...................................................................................................................................................... 5
PC01-1A 1
Track frame 1
2 PC01-1A
1. Idler
2. Track frame
3. Sprocket
4. Travel motor
5. Track shoe
6. Track roller
7. Adjustment bolt
Unit: mm
Standard size Repair limit
Vertical width of Track frame
8 57.6 59
idler guide Rebuild or
Idler support 55 52
replace
Horizontal width Track frame 115.6 118
9
of idler guide Idler support 112 108
PC01-1A 3
Idler 1
Unit: mm
1 Outside diameter of tread Rebuild or
206 202
replace
2 Width of tread 20 17
3 Axial play of shaft Repair limit: 1.5 Replace bearing
4 PC01-1A
Track roller 1
Unit: mm
1 Outside diameter of tread Rebuild or
130 126
replace
2 Width of tread 20 17
3 Side clearance of roller Repair limit: 1.5 Replace bearing
PC01-1A 5

© 2007 KOMATSU
All Rights Reserved
6 PC01-1A
SEN02698-00
HYDRAULIC EXCAVATOR
PC01-1A


Hydraulic system
Hydraulic piping .............................................................................................................................................. 2
Valve control ................................................................................................................................................... 3
Hydraulic tank ................................................................................................................................................. 4
Hydraulic pump ............................................................................................................................................... 5
9-spool control valve ....................................................................................................................................... 6
Swing motor .................................................................................................................................................. 10
Center swivel joint......................................................................................................................................... 12
Travel motor .................................................................................................................................................. 14
Hydraulic cylinder.......................................................................................................................................... 15
PC01-1A 1
Hydraulic piping 1
1. Bucket cylinder 7. Hydraulic filter

2. Arm cylinder 8. Hydraulic pump
3. Boom cylinder 9. Travel motor
4. Boom swing cylinder 10. 9-spool control valve
5. Swing motor 11. Center swivel joint
6. Engine 12. Blade cylinder
2 PC01-1A
Valve control 1
1. 9-spool control valve A: Blade RAISE M: Boom SWING

2. Lock lever B: Blade LOWER N: Swing
3. Blade control lever C: Boom RAISE O: Low idle
4. R.H. work equipment control D: Boom LOWER P: High idle
lever E: Bucket DUMP Q: Choke
5. Travel control lever F: Bucket CURL
6. L.H. work equipment control G: FORWARD
lever H: REVERSE
7. Swing, boom swing change I: L.H. SWING/L.H. boom SWING
lever J: R.H. SWING/R.H. boom SWING
8. Fuel control dial K: Arm IN
L: Arm OUT
PC01-1A 3
Hydraulic tank 1
1. Sight gauge Specifications

2. Hydraulic filter q Tank capacity: 6.1 l
3. Oil filler q Oil amount: 4.8 l
4. Hydraulic tank
5. Strainer
6. Drain plug
4 PC01-1A
Hydraulic pump 1
FBR (00) 1.6 + 1.6
1. Cover Specifications
2. Side plate q Type: FBR (00) 1.6 + 1.6
3. Drive gear q Theoretical delivery: 1.59 + 1.59 cc/rev
4. Body q Rated flow: 4.5 + 4.5 l/min (at 3,000 rpm)
5. Coupling
6. Cover
7. Drive gear
8. Body
9. Driven gear
10. Driven gear
Unit: mm
11 Spline shaft rotating torque 1.96 – 4.90 Nm (0.2 – 0.5 kgm)
Discharge
Pump speed Standard value Repair limit
Delivery pressure
(rpm) (l/min) (l/min) Replace
— (kg/cm2)
(SAE10W-CD 45 – 55°C) 14.7 MPa
4.000 5.97 5.41
{150 kg/cm2}
PC01-1A 5
9-spool control valve 1
A1: To bucket cylinder head side B7: To arm cylinder head side
A2: To boom cylinder bottom side B8: To swing motor port A
A3: To travel motor (right) port B B9: To boom swing cylinder head side
A4: To blade cylinder bottom side P1: From hydraulic pump
A5: Service port P2: From hydraulic pump
A6: To travel motor (left) port A T: To hydraulic tank
A7: To Arm cylinder bottom side
A8: To swing motor port B 1. Overload relief valve
A9: To boom swing cylinder bottom side 2. Overload relief valve
B1: To bucket cylinder bottom side 3. Relief valve
B2: To boom cylinder head side 4. Overload relief valve
B3: To travel motor (right) port A 5. Overload relief valve
B4: To blade cylinder head side 6. Relief valve
B5: Service port
B6: To travel motor (left) port B
6 PC01-1A
1. Check valve 7. Spool (left travel)

2. Check valve spring 8. Spool (blade)
3. Spool (service) 9. Spool (right travel)
4. Spool (boom swing) 10. Spool (boom)
5. Spool (swing) 11. Spool (bucket)
6. Spool (arm)
PC01-1A 7
8 PC01-1A
PC01-1A 9
Swing motor 1
1. Swing pinion Specifications

2. Flange q Type: S-050A82V8-K
3. Check valve q Theoretical delivery: 54 ml/rev
4. Body
5. Check valve spring
6. Housing
7. Spacer plate
8. Geroler
9. End cap
10. Drive shaft
11. Thrust bearing needle
12. Thrust bearing race
10 PC01-1A
PC01-1A 11
Center swivel joint 1
12 PC01-1A
1. Shaft A1: From 9-spol control valve (A3 port)

2. Slipper seal A2: To R.H. travel motor (B port)
3. Body B1: From 9-spool control valve (B6 Port)
4. Cover B2: To L.H. travel motor (B port)
C1: From 9-spool control valve (B3 port)
C2: To R.H. travel motor (A port)
D1: From 9-spool control valve (A6 port)
D2: To L.H. travel motor (A port)
E1: From 9-spool control valve (A4 port)
E2: To blade cylinder bottom side
F1: From 9-spool control valve (B4 port)
F2: To blade cylinder head side
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
5 Replace
shaft 45 0.055 – 0.085 0.090
PC01-1A 13
Travel motor 1
1. Output shaft 10. Drive shaft Specifications

2. Flange 11. Thrust bearing needle q Type: S-160B62V3-K
3. Ball 12. Thrust bearing race q Theoretical delivery:
4. Body 13. Counter balance valve 159 ml/rev
5. Spring 14. Spool
6. Housing 15. Poppet assembly
7. Spacer plate 16. Poppet spring
8. Geroler 17. Spool return spring
9. End cap 18. Plug
14 PC01-1A
Hydraulic cylinder 1
Note: This figure is for boom cylinder.
Unit: mm
Standard Tolerance Standard Clearance
Cylinder size Shaft Hole clearance limit
–0.020 +0.081 0.011 –
Boom 20 0.453
–0.072 –0.009 0.153
–0.020 +0.081 0.011 –
Clearance Arm 20 0.453
–0.072 –0.009 0.153
1 between piston
rod and bushing Bucket –0.020 +0.081 0.011 –
20 0.453
–0.072 –0.009 0.153
–0.020 +0.081 0.011 –
Boom swing 20 0.453
–0.072 –0.009 0.153
–0.020 +0.081 0.011 –
Blade 20 0.453
–0.072 –0.009 0.153
–0.090 +0.010 0.020 –
Boom 20 1.0
–0.130 –0.070 0.140
–0.090 +0.010 0.020 –
Arm 20 1.0
Clearance –0.130 –0.070 0.140
Replace bushing
between piston –0.090 +0.010 0.020 –
2 Bucket 20 1.0
rod mounting pin –0.130 –0.070 0.140
and bushing –0.090 +0.010 0.020 –
Boom swing 20 1.0
–0.130 –0.070 0.140
–0.090 +0.010 0.020 –
Blade 20 1.0
–0.130 –0.070 0.140
–0.090 +0.010 0.020 –
Boom 20 1.0
–0.130 –0.070 0.140
–0.090 +0.010 0.020 –
Clearance Arm 20 1.0
–0.130 –0.070 0.140
between cylin-
–0.090 +0.010 0.020 –
3 der bottom Bucket 20 1.0
–0.130 –0.070 0.140
mounting pin
and bushing –0.090 +0.010 0.020 –
Boom swing 20 1.0
–0.130 –0.070 0.140
–0.090 +0.010 0.020 –
Blade 20 1.0
–0.130 –0.070 0.140
PC01-1A 15

© 2007 KOMATSU
All Rights Reserved
16 PC01-1A
SEN02699-00
HYDRAULIC EXCAVATOR
PC01-1A


Work equipment
Work equipment .............................................................................................................................................. 2
PC01-1A 1
Work equipment 1
2 PC01-1A
Unit: mm
Standard Tolerance Standard Clearance
Clearance between bushing size clearance limit
Shaft Hole
1 and connecting pin of revolving
frame and swing bracket –0.090 +0.010 0.020 –
25 1.0
–0.130 –0.070 0.140
Clearance between bushing –0.090 +0.110 0.120 –
2 20 1.0
and boom foot pin –0.130 –0.030 0.240
Clearance between bushing
–0.090 +0.110 0.120 –
3 and connecting pin of boom and 20 1.0
–0.130 –0.030 0.240
arm
–0.090 +0.110 0.120 –
4 and connecting pin of arm and 20 1.0
–0.130 –0.030 0.240
link Replace bushing
–0.090 +0.110 0.120 –
5 and connecting pin of arm and 20 1.0
–0.130 –0.030 0.240
bucket
–0.090 +0.110 0.120 –
6 and connecting pin of link and 20 1.0
–0.130 –0.030 0.240
link
–0.090 +0.110 0.120 –
7 and connecting pin of link and 20 1.0
–0.130 –0.030 0.240
bucket
–0.090 +0.080 0.120 –
8 and connecting pin of blade and 20 1.0
–0.130 +0.030 0.210
track frame
PC01-1A 3

© 2007 KOMATSU
All Rights Reserved
4 PC01-1A
SEN02719-00
PC01-1A

20 Standard value table 1

Standard service value table
Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
PC01-1A 1
SEN02719-00 20 Standard value table
Standard service value table for engine 1

Engine GX160K1-SKM
Item Measurement conditions Unit Standard value Permissible value
High idling rpm 3,200 ± 100

Engine speed Low idling rpm 1,400 ± 200 —
Rated speed rpm 3,000
Valve clearance Intake valve mm 0.15 ± 0.02
—
(normal temperature) Exhaust valve mm 0.20 ± 0.02
MPa 0.60 – 0.85
Oil temperature: 40 – 60°C
Compression pressure {kg/cm2} {6.0 – 8.5} —
(Engine speed)
(rpm) (600)
Whole speed range
Oil temperature °C — Max. 140
(inside oil pan)
Fuel injection timing B.T.D.C. degree 25 —
2 PC01-1A
Standard service value table for chassis 1

Classifi-
Item Condition, etc. Unit Standard value Permissible value
cation
• Oil temperature: 45 – 55°C
Engine speed when • Engine oil pressure: in correct
one pump circuit oil is range 3,100
relief. • Engine coolant temperature: in cor-
Engine
rect range rpm

Engine speed when • At one pump relief: Bucket circuit
two pump circuit oil is relief 2,800
relief. • At two pump relief: Bucket and arm
circuit relief
Boom control valve l a b l a b
Arm control valve
Bucket control valve

Spool travel
Swing control valve

mm
Boom swing control
17 6 6 17 6 6
valve
Blade control valve
L.H. travel control

valve
R.H. travel control
valve
Neutral o
Boom control lever 60
Raise and lower
In 67
Arm control lever Neutral o
Out 65
Curl 67
Bucket control lever Neutral o
Dump 60
L.H. swing 60
Swing control lever Neutral o mm
R.H. swing 55
Travel of control levers
• At center of L.H. swing 60

