SEBM008611

DIESEL ENGINE
 Contents
No. of page
01 General .......................................................................................................................... 01-1

11 Structure and function................................... .................................. ................. 11-1

11-1

12 Testing and adjusting........................................................................................ 12-1

13 Disassembly
Disassembl y and assembly .......................................................................... 13-1

14 Maintenance standard.........................................................................................14-1

15 Repair and replacement

replacement of parts
parts.............................................................. 15-1
 List of revised pages

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S a f et y Safety notice

Safety
Safety notice

Important safety notice

Proper service and repair is extremely important for safe machine operation. The service and repair 
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.

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.

General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear 
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Alway
Alwayss wea
wearr saf
safet
ety
y gla
glass
sses
es when
when hit
hitti
ting
ng the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Alway
Alwayss wea
wearr saf
safet
ety
y glas
glasse
ses
s when
when grind
grindin
ing
g
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If 
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear  ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or  machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other 
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's  Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or 
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
Sa f e t y Safety notice

Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or 
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When
When inst
instal
alli
ling
ng hose
hoses
s and
and wire
wires,
s, be sure
sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or 
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
 Always
 Alwa ys use lifting
lifti ng equipment
equi pment which
whic h has
h as ample
ampl e
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either 
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.

16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.

17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor 
can cause you to slip, or can even start fires.

18.  As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gas-
oline when washing electrical parts.
Foreword General

Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand t he contents of this manual and use it to full effect at e very opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.

Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may c ontain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.

Testing and adjusting

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.

Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.

Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.