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FOREWORD

HANDLING OF INTAKE SYSTEM PARTS

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PC390LL-10

HANDLING OF INTAKE SYSTEM PARTS

00

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The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the
conventional turbocharger. If foreign matter enters this system, it can cause a problem. Use special care to prevent entry of
foreign matter when servicing the air intake system.

Be careful of the work environment

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Avoid repairing the machine in rain, high winds, or at places where there is a lot of dust.

Sealing openings

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Install a cap, tape, plastic bag, etc. to the open ends of disconnected piping to prevent entry of foreign matter. Never leave
the openings uncovered nor plug the openings with rags. Foreign matter will enter the system.

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Содержание A50601

Страница 1: ...olicy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes o...

Страница 2: ...10 1 10 STRUCTURE AND FUNCTION 10 1 20 STANDARD VALUE TABLES 20 1 30 TESTING AND ADJUSTING 30 1 40 TROUBLESHOOTING 40 1 50 DISASSEMBLY AND ASSEMBLY 50 1 60 MAINTENANCE STANDARD 60 1 80 AIR CONDITIONIN...

Страница 3: ...them Before starting work thoroughly check the tools machine forklift truck service car etc 7 Decide a place in the repair workshop to keep tools and removed parts Always keep the tools and parts in t...

Страница 4: ...t in particular shut down the engine When checking the machine without stopping the engine measuring oil pressure revolving speed temperature etc take extreme care not to get caught in rotating or mov...

Страница 5: ...15 Take care when removing or installing the tracks of track type machines When removing the track the track separates suddenly so never let anyone stand at either end of the track 16 If the engine is...

Страница 6: ...tted to every joint of hoses and tubes For tightening torque see the precautions for installation in each section of Disassembly and Assembly 18 When jump starting the machine only use a machine of si...

Страница 7: ...as reference material for troubleshooting 20 STANDARD VALUE TABLE This section explains the standard values for new machine and judgement criteria for testing adjusting and troubleshoot ing This stan...

Страница 8: ...PC390LL 10 NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice Contact your distributor for the latest information Find manuals at...

Страница 9: ...e page number Example 10 3 Item number 10 Structure and Function Consecutive page number for each item 3 Additional pages Additional pages are indicated by a hyphen and numbered after the page number...

Страница 10: ...sling a heavy load with one rope alone but sling with two or more ropes symmetrically wound on to the load 6 Limit the hanging angle to 60 as a rule Do not sling a heavy load with ropes forming a wide...

Страница 11: ...ation Maintenance Manual provided with the crane in advance and operate the crane safely Precautions for Using Overhead Hoist Crane 00 1 Before starting work inspect the wire ropes brake clutch contro...

Страница 12: ...the specified posi tion and raise the hook to at least 2 m 6 6 ft above the floor Do not leave the sling installed to the hook Selecting Wire Ropes 00 1 Use adequate ropes depending on the weight of p...

Страница 13: ...cting the wiring Compared with other electrical components fitted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore du...

Страница 14: ...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 circuited by the water so if any water gets in immediately d...

Страница 15: ...nnectors apart Never pull with one hand B When removing from clips Both of the connector and clip have stoppers which are engaged with each other when the connector is installed When removing a connec...

Страница 16: ...rely Align the position of the connector correctly and then insert it securely For connectors with lock stopper push in the connector until the stopper clicks into position C Correct any protrusion of...

Страница 17: ...the compressed air before blowing with air Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector Hot air from the dryer can be used but regul...

Страница 18: ...Ambient pressure sensor PAMB 125 170 12V140 series A Disconnection i Slide lock L1 to the right ii While pressing lock L2 pull out connector 1 toward you Even if lock L2 is pressed connector 1 cannot...

Страница 19: ...e back of connector 1 B Connection i Insert the connector straight until it clicks 8 Pull lock type PACKARD 2 95 107 114 125 140 170 12V140 Series Various temperature sensors Examples i Charge boost t...

Страница 20: ...LECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS 00 20 PC390LL 10 i Disconnect the connector by pulling lock B on the wiring harness side of connector 2 outward B Connection i Insert the connector straight...

Страница 21: ...hile pressing lock C pull out connector 3 in the direction of the arrow 114 series 107 series If the lock is located on the underside use a flat head screwdriver 1 since you cannot insert your fingers...

Страница 22: ...essing lock D pull out connector 4 in the direction of the arrow B Connection i Insert the connector straight in until it clicks 11 Push lock type 3 95 125 140 170 12v140 series A Disconnection i Whil...

Страница 23: ...140 series Example Charge boost pressure sensor in the air intake manifold PIM CANNON 4 etc A Disconnection i Turn housing H1 in the direction of the arrow When the connector is unlocked housing H1 b...