Boom swing control lever knob Neutral o
lever • Measure at R.H. swing 55
end of travel Neutral o
Blade control lever • Engine 44
Raise and lower
speed:
Stopped Neutral o
Travel control lever 63
Forward and reverse
Boom io Bucket Max. 20

Amount of play in
mm
control lever
Arm i
o Swing Max. 20
Low idling i
o
45
High idling
Fuel control dial degree
High idling io Choke 30
PC01-1A 3
Classifi-
cation
• Engine speed: High idling 14.7 ± 4.9 Max. 29.4
Boom control lever
• Oil temperature: 45 – 55°C {1.5 ± 0.5} {Max. 3}
• Hook push-pull scale on center of 15.7 ± 4.9 Max. 29.4
Arm control lever control lever knob to measure {1.6 ± 0.5} {Max. 3}
• Measure maximum value in travel-
ing 15.7 ± 4.9 Max. 29.4
Bucket control lever
{1.6 ± 0.5} {Max. 3}
Control lever operating force
15.7 ± 4.9 Max. 29.4

Swing control lever
{1.6 ± 0.5} {Max. 3}
Boom swing control 15.7 ± 4.9 Max. 29.4
lever N {1.6 ± 0.5} {Max. 3}
{kg} 12.7 ± 2.9 Max. 34.3
Blade control lever
{1.3 ± 0.3} {Max. 3.5}
29.4 ± 7.9 Max. 68.6
Forward
{3.0 ± 0.8} {Max. 7.0}
Travel control lever
37.3 ± 7.9 Max. 68.6
Reverse
{3.8 ± 0.8} {Max. 7.0}
Low idling i
o 39.2 ± 9.8 39.2 ± 9.8
High idling {4.0 ± 1.0} {4.0 ± 1.0}
Fuel control dial
83.4 ± 4.9 83.4 ± 4.9
High idling io Choke
{8.5 ± 0.5} {8.5 ± 0.5}
• Oil temperature: 45 – 55°C 14.7 +0.5
+0.5 14.7 +0.5
+0.5
Boom circuit
• Relief pressure with engine at high {150 +5
+0.
} {150 +5
+0.
}
idling 14.7 +0.5
+0.5 14.7 +0.5
+0.5
Arm circuit (Relief only circuit to be measured) {150 +5
+0.} {150 +5
+0.}
14.7 +0.5
+0.5 14.7 +0.5
+0.5
Bucket circuit
{150 +5
+0.
} {150 +5
+0.
}
4.4 ± 0.3 4.4 ± 0.3
Swing circuit
Hydraulic pressure
{45 ± 3} {45 ± 3}
14.7 +0.5
+0.5 14.7 +0.5
+0.5
Boom swing circuit
MPa {150 +5
+0.} {150 +5
+0.}
{kg/cm2}
14.7 +0.5
+0.5 14.7 +0.5
+0.5
Blade circuit
{150 +5
+0.
} {150 +5
+0.
}
14.7 +0.5
+0.5 14.7 +0.5
+0.5
Travel circuit
{150 +5
+0.
} {150 +5
+0.
}
• Difference oil relief pressure
Lowered hydraulic between at engine high idling and Max. 1.0 Max. 1.0
pressure at engine a half speed. (Measure {Max. 10} {Max. 10}
pressure when one pump circuit oil
is relief.)
4 PC01-1A
Classifi-
cation
• Measuring posture
Swing brake angle degree 20

• Engine speed: High idling
• Put match marks on the swing cir-
cle outer race and the track frame.
• Swing the upper structure 360°,
then stop it. Measure the distance
between the match marks after the
upper structure comes to a stop.
90° 2.5
Swing
Time taken to start

sec.
swing

• Oil temperature: 45 – 55°C 180° 5.0
• Measure time taken for 90°
and 180° swing from starting
point.
Time taken to swing sec. Max. 45.5

• Measure time taken to swing for 5
turns, after swinging one turn as an
approach swing.
PC01-1A 5
Classifi-
cation
Swing
Hydraulic drift of
mm Max. 210
swing • Engine speed: Stopped
• Stop the machine on 15° slope and
set boom at 45° angle across the
slope.
• Write the match marks on the swing
circle outer race and track frame.
After 15 minutes, measure the lag
of match marks.
Travel speed (1) sec. Max. 29 Max. 38

• Raise one track off the ground, let it
spin one revolution, then measure
the time required for it to spin 5
revolutions. Repeat this procedure
Travel
for the other track.

Travel speed (2) sec. Max. 52 Max. 60

• On a flat surface, make an
approach run of at least 10 m, then
measure the time required for the
machine to travel 20 m.
6 PC01-1A
Classifi-
cation

Travel deviation • On a flat surface, make an mm 900 990
approach run of at least 10 m, then
travel another 20 m.
Measure the travel deviation.
Travel
aMeasuring dimension .
Hydraulic drift of
mm 100
travel
• Engine speed: Stopped

• Stop the machine on 15° slope with
setting sprocket on uphill.
• Measure distance moved by
machine in 15 min.
PC01-1A 7
Classifi-
cation
Boom
RAISE
1.8 ± 0.2 1.8 ± 0.4
Bucket teeth on
the ground
I
O
LOWER
Cylinder fully 1.8 ± 0.2 1.8 ± 0.4
extended • Engine speed: High idling
Arm • Measuring posture
ARM IN
2.7 ± 0.3 2.7 ± 0.6
Cylinder fully
retracted
ARM OUT
I
O
1.9 ± 0.2 1.9 ± 0.4
Cylinder fully • Engine speed: High idling
extended • Oil temperature: 45 – 55°C
Bucket • Measuring posture

Work equipment speed
CURL
2.4 ± 0.2 2.4 ± 0.4

Work equipment
Cylinder fully
retracted
sec.
I
O
DUMP
1.8 ± 0.2 1.8 ± 0.4

Cylinder fully • Engine speed: High idling
Blade
RAISE
1.2 ± 0.2 1.2 ± 0.4

Blade on the
ground
I
O
LOWER
Cylinder fully 1.0 ± 0.2 1.0 ± 0.4

extended • Engine speed: High idling
R.H. SWING L.H. SWING
Boom swing • Measuring posture

2.9 ± 0.3 2.9 ± 0.6
Cylinder fully
retracted
I
O
Cylinder fully 3.8 ± 0.4 3.8 ± 0.8

8 PC01-1A
Classifi-
cation
Entire work • Measuring posture
equipment
(Hydraulic drift Max. 150 350
at the tip of
bucket teeth)
Boom cylinder
(Retraction of 10
• In the posture shown above,
cylinder)
measure the extension and
retraction of each cylinder as well
Hydraulic drift
as the hydraulic drift at the tip of the

Arm cylinder bucket teeth.
(Extension of • Work equipment rated load mm 14
cylinder) • Flat level surface
• Control levers in neutral
• Engine: Stopped
Bucket cylinder • Start measuring immediately after
(Retraction of setting 5
cylinder) • Measure the hydraulic drift every 5
minutes, and make judgement after
15 minutes.
Blade aRaise the blade to the maximum
(Hydraulic drift height then measure the amount —
at the tip of the edge of the blade goes down
Work equipment
blade) over 15 minutes.

Boom sec. 0 Max. 1
• Engine speed: Low idling

• Measure the time it takes for the
Time lag
front of the machine to be lifted off

the ground, starting from the time
the bucket contacts the ground.
Arm sec. 0 Max. 1

• Time required to momentarily stop
the arm.
PC01-1A 9
Classifi-
cation
Bucket 0 Max. 1

• Time required to momentarily stop
the bucket.
Time lag
Work equipment
• Measuring posture sec.
Blade 0 Max. 1

• Measure the time it takes for the
rear of the machine to be lifted off
the ground, starting from the time
the blade contacts the ground.
leakage
Internal

Each cylinder cc/min. 0.8
• Relief circuit to be measured.
10 PC01-1A
PC01-1A 11

© 2007 KOMATSU
All Rights Reserved
12 PC01-1A
SEN02720-00
PC01-1A

30 Testing and adjusting 1

Testing and adjusting
Tools for testing, adjusting, and troubleshooting............................................................................................. 2
Testing and adjusting hydraulic pressure........................................................................................................ 3
Testing locations causing hydraulic drift of work equipment ........................................................................... 5
Bleeding air from cylinders.............................................................................................................................. 6
PC01-1A 1
SEN02720-00 30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting 1

q For engine
No. Check item Tool Part No. Remarks
Tachometer for gasoline Commercially

1 Engine speed —
engine available
2 Water and oil temperature Digital thermometer kit 799-101-1502 -99.9 – 1,299°C
Pressure gauge:
Hydraulic tester 799-101-5002 2.5, 6, 40, 60 MPa
3 Oil pressure {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Digital hydraulic tester 790-261-1204
60 MPa {600 kg/cm2}
Compression gauge 795-502-1590 0 – 7 MPa
4 Compression pressure
• Adapter 795-101-1580 {0 – 70 kg/cm2}
5 Blow-by pressure Blow-by checker 799-201-1504 0 – 5 kPa {0 – 500 mmH2O}
Commercially
6 Valve clearance Feeler gauge
available
Commercially
7 Exhaust gas CO meter
available
q For chassis
No. Check item Tool Part No. Remarks
1 Oil temperature Digital thermometer kit 799-101-1502 -99.9 – 1,299°C

Pressure gauge:
Hydraulic tester 799-101-5002 2.5, 6, 40, 60 MPa
2 Oil pressure {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Digital hydraulic tester 790-261-1204
60 MPa {600 kg/cm2}
Tachometer for gasoline Commercially
3 Engine speed —
engine available
Commercially
4 Operating force Push-pull scale —
available
Commercially
5 Stroke, hydraulic drift Scale —
available
Commercially
6 Work equipment speed Stopwatch —
available
7 Pump performance Flowmeter kit 790-303-1002 —
2 PC01-1A
Testing and adjusting hydraulic

pressure 1
k Lower the work equipment completely to
the ground and stop the engine. Operate
the control levers several times to release
the remaining pressure in the hydraulic pip-
ing. Then loosen the oil filler plate slowly to
release the pressure inside the hydraulic
tank.
1. Measuring
1) Remove the pressure pick-up plugs (1) or
(2) from the side to be measured, and
install hydraulic pressure gauge {19.6
MPa (200 kg/cm2)}.
a Plug (1): For bucket, boom, R.H.
travel, blade
a Plug (2): For L.H. travel, arm, swing,
boom swing
2) Run the engine, operate the circuit to be

measured, and measure the relief pres-
sure.
a For the swing circuit, measure the
relief pressure of the safety valve.
(The set pressure of the safety valve
is lower than the set pressure of the
main relief valve, so the main relief
valve is not actuated.)
a When relieving the swing circuit, put
the bucket in contact with a pillar or
block to lock the swing.
a When relieving the travel circuit, fit
wooden block [1] between the track
shoe and sprocket to lock the track.
Measure the pressure for one side at
a time.
PC01-1A 3
2. Adjusting
a If the result of the measurement shows
that there is an abnormality in the set
pressure, adjust the set pressure of the
main relief valve as follows.
1) Loosen locknut (5) of the main relief valve
(3) or (4) on the side to be adjusted, turn
adjustment screw (6), and adjust the set
procedure.
a (3): For bucket, boom, R.H. travel,
blade
a (4): For L.H. travel, arm, swing, boom
swing
a Turn the adjustment screw to adjust
as follows.
To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
a One turn of the adjustment screw
adjusts by: 12.2 MPa {124 kg/cm2}.
3 Locknut:
19.6 ± 0.98 Nm {2 ± 0.1 kgm}
a After adjusting, repeat Step 1 to
check again.
4 PC01-1A
Testing locations causing a If it is difficult to judge the condition, fill the

hydraulic drift of work equipment1 bucket with soil or apply the rated load
when carrying out the test.
a If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine [Reference]
if the cause is in the cylinder packing or in the If the cause of the hydraulic drift is in the packing,
control valve. and the above operation is carried out, the down-
ward movement becomes faster because of the fol-
1. Checking for defective cylinder packing lowing reasons.
1) Checking boom and bucket cylinders 1) If the work equipment is set to the above pos-
1] Set in the same posture as when ture (holding pressure applied to the bottom
measuring hydraulic drift, and stop end), the oil at the bottom end leaks to the
the engine. head end. However, the volume at the head
2] Operate the boom control lever to end is smaller than the volume at the bottom
RAISE or the bucket control lever to end by the volume of the rod, so the internal
CURL. pressure at the head end increases because of
q If the lowering speed increases, the oil flowing in from the bottom end.
the packing is defective. 2) When the internal pressure at the head end
q If there is no change, the control increase, the balance is maintained by a cer-
valve is defective. tain pressure (this differs according to the
Boom, bucket cylinder amount of leakage) in proportion to it.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit of the head end is opened to
the drain circuit (the bottom end is closed by
the check valve), so the oil at the head end
flows to the drain circuit and the downward
movement becomes faster.
2) Checking arm cylinder

1] Operate the arm cylinder to move the
arm in fully, then stop the engine.
2] Operate the arm control lever to IN.
q If the lowering speed increases,
the packing is defective.
q If there is no change, the control
valve is defective.
a Set safety lock lever OFF position.
Arm cylinder
PC01-1A 5
Bleeding air from cylinders 1

a When installing hydraulic cylinders or hydraulic
piping after they have been removed, bleed
the air from the hydraulic cylinder as follows.
1. Start the engine and run it at low idling for
approx. 5 min.
2. Run engine at low idling, and raise and lower
boom 4 – 5 times in succession.
a Stop the piston rod approx. 100 mm
before the end of the stroke. Do not
relieve the circuit.
3. Run the engine at high idling and repeat Step
2. After this, run the engine at low idling and
operate the piston rod to the end of its stroke to
relieve the circuit.
4. Carry out the procedure in Steps 2. and 3. for
both the arm and bucket cylinders.
6 PC01-1A
PC01-1A 7

© 2007 KOMATSU
All Rights Reserved
8 PC01-1A
SEN02796-00
PC01-1A

80 Others 1
Engine
General purpose engine GX120K1, GX160K1 ............................................................................................ 0-2
PC01-1A 0-1
SEN02796-00 80 Others
General purpose engine GX120K1, GX160K1 1

Preface 1 Contents 1
This manual covers the construction, function and
servicing procedures of Honda GX120K1• Specifications 1
GX160K1 engines. Careful observance of these
instructions will result in better, safer service work. Service information 2
Indicates a strong possibility of
severe personal injury or death of
instructions are not followed.
Maintenance 3
Caution: Indicates a possibility of personal Air cleaner, muffler 4
injury or equipment damage if
instructions are not followed.
Recoil starter, fan cover 5
Note: Gives helpful information.
Caution: Detailed descriptions of standard Carburetor 6

workshop procedures, safety principles and
Fuel tank, governor arm, con-
service operations are not included. Please
note that this manual does contain warnings trol base 7
and cautions against some specific service Flywheel, ignition coil, starter
methods which could cause PERSONAL motor 8
INJURY or could damage the product or make
it unsafe. Please understand that these warn-
ings cannot cover all conceivable ways in
Cylinder head, valves 9
which service, whether or not recommended
Crankcase cover, crankshaft,
by American Honda, might be done, or of the
piston 10
possible hazardous consequences of each
conceivable way, nor could American Honda
investigate all such ways. Anyone using ser- Governor, oil level switch 11
vice procedures or tools, whether or not rec-
ommended by American Honda, must satisfy
himself thoroughly that neither personal
Reduction unit 12
safety nor product safety will be jeopardized.
Optional parts 13
All information contained in this manual is based
on the latest product information available at the
time of printing. We reserve the right to make
changes at any time without notice. No part of this
publication may be reproduced, stored in a
retrieval system or transmitted, in any form by any
means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of the publisher. This includes text, fig-
ures and tables.
a This engine manual covers the GX120K1 and GX160K1. The GX160K1 is used on the PC01-1A.
The content of this manual is based on the material provided by the manufacturer, so there may
be some differences between the actual machine and the parts installed, the values, or the illus-
trations.
0-2 PC01-1A
Specifications
Specifications ................................................ 1-2
Dimensions and weights ............................... 1-4
Performance curves...................................... 1-5
Dimensional drawings................................... 1-7
P.T.O. Dimensional drawings .......................1-11
PC01-1A 1-1
SEN02796-006-00SEN02796-00vSEN02796-00SEN02796-00 80 Others
Specifications 1
Machine model: —
Model GX120K1
Type 4-stroke, overhead valve single cylinder, inclined by 25°
Total displacement 118 cm3 (7.2 cu in)
Bore and stroke 60 x 42 mm (2.4 x 1.7 in)
Max. horsepower 2.9 kw/4,000 min–1 (4.0 HP/4,000 rpm)
Max. torque Crank P.T.O. 7.5 N•m (0.75 kg-m, 5 ft-lb)/2,500 rpm
With 1/2 reduction 15 N•m (1.5 kg-m, 11 ft-lb)/1,250 rpm
With 1/2 reduction* 2
15 N•m (1.5 kg-m, 11 ft-lb)/1,250 rpm
With 1/6 reduction 45 N•m (4.5 kg-m, 33 ft-lb)/420 rpm
Compression ratio 8.5 : 1
Fuel consumption 310 g/kwh (230 g/HPh, 0.51 lb/HPh)
Cooling system Forced-air
Ignition system Transistorized magneto ignition
Ignition timing 25°B.T.D.C. (Fixed)
Spark plug BPR6ES (NGK), W20EPR-U (ND*1)
Carburetor Horizontal type, butterfly valve
Air cleaner Dual element type
Semi-dry type
Oil bath type
Cyclone type
Lubricating system Splash
Oil capacity 0.6 l (0.63 US qt, 0.53 Imp qt)
Starting system Recoil or electric starter
Stopping system Ignition primary circuit ground
Fuel used Regular gasoline (86 pump octane: unleaded preferred)
Fuel tank capacity 2.5 l (0.66 US gal. 0.55 Imp gal)
Reduction oil capacity 1/2 reduction * 2 0.5 l (0.53 US qt, 0.44 Imp qt)
1/2 reduction Lubricated from engine crankcase
1/6 reduction 0.15 l (0.159 US qt, 0.132 Imp qt)
Clutch type 1/2 reduction Centrifugal
Clutch engagement 1/2 reduction 1,800 rpm
Clutch lock 1/2 reduction 2,200 rpm
P.T.O. shaft rotation Counterclockwise (from P.T.O. side)
*1: NIPPONDENSO CO., LTD.
*2: Centrifugal clutch type
1-2 PC01-1A
Machine model: PC01-1A

Model GX160K1
Type 4-stroke, overhead valve single cylinder, inclined by 25°
Total displacement 163 cm3 (9.9 cu in)
Bore and stroke 68 x 45 mm (2.7 x 1.8 in)
Max. horsepower 4.0 kw/4,000 min–1 (5.5HP/4,000 rpm)
Max. torque Crank P.T.O. 11 N•m (1.1 kg-m, 8 ft-lb)/2,500 rpm
With 1/2 reduction 22 N•m (2.2 kg-m, 16 ft-lb)/1,250 rpm
With 1/2 reduction * 2
22 N•m (2.2 kg-m, 16 ft-lb)/1,250 rpm
With 1/6 reduction 66 N•m (6.6 kg-m, 48 ft-lb)/420 rpm
Compression ratio 8.5 : 1
Fuel consumption 310 g/kwh (230 g/HPh, 0.51 lb/Hh)
Cooling system Forced-air
Ignition system Transistorized magneto ignition
Ignition timing 25°B.T.D.C. (Fixed)
Spark plug BPR6ES (NGK), W20EPR-U (ND*1)
Carburetor Horizontal type, butterfly valve
Air cleaner Dual element type
Semi-dry type
Oil bath type
Cyclone type
Lubricating system Splash
Oil capacity 0.6 l (0.63 US qt, 0.53 Imp qt)
Starting system Recoil or electric starter
Stopping system Ignition primary circuit ground
Fuel used Regular gasoline (86 pump octane: unleaded preferred)
Fuel tank capacity 3.6 l (0.95 US gal. 0.79 Imp gal)
Reduction oil capacity 1/2 reduction * 2
0.5 l (0.53 US qt, 0.44 Imp qt)
1/2 reduction Lubricated from engine crankcase
1/6 reduction 0.15 l (0.159 US qt, 0.132 Imp qt)
Clutch type 1/2 reduction Centrifugal
Clutch engagement 1/2 reduction 1,800 rpm
Clutch lock 1/2 reduction 2,200 rpm
P.T.O. shaft rotation Counterclockwise (from P.T.O. side)
*1: NIPPON DENSO CO., LTD.
*2: Centrifugal clutch type
PC01-1A 1-3
Dimensions and weights 1

GX120K1
*Type QXC
S+
S Q L H U P T V Cyclone
Reduction
Item A/C
Length mm 297 305 332 370 310 305 305 315 384 305
(in) (11.7) (12.0) (13.1) (14.6) (12.2) (12.0) (12.0) (12.4) (15.1) (12.0)
Width mm 341 341 341 341 341 341 341 341 341 410
(in) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (16.1)
Height mm 318 318 318 318 318 318 318 318 318 325
(in) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.8)
Dry weight kg 13.0 13.0 14.0 15.5 13.0 13.0 13.0 13.0 18.0 13.0
(lb) (28.7) (28.7) (30.9) (34.2) (28.7) (28.7) (28.7) (28.7) (39.7) (28.7)
Operating kg 15.5 15.5 16.5 18.0 15.5 15.5 15.5 15.5 21.0 15.5
weight (lb) (34.2) (34.2) (36.4) (39.7) (34.2) (34.2) (34.2) (34.2) (46.3) (34.2)
GX160K1
*Type QXC
S+
S Q L H U P T V Cyclone
Reduction
Item A/C
Length mm 304 312 343 377 317 312 312 322 391 312
(in) (12.0) (12.3) (13.5) (14.8) (12.5) (12.3) (12.3) (12.7) (15.4) (12.3)
Width mm 362 362 362 362 362 362 362 362 362 426
(in) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (16.8)
Height mm 335 335 335 335 335 335 335 335 335 335
(in) (13.2) (13.2) (13.2) (13.2) (13.2) (13.2) (13.2) (13.2) (13.2) (13.2)
Dry weight kg 15.0 15.0 16.0 17.5 15.0 15.0 15.0 15.0 20.0 15.0
(lb) (33.1) (33.1) (35.3) (38.6) (33.1) (33.1) (33.1) (33.1) (44.1) (33.1)
Operating kg 18.5 18.5 19.5 21.0 18.5 18.5 18.5 18.5 24.0 18.5
weight (lb) (40.8) (40.8) (43.0) (46.3) (40.8) (40.8) (40.8) (40.8) (52.9) (40.8)
*: Refer to P. 2-2 for engine model and type location.
1-4 PC01-1A
Performance curves 1
Tests were conducted according to SAE standard No. J607a. Power curves are for standard sea level atmo-
spheric pressure of 29.92 in. (760 mm) Hg at a temperature of 60°F (15.6°C). Power curves are of a standard
test engine equipped with standard air cleaner, muffler and other power consuming devices. Power output
will decrease 3.5% for each, 1,000 ft. (305 m) of elevation above sea level and 1% for each 10 °F (5.6 °C)
Frise above the standard temperature of 60 °F (15.6 °C). As shipped, production engines will develop not
less than 90% of the "Maximum B.H.P."
After being run-in, they will develop not less than 95% of the "Maximum B.H.P." For practical operations, the
B.H.P. load and engine speed should not exceed the limit defined by the "Recommended Maximum Operat-
ing B.H.P." curve. Continuous operation should not exceed 85% of the Maximum B.H.P.
PC01-1A 1-5
1-6 PC01-1A
Dimensional drawings 1
<GX120K1>
Unit: mm (in)
PC01-1A 1-7
<1/2 Reduction>
<1/2 Reduction (Centrifugal clutch type)>
<1/6 Reduction>
1-8 PC01-1A
<GK160K1>
PC01-1A 1-9
<1/2 REDUCTION>
<1/2 REDUCTION (Centrifugal clutch type)>
<1/6 REDUCTION>
1-10 PC01-1A
P.T.O. Dimensional drawings 1