Страница 24: ...ing on the body disconnect all wiring harness connectors connected to the controller Fit an arc welding ground close to the welding point 14 Points to remember when troubleshooting electric circuits A...

Страница 25: ...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 dirt...

Страница 26: ...ary flushing is performed with flushing oil and secondary flushing is performed with the specified hydraulic oil 7 Cleaning operations After repairing the hydraulic equipment pump control valve etc or...

Страница 27: ...out prepare a container for the drained oil Connection 00 1 Hold the hose adapter 1 or hose 5 and insert it in the mating adapter 3 aligning them with each other Do not hold the rubber cap portion 4 2...

Страница 28: ...a of the hexagonal portion at the male end 2 Hold in the condition in Step 1 and turn the lever 4 to the right clockwise 3 Hold in the condition in Steps 1 and 2 and pull out the whole body 2 to disco...

Страница 29: ...n at the male end 2 Hold in the condition in Step 1 and push until the cover 3 contacts surface a of the hexagonal portion at the male end 3 Hold in the condition in Steps 1 and 2 and pull out the who...

Страница 30: ...of size of rotating shaft and hole and relationship drawing of them 2 Standard Clearance And Standard Value The clearance made when new parts are assembled is called the standard clearance which is in...

Страница 31: ...eplaced or repaired HANDLING OF FUEL SYSTEM DEVICES 00 The common rail fuel injection system CRI consists of more precise parts than the conventional fuel injection pump and nozzles If foreign matter...

Страница 32: ...can cause a problem Use special care to prevent entry of foreign matter when servicing the air intake system Be careful of the work environment Avoid repairing the machine in rain high winds or at pl...

Страница 33: ...ats Tightening torque mm mm N m lbf ft 6 10 10 11 8 14 7 8 70 10 84 8 13 12 27 34 19 91 25 07 10 17 14 59 74 43 51 54 57 12 19 17 98 123 72 28 90 72 14 22 157 196 115 79 144 56 16 24 245 309 180 70 22...

Страница 34: ...6 04 22 27 58 9 98 1 44 4 72 4 05 24 32 107 9 166 7 79 6 123 0 06 30 36 147 1 205 9 108 5 151 9 10 33 41 147 1 245 1 108 5 180 8 12 36 46 196 2 294 2 144 7 217 0 14 42 55 245 2 343 2 180 9 253 1 Thre...

Страница 35: ...mm mm Range Target 02 14 Varies depending on type of connector 35 63 25 81 46 46 44 32 45 18 59 to 98 43 5 72 3 78 57 5 03 04 20 84 132 61 95 97 35 103 75 96 05 06 24 128 186 94 40 137 18 157 115 79...

Страница 36: ...ds per inch Thread series Root diameter mm Reference 02 19 34 54 25 0 39 8 44 32 4 9 16 18UN 14 3 34 63 25 0 46 4 44 32 4 14 03 22 54 93 39 8 68 5 74 54 5 11 16 16UN 17 5 24 59 98 43 5 72 2 78 57 5 18...

Страница 37: ...ize Tightening Torque mm N m kgm lbf in 6 8 2 0 81 0 20 70 81 17 70 8 10 2 1 02 0 20 88 51 17 70 10 12 2 1 22 0 20 106 21 17 70 12 24 4 2 45 0 41 212 42 35 40 14 36 5 3 67 0 51 26 55 3 69 Tightening T...

Страница 38: ...etc 5 65 0 32 5 23 4 6 37 Charging and signal 15 84 0 45 13 36 7 0 59 Starting Glow plug 40 85 0 80 42 73 11 4 135 Starting 60 127 0 80 63 84 13 6 178 Starting 100 217 0 80 109 1 17 6 230 Starting Pr...

Страница 39: ...or 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 a...

Страница 40: ...2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diameter of strand 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 Sectional area...

Страница 41: ...e 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 Gre...

Страница 42: ...ll the wires Fit wires and hoses with tags to show their installation position to prevent any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising...

Страница 43: ...nnecting wiring connectors clean the connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration screw them in completely an...

Страница 44: ...INE AND COOLING SYSTEM Cylinder Head Assembly in the Disassembly and Assembly section 3 Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage the mounti...

Страница 45: ...n the table so divide by 10 move the decimal one place to the left to convert it to 55 mm B Carry out the same procedure as above to convert 55 mm to 2 165 inches C The original value 550 mm was divid...

Страница 46: ...8 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 6...

Страница 47: ...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 Liter to U K Gallon 1 L 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 0 220 0 4...

Страница 48: ...00 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...

Страница 49: ...1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 182...

Страница 50: ...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...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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