Type GX120K1 GX160K1
S
Straight shaft (mm)
Q
Straight shaft (in)
L
Straight shaft (mm)
H
Straight shaft (in)
PC01-1A 1-11
Type GX120K1 GX160K1
U
Stepped shaft with
screw (in)
P
Straight shaft with
screw (in)
T
Straight shaft with
screw (in)
V
Taper shaft (in)
1-12 PC01-1A
Service information
General safety............................................... 2-2
Service rules ................................................. 2-2
Serial number location .................................. 2-2
Maintenance standards................................. 2-3
Torque values................................................ 2-5
Special tools.................................................. 2-6
Troubleshooting ............................................ 2-7
Maintenance schedule ................................ 2-12
PC01-1A 2-1
General safety 1
Pay attention to these symbols and their meanings:
Indicates a strong possibility of severe personal injury or death if instructions are not
followed.
Caution: Indicates a possibility of personal injury or equipment damage if instructions are not fol-
lowed.
• Stop the engine, and remove the spark plug cap and ignition key before servicing.
• If the motor must be running to do some work, make sure the area is well ventilated. Never run the
engine in a closed area; the exhaust contains poisonous carbon monoxide gas.
• Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or
allow flames or sparks in your working area.
Caution
• Keep away form rotating or hot parts and high voltage wires when the engine is running.
Service rules 1
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not
meet Honda's design specifications may damage the engine.
2. Use the special tools designed for the engine.
3. Install new gaskets, O-rings, etc. when reassembling.
4. When torquing bolts or nuts, beginning with larger-diameter or inner bolts first and tighten to the speci-
fied torque diagonally, unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6. After reassembly, check all parts for proper installation and operation.
7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening
these screws will strip the female threads and ruin the hole.
8. Use only metric tools when servicing this engine. Metric bolts, nuts and screws are not interchangeable
with nonmetric fasteners. The use of incorrect tools and fasteners will damage the engine.
9. Follow the instructions represented by these symbols when they are used:
: Apply oil : Use special tool : Apply grease
Q x Q (Q): Indicates the type, length, and number of the flange bolt used.
Serial number location 1

The engine serial number, the type and the variation are stamped on the crankcase. Refer to these when
ordering parts or making technical inquiries.
2-2 PC01-1A
Maintenance standards 1
GX120K1
Part Item
Standard Service limit
Engine Maximum speed 3.850 ± 150 rpm —
Maximum speed (DS type) 3,750 ± 150 rpm —
Idle speed 1,400 ± 150 rpm —
Cylinder compression 6.0 – 8.5 kg/cm2 (85 – 121 psi) at 600 rpm —
Cylinder Sleeve I.D. 60.0 mm (2.36 in) 60.165 mm (2.3687 in)
Cylinder head Warpage — 0.10 mm (0.004 in)
Piston Skirt O.D. 59.985 mm (2.3616 in) 59.845 mm (2.3561 in)
Piston-to-cylinder clearance 0.015 – 0.050 mm (0.0006 – 0.0020 in) 0.12 mm (0.005 in)
Piston pin bore I.D. 13.002 mm (0.5119 in) 13.048 mm (0.5137 in)
Pin O.D. 13.0 mm (0.51 in) 12.954 mm (0.5100 in)
Piston to piston pin bore
clearance 0.002 – 0.014 mm (0.0001 – 0.0006 in) 0.08 mm (0.003 in)
Piston rings Ring side clearance:
Top/second/oil 0.015 – 0.045 mm (0.0006 – 00018 in) 0.15 mm (0.006 in)
Ring end gap: Top/second 0.2 – 0.4 mm (0.008 – 0.016 in) 1.0 mm (0.04 in)
Oil 0.15 – 0.35 mm (0.006 – 0.014 in) 1.0 mm (0.04 in)
Ring width: Top/second 1.5 mm (0.06 in) 1.37 mm (0.054 in)
Oil 2.5 mm (0.10 in) 2.37 mm (0.093 in)
Connecting rod Small end I.D. 13.005 mm (0.5120 in) 13.07 mm (0.515 in)
Big end I.D. 26.02 mm (1.024 in) 26.066 mm (1.0262 in)
Big end oil clearance 0.040 – 0.063 mm (0.0016 – 0.0025 in) 0.12 mm (0.005 in)
Big end side clearance 0.1 – 0.7 mm (0.004 – 0.028 in) 1.1 mm (0.043 in)
Crankshaft Crankshaft O.D. 25.98 mm (1.023 in) 25.92 mm (1.020 in)
Valves Valve clearance IN 0.15 ± 0.02 mm (0.006 ± 0.001 in) —
EX 0.20 ± 0.02 mm (0.008 ± 0.001 in) —
Stem O.D. IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)
EX 5.44 mm (0.214 in) 5.275 mm (0.2077 in)
Guide I.D. IN/EX 5.50 mm (0.217 in) 5.572 mm (0.2194 in)
Stem clearance IN 0.02 – 0.044 mm (0.0008 – 0.0017 in) 0.10 mm (0.004 in)
EX 0.06 – 0.087 mm (0.0024 – 0.0034 in) 0.12 mm (0.005 in)
Seat width 0.8 mm (0.03 in) 2.0 mm (0.08 in)
Spring free length 34.0 mm (1.34 in) 32.5 mm (1.28 in)
Camshaft Cam height IN 27.7 mm (1.09 in) 27.45 mm (1.081 in)
EX 27.75 mm (1.093 in) 27.50 mm (1.083 in)
Camshaft O.D. 13.984 mm (0.5506 in) 13.916 mm (0.5479 in)
Crankcase cover Camshaft holder I.D. 14.0 mm (0.55 in) 14.048 mm (0.5531 in)
Carburetor Main jet * #60, * #62
1 2
—
Float height 13.7 mm (0.54 in) —
Pilot screw opening *12 turns out, *22-3/8 turns out —
Spark plug Gap 0.7 – 0.8 mm (0.028 – 0.031 in) —
Spark plug cap Resistance 7.5 – 12.5 kz —
Ignition coil Resistance Primary coil 0.8 – 1.0 z —
Secondary coil 5.9 – 7.1 kz —
Air gap (at flywheel) 0.4 ± 0.2 mm (0.016 ± 0.008 in) —
Starter motor Brush length 11.0 mm (0.43 in) 6.0 mm (0.24 in)
Mica depth 1.6 mm (0.06 in) 1.1 mm (0.04 in)
1/2 Reduction Friction disc thickness 3.5 mm (0.14 in) 3.0 mm (0.12 in)
(centrifugal clutch Clutch plate warpage — 0.10 mm (0.004 in)
type)
*1: Externally vented carburetor bowl (all types except QXC). *2: Internally vented carburetor bowl (QXC type only).
Refer to P. 6-4 for identification of the carburetor vent type.
PC01-1A 2-3
GX160K1
Part Item
Engine Maximum speed 3,850 ± 150 rpm —
Maximum speed (DS type) 3,750 ± 150 rpm —
Idle speed 1,400 ± 150 rpm —
Cylinder compression 6.0 – 8.5 kg/cm2 (85 – 121 psi) at 600 rpm —
Cylinder Sleeve I.D. 68.0 mm (2.68 in) 68,165 mm (2.6837 in)
Cylinder head Warpage — 0.10 mm (0.004 in)
Piston Skirt O,.D. 67.985 mm (2.6766 in) 67.845 mm (2.6711 in)
Piston-to-cylinder clearance 0.015 – 0.050 mm (0.0006 – 0.0020 in) 0.12 mm (0.005 in)
Piston pin bore I.D. 18.002 mm (0.7087 in) 18.048 mm (0.7105 in)
Pin O.D. 18.0 mm (0.71 in) 17.954 mm (0.7068 in)
Piston to piston pin bore
clearance 0.002 – 0.014 mm (0.0001 – 0.0006 in) 0.06 mm (0.002 in)
Piston rings Ring side clearance:
Top/second/oil 0.015 – 0.045 mm (0.0006 – 00018 in) 0.15 mm (0.006 in)
Ring end gap: Top/second 0.2 – 0.4 mm (0.008 – 0.016 in) 1.0 mm (0.04 in)
Oil 0.15 – 0.35 mm (0.006 – 0.014 in) 1.0 mm (0.04 in)
Ring width: Top/second 1.5 mm (0.06 in) 1.37 mm (0.054 in)
Oil 2.5 mm (0.10 in) 2.37 mm (0.093 in)
Connecting rod Small end I.D. 18.002 mm (0.7087 in) 18.07 mm (0.711 in)
Big end I.D. 30.02 mm (1.182 in) 30.066 mm (1.1837 in)
Big end oil clearance 0.040 – 0.063 mm (0.0016 – 0.0025 in) 0.12 mm (0.005 in)
Big end side clearance 0.1 – 0.7 mm (0.004 – 0.028 in) 1.1 mm (0.043 in)
Crankshaft Crankshaft O.D. 29.98 mm (1.180 in) 29.92 mm (1.178 in)
Valves Valve clearance IN 0.15 ± 0.02 mm (0.006 ± 0.001 in) —
EX 0.20 ± 0.02 mm (0.008 ± 0.001 in) —
Stem O.D. IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)
EX 5.44 mm (0.214 in) 5.275 mm (0.2077 in)
Guide I.D. IN/EX 5.50 mm (0.217 in) 5.572 mm (0.2194 in)
Stem clearance IN 0.02 – 0.044 mm (0.0008 – 0.0017 in) 0.10 mm (0.004 in)
EX 0.06 – 0.087 mm (0.0024 – 0.0034 in) 0.12 mm (0.005 in)
Seat width 0.8 mm (0.03 in) 2.0 mm (0.08 in)
Spring free length 34.0 mm (1.34 in) 32.5 mm (1.28 in)
Camshaft Cam height IN 27.7 mm (1.09 in) 27.45 mm (1.081 in)
EX 27.75 mm (1.093 in) 27.50 mm (1.083 in)
Camshaft O.D. 13.984 mm (0.5506 in) 13.916 mm (0.5479 in)
Crankcase cover Camshaft holder I.D. 14.0 mm (0.55 in) 14.048 mm (0.5531 in)
Carburetor Main jet * #72, * #68
1 2
—
Float height 13.7 mm (0.54 in) —
Pilot screw opening *13 turns out, *22-1/8 turns out —
Spark plug Gap 0.7 – 0.8 mm (0.028 – 0.031 in) —
Spark plug cap Resistance 7.5 – 12.5 kz —
Ignition coil Resistance Primary coil 0.8 – 1.0z —
Secondary coil 5.9 – 7.1 kz —
Air gap (at flywheel) 0.4 ± 0.2 mm (0.016 ± 0.008 in) —
Starter motor Brush length 11.0 mm (0.43 in) 6.0 mm (0.24 in)
Mica depth 1.6 mm (0.06 in) 1.1 mm (0.04 in)
1/2 Reduction Friction disc thickness 3.5 mm (0.14 in) 3.0 mm (0.12 in)
(centrifugal clutch Clutch plate warpage — 0.10 mm (0.004 in)
type)
*1: Externally vented carburetor bowl (all types except QXC). *2: Internally vented carburetor bowl (QXC type only).
Refer to P. 6-4 for identification of the carburetor vent type.
2-4 PC01-1A
Torque values 1
Thread dia Torque
Item
(mm) N•m kg-m ft-lb
Connecting rod bolt M7 x 1.0 12 1.2 9
Cylinder head bolt M8 x 1.25 24 2.4 17
Flywheel nut M14 x 1.5
75 7.5 54
(Special nut)
Rocker arm pivot lock nut M6 x 0.5 10 1.0 7
Rocker arm pivot bolt M8 x 1.25
24 2.4 17
(Special bolt)
Crankcase cover bolt (GX120K1) M6 x 1.0 (CT) 12 1.2 9
(GX160K1) M8 x 1.25 24 2.4 17
Oil level switch joint nut M10 x 1.25 10 1.0 7
Fuel filter joint nut M10 x 1.25 2 0.2 1.4
Muffler mounting nut M8 x 1.25 24 2.4 17
Air cleaner wing nut M6 x 1.0 9 0.9 6.5
Oil drain bolt M10 x 1.25 18 1.8 13
Fuel talk bolt, nut M6 x 1.0 10 1.0 7
Air cleaner mounting nut (6 mm cap nut) M6 x 1.0 8.5 0.85 6.1
Fuel strainer cup M24 x 1.0 4 0.4 2.9
Standard torque values 5 mm bolt, nut 5.5 0.55 4.0
6 mm bolt, nut 10 1.0 7
8 mm bolt, nut 24 2.4 17
10 mm bolt, nut 37.5 3.75 2
12 mm bolt, nut 55 5.5 40
NOTE:
q Use standard torque values for items not specifically described in this table.
q (CT) indicates a self-tapping bolt.
PC01-1A 2-5
Special tools 1
REF. NO. Description Tool number Application
1 Float level gauge 07401-0010000 Carburetor float level inspection
2 Attachment, 42 x 47 mm 07746-0010300 6204 bearing installation
3 Attachment, 52 x 55 mm 07746-0010400 6205, 62/22 bearing installation
4 Attachment, 62 x 68 mm 07746-0010500 6206, 6305 bearing installation
5 Driver, 40 mm I.D. 07746-0030100 Driver for tools 6, 7 and 8
6 Attachment, 25 mm I.D. 07746-0030200 Timing gear installation (GX120K1)
7 Attachment, 30 mm I.D. 07746-0030300 Governor drive gear (GX120K1) and timing gear
(GX160K1) installation
8 Attachment, 35 mm I.D. 07746-0030400 Governor drive gear installation (GX160K1)
Pilot, 20 mm 07746-0040500 6204 bearing installation
9 Pilot, 22 mm 07746-0040100 62/22 bearing installation
10 Pilot, 25 mm 07746-0040600 6205, 6305 bearing installation
11 Pilot, 30 mm 07746-0040700 6206 bearing installation
12 Driver 07749-0010000 Driver for tools 2, 3 and 4
13 Valve seat cutter #122 45° 07780-P01030A Valve seat reconditioning
14 Valve seat cutter #115 31° 07780-P01040A Valve seat reconditioning
Valve seat cutter #111 60° 07782-P01050A Valve seat reconditioning
Solid pilot bar, 5.50 mm 07781-P03010A Valve seat reconditioning
T-wrench, #505 07782-P01010A Valve seat reconditioning
T-wrench adapter, #503-1 07782-P01020A Valve seat reconditioning
Accessory package, #246 07782-P01030A Valve seat reconditioning
15 Flywheel puller 07935-8050002 Flywheel removal
16 Valve guide driver 07942-8920000 Valve guide removal/installation
17 Valve guide reamer 07984-4600000 Valve guide I.D. reaming
18 Digital multimeter KS-AHM-32-003 Electrical testing
2-6 PC01-1A
Troubleshooting 1
a. General symptom and possible causes
FUEL FILTER clogged.

Clean: P. 3-8
CARBURETOR out of adjustment.

Readjust: P. 3-6
Disassemble and inspect: Engine will not rev
P. 6-2, 3 sufficiently.
Hard starting. IGNITION COIL air gap incorrect.

Readjust: P. 8-4
IGNITION COIL faulty.

Inspect: P. 8-4
Poor performance at high

SPARK PLUG faulty.
speed
Inspect: P. 3-6
GOVERNOR out of adjustment.

Readjust: P. 3-7 Poor performance at low
speed
Engine lacks power. VALVE CLEARANCE incorrect.

Readjust: P. 3-5
VALVE OR VALVE SEAT worn or

damaged.
Inspect and correct: P. 9-4, 5, 7
CYLINDER, PISTON or PISTON

RING worn.
Disassemble and inspect: P. 10-2, 4, 5, 6
PC01-1A 2-7
b. Hard starting
1. First, check the fuel level in No fuel • Fill with fuel and start again.
the tank.
Sufficient fuel
2. Remove spark plug and Dry • Check for blockage of the fuel
inspect for wet or fouled tube or strainer.
electrodes. • Check for blockage the main
jet or nozzle of the carburetor.
Wet • Clean electrodes and restart,

taking care that the choke in
not closed too much.
• If flooding is severe, check the
carburetor float valve.
3. Check the ignition system No spark or weak spark • Replace parts as indicated on
(P. 2-10). P. 2-10.
Good spark
4. Check the cylinder Abnormal compression • Check that the valve

compression. clearance is correct.
• Check that the cylinder head
Normal compression is correctly tightened.
• Check to see whether
excessive carbon has
accumulated in the
5. Install the spark plug and
combustion chamber.
restart the engine. • Check for defective cylinder
head gasket, valves or valve
seats.
• Check for worn piston rings,
piston or cylinder.
Cylinder compression check

(Mechanical decompressor engaged)
1) Remove the spark plug and install a compres-
sion gauge in the spark plug hole.
2) Crank the engine several times with the recoil
starter and measure the compression.
6.0 – 8.5 kg/cm2 (85 – 121 psi)
Compression
at 600 rpm
2-8 PC01-1A
c. Oil alert system

Caution: Never start the engine when the oil has been drained.
Note: Some GX120K1 • GX160K1 engine are not equipped with oil alert.
Engine does not start with the Check continuity between oil • OIL LEVEL SWITCH faulty.
engine switch turned to the level switch yellow and green
"ON" position. leads. Continuity • Replace oil level switch.
• Check oil level before proceeding.

Add the recommended engine oil if
necessary. No continuity
Check the ignition system

(P. 2-10).
Engine does not stop when Disconnect the engine switch • ENGINE SWITCH (OIL
the engine switch is turned to (oil alert unit) lead wire ALERT UNIT) faulty.
the "OFF" position. (black), ground transistor unit •
side (primary wire), and No spark Replace engine switch.
(Engine oil is sufficient) • Repair or replace the
perform spark test (P. 2-10). primary wire.
• Check oil level before proceeding.
Add the recommended engine oil if
necessary. IGNITION COIL PRIMARY
Spark WIRE broken.
Engine does not stop when Check continuity between oil • OIL LEVEL SWITCH faulty.
the engine oil is insufficient. level switch yellow and green (LEAD WIRE faulty)
(Oil alert malfunctioning) lead wires. No • Replace oil level switch.
continuity
• Drain oil before proceeding.
Continuity
Disconnect the engine switch

(oil alert unit) lead wire • ENGINE SWITCH (OIL
(black), ground transistor unit ALERT UNIT) faulty.
side (primary wire), and No spark • Replace engine switch.
perform spark test (P. 2-10).
• IGNITION COIL PRIMARY

WIRE broken.
Spark • Repair or replace the
primary wire.
Completely drain the oil to

ensure that the oil alert
Oil alert lamp does not light system should actuate, then • LAMP BULB burnt out.
up when oil alert is actuated. pull the recoil starter. No light • Replace engine switch.
• Drain oil before proceeding. Observe the oil alert lamp.
PC01-1A 2-9
d. Ignition system
Engine does not start with the Test the spark plug.
engine switch turned to the
"ON" position (oil alert system
is OK). No spark
Check again with a new Sparks • SPARK PLUG faulty.

spark plug. • Install a new spark plug.
No spark
Check again with a new Sparks • SPARK PLUG CAP faulty.

spark plug cap. • Install a new spark plug cup.
No spark
Disconnect the black wire

(black/red wire on control box Sparks • ENGINE SWITCH faulty.
equipped model) from the • Replace engine switch.
engine switch and recheck.
No spark • TRANSISTORIZED
IGNITION COIL defective.
• Replace transistorized
ignition coil.
Spark test
1) Remove the spark plug.
2) Install the spark plug to the spark plug cap and
ground the side electrode against the cylinder
head cover.
3) Turn the engine switch to the "ON" position,
pull the recoil starter and check to see if sparks
jump across the electrodes.
• Never hold the spark plug lead with wet hands

while performing this test.
• Make sure that no fuel has been spilled on the
engine and the plug is not wet with fuel.
• To avoid fire hazards, do not allow sparks near
the plug hole.
2-10 PC01-1A
e. Starter motor (Starter motor equipped type only)
Starter motor will not operate. COMBINATION SWITCH faulty.
Inspection: P. 5-7
FUSE burnt out.
Inspection: P. 5-6
STARTER SOLENOID faulty.
Inspection: P. 8-5
STARTER MOTOR faulty.
Inspection: P. 8-6, 7
Battery not charged. BATTERY faulty.
CIRCUIT BREAKER faulty.
Inspection: P. 5-8
RECTIFIER faulty.
Inspection: P. 5-8
CHARGE COIL faulty.
Inspection: P. 8-5
PC01-1A 2-11
Maintenance schedule 1
q For any inspection items in the table below that are also given in the operation manual, follow the
instructions given in the operation manual.
Regular service period
Perform at every indicated operating hour interval. Each First Every Every Every Refer to
use 20hrs 50hrs 100hrs 300hrs page
Item
Engine oil Check level Q
3-2
Change Q Q
Reduction gear oil Check level Q
3-2
Change Q Q
Air cleaner Check Q
3-3
Clean Q (1)
Fuel strainer cup Clean Q 3-7
Spark plug Check-Clean Q 3-6
Valve clearance Check-Adjust Q 3-5
Combustion chamber and valves Clean-Lap Q 9-3, 4
Check
Fuel line Every 2 years 3-8
(Replace if necessary)
Note: (1) Service more frequently when used in dusty areas.
2-12 PC01-1A
Maintenance
Engine oil ...................................................... 3-2
Reduction case oil......................................... 3-2
Oil alert.......................................................... 3-3
Air cleaner..................................................... 3-3
Valve clearance............................................. 3-5
Spark plug ..................................................... 3-6
Carburetor..................................................... 3-6
Governor ....................................................... 3-7
Fuel strainer .................................................. 3-7
Spark arrester (Optional parts)...................... 3-7
Fuel filter ....................................................... 3-8
PC01-1A 3-1
Engine oil 1
Note
• Change the engine oil with the engine warm and in a hori-
zontal position to assure complete and rapid draining.
1) Remove the oil filler cap/dipstick and drain bolt.
Allow the oil to drain completely.
2) Reinstall the drain bolt, and tighten it to specified
torque.
Torque: 18 N•m (1.8 kg-m, 13 ft-lb)
3) Fill the crankcase with the recommended engine oil
to the outer edge of the oil filler neck.
Reinstall the filler cap/dipstick.
Engine oil capacity 0.6 l (0.63 US qt, 0.53 Imp qt)
Use Honda 4-stroke oil or an equivalent high-detergent, pre-

mium quality motor oil certified to meet or exceed U.S. auto-
mobile manufacturer's requirements for Service Classification
SG, SF/CC. CD. Motor oils classified SG. SF/CC. CD. will show
this designation on the container.
SAE 10W-30 is recommended for general, all-temperature
use.
Other viscosities shown in the chart may be used when the
average temperature in your area is within the indicated range.
Caution
• Do not overfill with engine oil.
• Check the engine oil with the engine positioned hori-
zontally.
• Used engine oil may causes skin cancer if repeatedly
left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil on
a daily basis, it is still advisable to thoroughly wash
your hands with soap and water as soon as possible
after handling used oil.
Reduction case oil 1

1/2 Reduction (Centrifugal clutch type):
1) Remove the oil filler cap/dipstick, and drain bolt.
Allow the oil to drain completely.
2) Reinstall the drain bolt, and tighten it to specified
torque.
3) Fill the reduction case with the same oil that is rec-
ommended for the engine. Fill to the upper limit
mark on the dipstick.
Oil capacity 0.5 l (0.53 US qt. 0.44 Imp qt)
Caution
• Check the engine oil with the engine positioned hori-
zontally.
1/6 Reduction
1) Remove the filler bolt and oil level bolt. Tilt the
engine to drain the used oil through the oil level bolt
hole. Allow the oil to drain completely.
2) Stand the engine upright, and fill the reduction case
with the same oil that is recommended for the
engine. Fill until oil starts to flow from the oil level
bolt hole.
3) Install the oil level bolt and filler bolt. Tighten them to
the specified torque.
Torque: 18 N•Em (1.8 kg-m, 13 ft-lb)
Oil capacity 0.15 l (0.159 US qt. 0.132 Imp qt)
3-2 PC01-1A
Oil alert 1
Note
• For convenience, perform this test in conjunction with the
engine oil change.
1) With the engine running, disconnect the yellow lead
from the engine switch, and ground the lead against
the engine. The oil alert lamp should flash, and the
engine should stop.
2) With the engine stopped, the crankcase filled with

oil, and the oil level switch leads disconnected,
check continuity between the yellow and green oil
level switch leads. There should be no continuity.
3) With the engine stopped, the oil drained from the
crankcase, and the oil level switch leads discon-
nected, check continuity between the yellow and
green oil level switch leads. There should be conti-
nuity.
Air cleaner 1
• Never use gasoline or low flash point solvents for

cleaning the air cleaner element. A fire or explosion
could result.
Dual element, cyclone type:
1) Remove the nut, air cleaner cover and wing nut.
Remove the air cleaner elements and separate
them. Carefully check both elements for holes or
tears and replace if damaged.
2) Foam element: Clean in warm soapy water, rinse
and allow to dry thoroughly. Or clean in high flash
point solvent and allow to dry. Dip the element in
clean engine oil and squeeze out all the excess.
The engine will smoke during initial start-up if too
much oil is left in the foam.
3) Paper element: Tap the element lightly several
times on a hard surface to remove excess dirt or
blow compressed air lightly (30 PSI or less) through
the filter from the inside out. Never try to brush the
dirt off; brushing will force dirt into the fibers.
4) Wash the paper element with clean, high flash point
solvent.
q If you are using a parts washer with a recirculat-
ing stream of solvent, direct the stream at the
inside of the element. Do not use equipment
that delivers solvent under high pressure.
q If you are using a container filled with solvent,
immerse the filter and agitate it. Do not use a
brush to clean the filter.
PC01-1A 3-3
5) Shake excess solvent out the filter, and use com-

pressed air (30 PSI or less) to dry it further. Direct
the compressed air at the inside of the filter.
Let the filter dry completely, for 24 hours if possible.
A wet filter will restrict air flow.
6) Shine a light through the elements, and inspect
them carefully. Reinstall the elements if they are
free of holes and tears.
If the air filter still affects engine performance,
replace it with a new one.
Caution
• Carefully check both elements for holes or tears and
replace as required. Damaged elements will allow dirt
to pass into the engine; causing rapid wear. Always
clean the filter housing and air passages before install-
ing clean elements.
Note
• The engine will run poorly when the air cleaner needs main-
tenance. If it runs better without the air cleaner than it does
with the elements, or if the length of time between needed
cleanings keeps getting shorter, replace the elements.
Under extremely dusty conditions such as volcanic ash, slit,
etc., the system may need daily maintenance.
Semi-dry type:
1) Remove the wing nut, air cleaner cover and foam
element. Carefully check the element for holes or
2) Clean, wash and oil the foam element (P. 3-3, 4)
Oil bath type:

1) Remove the wing nut, air cleaner cover and foam
element. Carefully check the element for holes or
2) Clean, wash and oil the foam element (P. 3-3, 4)
3) Empty the oil from the air cleaner case, and wash
out any accumulated dirt with non flammable or high
flash point solvent. Dry the case.
4) Fill the air cleaner case to the level mark with the
same oil that is recommended for the engine (see
engine oil recommendation on P. 3-2).
Air cleaner oil capacity 60 cc (2.0 US oz, 2.1 Imp oz)
Note
• Do not overfill the air cleaner case. An excessive oil level
will saturate the foam element and restrict air flow.
3-4 PC01-1A
Valve clearance 1
Note
• Valve clearance inspection and adjustment must be per-
formed with the engine cold.
1) Remove the four cylinder head cover bolt, cylinder
head cover and gasket.
2) Set the piston at top dead center of the compression

stroke (both valves fully closed). The triangular
mark on the starter pulley will align with the top hole
on the fan cover when the piston is at top dead cen-
ter of the compression or exhaust stroke.
3) Insert a feeler gauge between the rocker arm and

valve to measure valve clearance.
0.15 ± 0.02 mm
IN
Standard valve (0.006 ± 0.001 in)
clearance 0.20 ± 0.02 mm
EX
(0.008 ± 0.001 in)
4) If adjustment is necessary, proceed as follows:
a. Hold the rocker arm pivot and loosen the rocker
arm pivot lock nut.
b. Turn the rocker arm pivot to obtain the specified
clearance.
c. Retighten the rocker arm pivot lock nut while
holding the rocker arm pivot.
d. Recheck valve clearance after tightening the
rocker arm pivot lock nut.
PC01-1A 3-5
Spark plug 1
1) Visually inspect the spark plug. Discard the plug if
the insulator is cracked or chipped.
2) Remove carbon or other deposits with a stiff wire
brush.
3) Measure the plug gap with a wire-type feeler gauge.
Standard spark plug BPR6ES (NGK), W20EPR-U (ND*)
*: NIPPONDENSO CO., LTD.

Spark plug gap 0.7 – 0.8 mm (0.028 – 0.031 in)
If necessary, adjust the gap by bending the side
electrode.
4) Make sure the sealing washer is in good condition;
replace the plug if necessary.
5) Install the plug fingertight to seat the washer, then
tighten with a plug wrench (an additional 1/2 turn if a
new plug) to compress the sealing washer,. If you
are reusing a plug, tighten 1/8 - 1/4 turn after the
plug seats.
Caution
• The spark plug must be securely tightened. An improp-
erly tightened plug can become very hot and possibly
damage the engine.
• Never use a spark plug with an improper heat range.
Carburetor 1
1) Start the engine and allow it to warm up to normal
operating temperature.
2) With the engine idling, turn the pilot screw in or out
to the setting that produces the highest idle rpm.
The correct setting will usually be obtained at
approximately the following number of turns out
from the fully closed (lightly seated) position.
External vent Internal vent
Pilot screw GX120K1 2 turns out 2-3/8 turns out
opening GX160K1 3 turns out 2-1/8 turns out
Refer to P. 6-4 for identification of the carburetor
vent type.
3) After the pilot screw is correctly adjusted, turn the

throttle stop screw to obtain the standard idle speed.
Standard idle speed 1,400 ± 150 rpm
3-6 PC01-1A
Governor 1
1) Remove the fuel tank (P. 7-2)
2) Loosen the nut on the governor arm and move the
governor arm to fully open the throttle.
3) Rotate the governor arm shaft as far as it will go in
the same direction the governor arm moved to open
the throttle.
Tighten the nut on the governor arm.
4) Start the engine and allow it to warm up to normal
operating temperature. Move the throttle lever to run
the engine at the standard maximum speed, and
adjust the throttle lever limiting screw so the throttle
lever cannot be moved past that point.
Maximum speed 3,850 ± 150 rpm
( ) DS type (3,750 ± 150 rpm)
Fuel strainer 1
• Gasoline is extremely flammable and is explosive

under certain conditions. Do not smoke or allow flames
or sparks in the area.
• After installing the fuel filter, check for leaks, and make
sure the area is dry before starting the engine.
1) Turn off the fuel valve and remove the strainer cup.
2) Clean the strainer cup with solvent.
3) Install the O-ring and strainer cup.
Tighten the strainer cup to the specified torque.
Torque: 4 N • m (0.4 kg-m, 2.9 ft-lb)
Spark arrester (Optional parts) 1
• The muffler becomes very hot during operation and

remains hot for a while after stopping the engine. Be
careful not to touch the muffler while it is hot. Allow it
to cool before proceeding.
Caution
• The spark arrester must be serviced every 100 hours to
maintain its efficiency.
1) Remove the four 5 x 8 mm tapping screws from the
upper muffler protector.
2) Remove the upper muffler protector.
3) Remove the 4 x 8 mm screw and spark arrester.
Be careful not to damage the wire mesh of the spark
arrester.
4) Check the carbon deposits around the exhaust port
and spark arrester. Clean, if necessary.
Replace the spark arrester if there are any breaks or
tears.
5) Install the spark arrester and upper muffler protector
in the reverse order of removal.
PC01-1A 3-7
Fuel filter 1
• Gasoline is extremely flammable and is explosive

under certain conditions. Do not smoke or allow flames
or sparks in the area.
• After installing the fuel filter, check for leaks, and make
sure the area is dry before starting the engine.
1) Drain the fuel into a suitable container, and remove
the fuel tank (P. 7-2).
2) Disconnect the fuel line, and unscrew the fuel filter
from the tank.
3) Clean the filter with solvent, and check to be sure
the filter screen is undamaged.
4) Place the O-ring on the filter and reinstall. Tighten
the filter to the specified torque. After reassembly,
check for fuel leaks.
Torque: 2 N•m (0.2 kg-m, 1.4 ft-lb)
3-8 PC01-1A
Air cleaner, muffler

Air cleaner..................................................... 4-2
Muffler ........................................................... 4-5
PC01-1A 4-1
Air cleaner 1
a. Disassembly/reassembly
Dual element type:
4-2 PC01-1A
Semi-dry type: Dual element (Silent) type:
PC01-1A 4-3
Oil bath type: Cyclone type:
4-4 PC01-1A
Muffler 1
PC01-1A 4-5
4-6 PC01-1A
Recoil starter, fan cover

Recoil starter................................................. 5-2
Fan cover ...................................................... 5-5
Control box (Starter motor equipped type).... 5-6
PC01-1A 5-1
Recoil starter 1
• Wear gloves and eye protection.

• During disassembly, take care not to
allow return spring to come out.
5-2 PC01-1A
b. Recoil starter assembly

1) Insert the hook on the outer side of the spring into
the groove inside the reel.
• Wear gloves and eye protection.

• During assembly, take care not to allow return spring to
come out.
2) Pass the starter rope through the starter reel and tie
it as shown. Wind the starter rope around the starter
reel in direction of arrow. Leave approximately 30
cm (11.8 in) of the starter rope outside of the starter
reel.
Note
• Be sure to leave approximately 30 cm (11.8 in) of the starter
rope outside of the starter reel.
3) Install the starter reel on the starter case so that the

spring inner hook is hooked to the case tab.
4) Hold the starter case and rotate the starter reel two
revolutions in the direction of the arrow for prelimi-
nary winding.
PC01-1A 5-3
5) Pass the starter rope end through the starter case

rope guide and pull it outwards. Pass the starter
rope through the starter grip and tie the rope as
shown.
• Do not separate the starter reel from the starter case.

Otherwise the return spring inside the case will come
off, which could cause injuries.
6) Install the ratchet with the spring and reel cover.

Tighten the reel cover bolt.
7) Check the operation of the ratchet by pulling the

starter rope several times.
5-4 PC01-1A
Fan cover 1
PC01-1A 5-5
Control box (Starter motor equipped 1type)

5-6 PC01-1A
b. Inspection
q Engine switch (Without oil alert)
Turn the switch, and check the continuity between the
wire and the fan cover with an ohmmeter.
Switch position Continuity
ON No
OFF Yes
Replace the switch if the correct continuity is not
obtained.
q Engine switch (With oil alert)

1) Check the continuity between the engine switch
black wire and the switch mounting bracket with an
ohmmeter.
Switch position Continuity
ON No
OFF Yes
Replace the switch assembly if the correct continuity is
not obtained.
2) Oil alert unit

Connect a battery (1.5 to 6V) to the oil alert unit
leads, as shown. The oil alert lamp should light.
Replace the oil alert unit if the lamp does not light.
Black lead to battery (+)
Yellow lead to battery (–)
Caution
• Never use a battery of more than 6V; it may burn out
the light.
q Control box
(Starter motor equipped type)
1) Combination switch
Check for continuity between the wires shown in the
following table. There should be continuity between
o-o marks with the switch in the indicated position.
Replace the combination switch if the correct conti-
nuity is not obtained.
Wire color Black/ Black/
(GROUND) White
Switch position Red White
OFF Q Q
ON
Start Q Q
Note
• The fuse must be installed before checking continuity.
PC01-1A 5-7
2) Oil alert unit

Connect a battery (1.5 to 6V) to the oil alert unit
leads, as shown. The oil alert lamp should light.
Replace the alert unit if the lamp does not light.
Black/Red lead to battery (+)
Yellow lead to battery (-)
Caution
• Never use a battery of more than 6V; it may burn out
the light.
3) Rectifier
Check continuity between the terminals. There
should be continuity in one direction only. Replace
the rectifier if there is continuity in both directions or
in neither direction.
4) Circuit breaker
Check continuity between the two terminals. There
should be continuity in the ON position (button in)
and no continuity in the OFF position (button out).
Replace the circuit breaker if the correct continuity is
not obtained.
5-8 PC01-1A
Carburetor
Carburetor..................................................... 6-2
PC01-1A 6-1
Carburetor 1
a. Removal/installation
6-2 PC01-1A
b. Disassembly/reassembly
• Remove the drain bolt and drain the carbure-

tor before disassembling. Fuel vapor or
spilled fuel may ignite.
Note
• Clean the outside of the carburetor before disas-
sembly.
c. Inspection
q Float level height
Place the carburetor in the position as shown and mea-
sure the distance between the float top and carburetor
body when the float just contacts the seat without com-
pressing the valve spring.
Standard float height 13.7 mm (0.54 in)
If the height is out of specification, replace the float and/
or the float valve. Recheck the float height.
PC01-1A 6-3
d. Cleaning
q Carburetor cleaning
• To prevent serious eye injury, always wear safety gog-

gles or other eye protection when using compressed
air.
Caution
• Some commercially available chemical cleaners are
very caustic. These cleaners may damage plastic parts
such as O-rings, floats and float valve seats. Check the
container for instructions. If you are in doubt, do not
use these products to clean Honda carburetors.
• High air pressure may damage the carburetor. Use low
pressure settings when cleaning passages and ports.
1) Clean the carburetor body with high flash point sol-
vent.
2) Use low air pressure and clean the following parts
and passages:
– Internal or external vent port
– Pilot screw hole
– Pilot jet hole
– Pilot air jet
– Main air jet
– Transition ports
– Pilot outlet
Note
• Both "INTERNAL and EXTERNAL" vent ports are found on
the carburetor.
• Carburetors that are "EXTERNALLY VENTED", the exter-
nal vent passage is open to the carburetor bowl and the
internal vent passage is closed.
• Carburetors that are "INTERNALLY VENTED", the internal
vent passage is open to the carburetor bowl and the exter-
nal vent passage is closed.
6-4 PC01-1A
Fuel Tank, governor arm,

control base
Fuel tank, governor arm, control base .......... 7-2
PC01-1A 7-1
Fuel tank, governor arm, control base 1

• Before disassembly, drain the tank and

fuel line completely.
• Fuel vapor or spilled fuel may ignite.
7-2 PC01-1A
Flywheel, ignition coil,

starter motor
Flywheel, ignition coil, starter motor.............. 8-2
PC01-1A 8-1
Flywheel, ignition coil, starter motor 1

Starter motor equipped type:
Measure starter performance while cranking the engine.
If performance is not within service limits, disassemble
and inspect as described on pages 8-3.
8-2 PC01-1A
q Starter motor
PC01-1A 8-3
b. Adjustment
q Ignition coil air gap
Adjustment is required only when the ignition coil or the
flywheel has been removed.
1) Loosen the ignition coil bolts.
2) Insert a long thickness gauge or a piece of paper of
the proper thickness between the ignition coil and
the flywheel. Both gaps should be adjusted simulta-
neously.
3) Push the ignition coil firmly toward the flywheel and
tighten the bolts.
Standard clearance 0.4 ± 0.2 mm (0.016 ± 0.008 in)
Note
• Avoid the magnet part of the flywheel when adjusting.
c. Inspection
q Ignition Coil
<Primary side>
Measure the resistance of the primary coil by attaching
one ohmmeter lead to the ignition coil's primary (black)
lead while touching the other test lead to the iron core.
Primary side resistance value 0.8 – 1.0 z
<Secondary side>
Measure the resistance of the secondary side of the coil
by removing the spark plug cap and touching one test
lead to the spark plug lead wire while touching the other
lead to the coil's iron core.
Secondary side resistance value 5.9 – 7.1 kz
Note
• A false reading will result if the spark plug cap is not
removed.
8-4 PC01-1A
q Spark plug cap

Measure the resistance of the spark plug cap by touch-
ing one test lead at the wire end of the cap, and the other
at the spark plug end.
Resistance 7.5 – 12.5 kz
Replace the spark plug cap if the resistance is not within
the range specified.
q Lamp coil
Measure the resistance between the wire terminals.
Resistance
6 V – 15W 0.21 – 0.27z
6 V – 25W 0.09 – 0.15z
12 V – 15W 1.24 – 1.44z
12 V – 25W 0.36 – 0.46z
12 V – 50W 0.18 – 0.23z
Note
• Refer to P. 13-2 to properly identify the lamp coil before
testing.
q Charge coil
(Model with electric starter)
Measure the resistance between the wire terminal and
ground.
Resistance 3.15 – 3.85 z
q Starter solenoid
Connect a 12 V battery between the starter terminal and
the solenoid body and check for continuity between the
terminals. Continuity should exist when the battery is
connected and not exist when the battery is discon-
nected.
PC01-1A 8-5
q Brush length
Measure the brush length.
If brush length is less than service limit, replace the
brush and brush holder plate.
11.0 mm (0.43 in) 6.0 mm (0.24 in)
q Armature
q Continuity check-commutator segments
Check for continuity between the segments. If an open
circuit (no continuity) exists between any two segments,
replace the armature.
q Continuity check-commutator-to-shaft
Check continuity between the commutator and the arma-
ture shaft. Replace the armature if continuity exists
between any of the commutator segments and the arma-
ture shaft.
q Mica depth
When the mica is clogged, or its depth is smaller than
the service limit value, recut the grooves using a hack-
saw blade or a small file.
1.6 mm (0.06 in) 1.1 mm (0.04 in)
8-6 PC01-1A
q Continuity check-brushes
Remove the armature and check for continuity between
the brushes.
There should be no continuity. (One of the brush holders
is insulated.)
q Overrunning clutch
1) Check the overrunning clutch for smooth axial
movement. Apply oil or replace the overrunning
clutch if necessary.
2) Check the reduction gear movement by holding the

pinion gear and turning the reduction gear. The
reduction gear should turn counterclockwise freely
and should not turn clockwise.
3) Check the pinion gear for wear or damage and
replace if necessary.
Note
• If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.
PC01-1A 8-7
8-8 PC01-1A
Cylinder head, valves

Cylinder head, valves.................................... 9-2
PC01-1A 9-1
Cylinder head, valves 1

a. Removal/installation
9-2 PC01-1A
b. Disassembly/reassembly
PC01-1A 9-3
c. Inspection
q Valve spring free length
Measure the free length of the valve springs.
34.0 mm (1.34 in) 32.5 mm (1.28 in)
Replace the springs if they are shorter than the service
limit.
q Valve seat width

Measure the valve seat width.
0.8 mm (0.03 in) 2.0 mm (0.08 in)
If the valve seat width is under the standard, or over the
service limit, recondition the valve seat (P. 9-7).
q Cylinder head
Remove carbon deposits from the combustion chamber.
Clear off any gasket material from the cylinder head sur-
face.
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight
edge and a feeler gauge.
Service limit 0.10 mm (0.004 in)
9-4 PC01-1A
q Valve stem O.D.

Inspect each valve for face irregularities, bending or
abnormal stem wear. Replace the valve if necessary.
Measure and record each valve stem O.D.
IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)
EX 5.44 mm (0.214 in) 5.275 mm (0.2077 in)
Replace the valves if their O.D. is smaller than the ser-
vice limit.
q Valve guide I.D.

Note
• Ream the valve guides to remove any carbon deposits
before measuring.
Measure and record each valve guide I.D.

5.50 mm (0.217 in) 5.572 mm (0.2194 in)
Replace the guides if they are over the service limit (P. 9-
6).
q Guide-to-stem clearance
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the stem-to-guide clearance.
0.02 – 0.044 mm 0.10 mm
IN (0.0008 – 0.0017 in) (0.004 in)
0.06 – 0.087 mm 0.12 mm
EX (0.0024 – 0.0034 in) (0.005 in)
If the stem-to-guide clearance exceeds the service limit,
determine if the new guide with standard dimensions
would bring the clearance within tolerance. If so, replace
any guide as necessary and ream to fit. If the stem-to-
guide clearance exceeds the service limit with new
guides, replace the valves as well.
Note
• Recondition the valve seats whenever the valve guides are
replaced (P. 9-7).
PC01-1A 9-5
d. Valve guide replacement

1) Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
2) Use a hot plate or oven to heat the cylinder head
evenly to 150°C (330°F).
Check the temperature with a temperature indicat-
ing stick (available at welding supply stores) or
equivalent.
• To avoid burns, use heavy gloves when handling the

heated cylinder head.
Caution
• Do not use a torch to heat the cylinder head; warpage
of the cylinder head may result.
• Do not get the head hotter than 150°C (300°F); exces-
sive heat may loosen the valve seats.
3) Remove the heated cylinder head from hot plate
and support it with wooden blocks. Drive the valve
guides out of the head from the combustion cham-
ber side.
Caution
• When driving the valve guides out, be careful not to
damage the head.
4) Remove the new valve guides from the refrigerator
one at a time as needed.
5) Install the new valve guides from the valve spring
side of the cylinder head.
Exhaust side: Drive the exhaust valve guide until the
clip is fully seated as shown.
Intake side: Drive the intake valve guide to the
specified height (measured from the
top of the valve guide, to the cylinder
casting as shown).
IN valve guide installation height 3.0 mm (0.12 in)
6) After installation, inspect the valve guide for dam-
age, replace the guide if damaged.
q Valve guide reaming

Note
• For best results, be sure the cylinder head is at room tem-
perature before reaming valve guides.
1) Coat the reamer and valve guide with cutting oil.
2) Rotate the reamer clockwise through the valve
guide the full length of the reamer.
3) Continue to rotate the reamer clockwise while
removing it from the valve guide.
9-6 PC01-1A
4) Thoroughly clean the cylinder head to remove any

cutting residue.
5) Check the valve guide bore; it should be straight,
round and centered in the valve guide. Insert the
valve and check operation. If the valve does not
operate smoothly, the guide may have been bent
during installation. Replace the valve guide if it is
bent or damaged.
6) Check the valve guide-to-stem clearance (P. 9-5).
e. Valve seat reconditioning

1) Thoroughly clean the combustion chamber and
valve seats to remove carbon deposits.
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to the valve face.
2) Insert the valve, and snap it closed against its seat
several times. Be sure the valve does not rotate on
the seat. The transferred marking compound will
show any area of the seat that is not concentric.
Note
• Follow the instructions of the valve seat cutter manufac-
turer.
3) Using a 45° cutter, remove enough material to pro-
duce a smooth and concentric seat.
Turn the cutter clockwise, never counterclockwise.
Continue to turn the cutter as you lift it from the
valve seat.
PC01-1A 9-7
4) Use the 30° – 32° and 60° cutters to narrow and

adjust the valve seat so that it contacts the middle of
the valve face. The 30° – 32° cutter removes mate-
rial from the top edge (contact too high).
The 60° cutter removes material from the bottom
edge (contact too low). Be sure that the width of the
finished valve seat is within specification.
q Valve seat width

0.8 mm (0.03 in) 2.0 mm (0.08 in)
5) Make a light pass with 45° cutter to remove any pos-
sible burrs at the edges of the seat.
6) After resurfacing the seats, inspect for even valve
seating. Apply Prussian Blue compound or erasable
felt-tipped marker ink to the valve faces. Insert the
valve, and snap it closed against its seat several
times. Be sure the valve does not rotate on the seat.
The seating surface, as shown by the transferred
marking compound, should have good contact all
the way around.
7) Lap the valves into their seats, using a hand valve
lapper and lapping compound (commercially avail-
able).
Caution
• To avoid severe engine damage, be sure to remove all
lapping compound from the engine before reassembly.
Note
• Adjust valve clearance after reassembly.
9-8 PC01-1A
Crankcase cover,
crankshaft, piston
Crankcase cover, crankshaft, piston ........... 10-2
PC01-1A 10-1
Crankcase cover, crankshaft, piston 1

10-2 PC01-1A
q Crankshaft bearing
Reassembly:
Oil the circumference of the bearing, and install the bear-
ing with the following special tools.
Driver 07749-0010000
Attachment, 52 ~ 55 mm 07746-0010400
Pilot, 22 mm (GX120K1) 07746-0040100
Pilot, 25 mm (GX160K1) 07746-0040600
q Timing gear/governor drive gear

DISASSEMBLY:
Mark a line on the crankshaft and a timing gear.
Set the commercially available bearing puller plate on
the bottom part of the governor drive gear and removes
the crankshaft and timing gear using a hydraulic press.
Remove the governor drive gear in the same way.
Reassembly:
q Timing gear
Using the old gear for reference, make a mark at the
same position on the new gear.
Using a hydraulic press, driver and attachment I.D. (spe-
cial tools), press the new gear onto the crankshaft.
GX120K1
Driver, 40 mm I.D. 07746-0030100
Attachment, 25 mm I.D. 07746-0030200
GX160K1
Driver, 40 mm I.D. 07746-0030100
Attachment, 30 mm I.D. 07746-0030300
q Governor drive gear

Use a hydraulic press and the common tools shown
below to press in a new governor drive gear.
GX120K1
Driver, 40 mm I.D. 07746-0030100
Attachment, 30 mm I.D. 00746-0030300
GX160K1
Driver, 40 mm I.D. 07746-0030100
Attachment, 35 mm I.D. 07746-0030400
PC01-1A 10-3
q Piston
10-4 PC01-1A
b. Inspection
q Cylinder I.D.
Measure and record the cylinder I.D. at three levels in
both the "X" axis (perpendicular to crankshaft) and the
"Y" axis (parallel to crankshaft). Take the maximum read-
ing to determine cylinder wear and taper.
GX120K1 60.0 mm (2.36 in) 60.165 mm (2.3687 in)
GX160K1 68.0 mm (2.68 in) 68.165 mm (2.6837 in)
q Piston skirt O.D.

Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90o to the piston
pin bore.
GX120K1 59.985 mm (2.3616 in) 59.845 mm (2.3561 in)
GX160K1 67.985 mm (2.6766 in) 67.845 mm (2.7111 in)
q Piston-to-cylinder clearance
0.015-0.050 mm 0.12 mm
(0.0006-0.0020 in) (0.005 in)
q Piston ring width

Top/second 1.5 mm (0.06 in) 1.37 mm (0.054 in)
Oil 2.5 mm (0.10 in) 2.37 mm (0.093 in)
q Piston ring side clearance

Top/second/ 0.015 – 0.045 mm 0.15 mm
oil (0.0006 – 0.0018 in) (0.006 in)
PC01-1A 10-5
q Piston ring end gap

0.2 – 0.4 mm 1.0 mm
Top/second (0.008 – 0.016 in) (0.04 in)
0.15 – 0.35 mm 1.0 mm
Oil (0.006 – 0.014 in) (0.04 in)
Note
• Use the top of the piston to position the ring horizontally in
the cylinder.
q Piston pin O.D.

GX120K1 13.0 mm (0.51 in) 12.954 mm (0.5100 in)
GX160K1 18.0 mm (0.71 in) 17.954 mm (0.7068 in)
q Piston pin bore I.D.

GX120K1 13.002 mm (0.5119 in) 13.048 mm (0.5137 in)
GX160K1 18.002 mm (0.7087 in) 18.048 mm (0.7105 in)
q Piston-to-piston pin bore clearance

0.002 – 0.014 mm 0.08 mm
GX120K1 (0.0001 – 0.0006 in) (0.003 in)
0.002 – 0.014 mm 0.06 mm
GX160K1 (0.0001 – 0.0006 in) (0.002 in)
q Connecting rod small end I.D.

GX120K1 13.005 mm (0.5120 in) 13.07 mm (0.515 in)
GX160K1 18.002 mm (0.7087 in) 18.07 mm (0.711 in)
10-6 PC01-1A
q Connecting rod big end I.D.

Original size
GX120K1 26.02 mm 26.066 mm

(1.024 in) (1.0262 in)
GX160K1 30.02 mm 30.066 mm

(1.182 in) (1.1837 in)
0.25 mm Undersize
25.770-25.783 mm 25.816 mm
GX120K1 (1.0146-1.0151 in) (1.0164 in)
29.770-29.783 mm 29.816 mm
GX160K1 (1.1720-1.1726 in) (1.1739 in)
q Crankpin O.D.
25.98 mm 25.92 mm
GX120K1 (1.023 in) (1.020 in)
29.98 mm 29.92 mm
GX160K1 (1.180 in) (1.178 in)
q Connecting rod big end side clearance

0.1 – 0.7 mm 1.1 mm
(0.004 – 0.028 in) (0.043 in)
q Connecting rod big end oil clearance

1) Clean all oil from the crankpin and connecting rod
big end surfaces.
2) Place a piece of plastigauge on the crankpin, install
the connecting rod and cap, and tighten the bolts to
the specified torque.
Note
• Do not rotate the crankshaft while the plastigauge is in
place.
PC01-1A 10-7
3) Remove the connecting rod and measure the plasti-

gauge.
0.040 – 0.063 mm 0.12 mm
(0.0016 – 0.0025 in) (0.005 in)
4) If the clearance exceeds the service limit, replace
the connecting rod and recheck the clearance.
Replacement connecting rods are available with
standard and undersized bearing surfaces.
q Camshaft cam height

IN 27.7 mm (1.09 in) 27.45 mm (1.081 in)
EX 27.75 mm (1.093 in) 27.50 mm (1.083 in)
q Camshaft O.D.
13.984 mm (0.5506 in) 13.916 mm (0.5479 in)
q Crankshaft bearing free play

1) Clean the bearing in solvent and dry it.
2) Spin the bearing by hand and check for play.
Replace the bearing if it is noisy or has excessive
play.
10-8 PC01-1A
q Camshaft holder I.D.

14.0 mm (0.55 in) 14.048 mm (0.5531 in)
PC01-1A 10-9
10-10 PC01-1A
Governor, oil level switch

Governor, oil level switch .............................11-2
PC01-1A 11-1
Governor, oil level switch 1

11-2 PC01-1A
b. Inspection
q Oil level switch
Check continuity between the yellow and green switch
leads with an ohmmeter.
1) Hold the switch in its normal position. The ohmme-
ter should read zero resistance.
2) Hold the switch upside down. The ohmmeter should
read infinite (c) resistance.
3) Inspect the float by dipping the switch into a con-
tainer of oil. The ohmmeter reading should go from
zero to infinity as the switch is lowered.
PC01-1A 11-3
11-4 PC01-1A
Reduction unit
L-Type reduction ......................................... 12-2
1/2 Reduction (Centrifugal clutch type)....... 12-3
1/6 Reduction.............................................. 12-4
PC01-1A 12-1
L-Type reduction 1
12-2 PC01-1A
1/2 Reduction (Centrifugal clutch type) 1

PC01-1A 12-3
1/6 Reduction 1
12-4 PC01-1A
b. Inspection
q Clutch friction disc thickness
3.5 mm (0.14 in) 3.0 mm (0.12 in)
q Clutch plate warpage

Check clutch plate warpage on a flat plate using a feeler
gauge.
Service limit 0.10 mm (0.004 in)
PC01-1A 12-5
12-6 PC01-1A
Optional parts
Lamp coil kit ................................................ 13-2
PC01-1A 13-1
q Lamp coil kit

Lamp coils are available for 6 V - 15W, 6 V - 25W, 12 V - 15W and 12 V - 25W output. They can be installed
singly or in pairs to produce the desired output.
One coil Two coils (Series) Two coils (Parallel)
Lamp coil types
6 V 15W 6 V 15W 12 V 15W 6 V 30W

6 V 25W 6 V 25W 12 V 25W 6 V 50W
12 V 15W 12 V 15W 24 V 15W 12 V 30W
12 V 25W 12 V 25W 24 V 25W 12 V 50W
*Use the parallel connector (No. 32105-ZEI-000) for the parallel two coils.
<Flywheel>
Standard flywheel Flywheel for lamp coil
13-2 PC01-1A
PC01-1A 13-3

© 2007 KOMATSU
All Rights Reserved
13-4 PC01-1A
SEN02706-00
PC01-1A

90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC01-1A 1
SEN02706-00 90 Diagrams and drawings
2 PC01-1A
90 Diagrams and drawings SEN02706
Hydraulic circuit diagram
PC01-1A 3
11213213123
PC01-1A 5

© 2007 KOMATSU
All Rights Reserved
6 PC01-1A
SEN02705-00
PC01-1A

90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
PC01-1A 1
2 PC01-1A
90 Diagrams and drawings SEN02705
Electrical circuit diagram
PC01-1A 3
11213213123
PC01-1A 5

© 2007 KOMATSU
All Rights Reserved
6 PC01-1A

Komatsu PC01-1 (JPN) 14001-Up Shop Manual

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Komatsu PC01-1 (JPN) 14001-Up Shop Manual

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SEN02688-01

HYDRAULIC PC01 -1A

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02688-01

00 Index and foreword SEN02689-01

10 Structure, function and maintenance standard SEN02694-00

20 Standard value table SEN02700-00

30 Testing and adjusting SEN02701-00

90 Diagrams and drawings SEN02704-00

Foreword and general information SEN02691-00

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

90 Diagrams and drawings

PC01-1A Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

5. Change hydraulic oil when the temperature