Tool Kit KAC

Form No.
SEPB1033-04
USEFUL 100
SERVICE TOOL
AND EQUIPMENT
INTRODUCTION
This booklet introduces 102 items of tools and equipment that we have carefully selected as
being very useful for work in field service and workshop.
1. One item each is introduced on one page.

2. The top column explains the characteristics of the item.
3. The central column explains the functions of each tool or equipment, describing the
features and expected effects of the functions.
4. A photograph of each tool or equipment (showing the appearance) is given together with
a photograph (or illustration) of it being used.
5. The specifications and Part No. are also shown to facilitate sending an inquiry or order.
Thus, this booklet contains explanations on the features and benefits of each tool and equip-
ment, in addition to conventional tool guides, and we are sure that it will be very helpful to our
distributors and customers.
Service Department
Product Support Division
2
• Component parts:
No. Part No. Part Name Remarks KIT A KIT B KIT C

1 799-401-2311 GAUGE -101 to +200 kPa 1
2 799-401-2320 GAUGE 1 MPa {10.2 kg/cm²} 1 1
3 799-101-5140 GAUGE 2.5 MPa {25.5 kg/cm²} 2 2
4 799-101-5130 GAUGE 6 MPa {61.2 kg/cm²} 2 1
5 799-101-5120 GAUGE 40 MPa {408 kg/cm²} 2
6 799-101-5110 GAUGE 60 MPa {612 kg/cm²} 2
7 799-401-2280 GAUGE 6 MPa {61.2 kg/cm²} (w/o glycerol) 1
8 799-401-2330 –NIPPLE – for No. 1 thru No. 5 8
9 799-401-2340 – COUPLING – for No. 1 thru No. 5 8
10 799-401-2350 – WASHER – for No. 1 thru No. 5 8
11 799-401-2530 HOLDER GAUGE HOLDER “5 in 1” 1
12 799-401-2360 HOSE 1.8 m (straight coupler): red tape 1
13 799-401-2370 HOSE 1.8 m (straight coupler): yellow tape 1
14 799-401-2380 HOSE 1.8 m (straight coupler): green tape 1 1
15 799-401-2390 HOSE 1.8 m (straight coupler): blue tape 1 1
16 799-401-2410 HOSE 1.8 m (90° coupler): white tape 1
17 799-401-2420 HOSE 1.8 m (90° coupler): brown tape 1
18 799-401-2430 HOSE 5 m (straight coupler): purple tape 1 1
19 799-401-2220 HOSE 5 m (straight coupler): w/o tape 1 1
20 799-401-2550 HOSE 5 m (90° coupler): red tape 1
21 799-401-2560 HOSE 5 m (90° coupler): yellow tape 1
22 799-401-2570 HOSE 5 m (90° coupler): white tape 1
23 799-101-5160 NIPPLE PT 1/8 (quick coupler) 3 3
24 799-101-5220 NIPPLE M10 x 1.25 (quick coupler) 6
25 07002-11023 – O-RING – for No. 24 6
26 799-101-5230 NIPPLE M14 x 1.5 (quick coupler) 1
27 07002-11423 – O-RING – for No. 26 1
28 790-301-1530 ELBOW PT 1/8 (90° ELBOW) 2
29 799-401-2440 ADAPTER for measuring the air pressure 1
30 790-261-1130 COUPLING for air-bleeding of hose 1 1
31 07042-20108 PLUG Blind plug (spare) 2
32 799-203-2560 WRENCH for removing or installing a blind plug 1
33 799-203-2570 WRENCH for removing or installing a blind plug 1
34 799-301-1430 TAPE Seal tape 1
35 79A-262-1910 METER Thermometer 1
36 79A-262-1970 – SENSOR – for measuring the surface temperature 1
37 79A-262-1930 – SENSOR – for measuring the oil & water temperatures 1
38 79A-262-1950 – ADAPTER – for securing No. 37 (PT 1/8) 1
39 799-201-1110 – CABLE – for measuring the exhaust temperature 2
40 790-261-1180 – DRY CELL – for No. 35 (AM3: 1.5 V) 2
41 799-205-1200 METER Tachometer 1 1
42 799-205-1300 – BRACKET – “Engine speed” tap 1 1
43 799-203-8230 – NUT – M22 x 1.5 1 1
44 799-203-8240 – NUT – U7/8-12 1 1
45 799-205-1220 – PROVE – Photoelectric sensor 1 1
46 799-203-8400 – CABLE – 5 m cable 1 1
47 799-203-8860 DRIVE Ass’y “Engine speed” take off gear box ass’y 1
48 6210-81-4111 • BODY • (component of No. 47) (1) 1
49 6215-81-3500 • SHAFT Ass’y • (component of No. 47) (1)
50 01010-30630 • BOLT • (component of No. 47) + spare (2) + 2
51 01640-20610 • WASHER • (component of No. 47) + spare (2) + 2
52 01584-20605 • NUT • (component of No. 47) (2)
53 07000-03050 • O-RING • (component of No. 47) + spare (2) + 2 1
54 01435-20616 – BOLT – for installing Drive ass’y 2
55 01010-80616 – BOLT – for installing Drive ass’y 2
56 799-201-1511 NOZZLE for measuring the engine blow-by 2 1
57 799-201-1450 ADAPTER for measuring the engine blow-by 2 1
58 799-201-1411 ADAPTER for measuring the engine blow-by 1
59 799-201-1590 GAUGE 1000 mmAq {9.81 kPa} 1
60 799-201-1571 TUBE Silicone tube 4 m 1 1
61 799-201-2110 TUBE Silicone tube 1 m 1
62 799-201-2120 – JOINT – for connecting No. 62 4
63 799-201-2130 – SUCKER – for sticking No. 62 6
64 799-201-2140 – BOTTLE – for driqining (water) No. 62 1
65 799-203-8870 STOPPER for fixing the bulldozer steering levers 1
66 799-201-1120 WATCH for measuring various time data 1 1
67 790-301-1410 MEASURE for measuring various dimensional data 1 1
68 799-401-2510 CASE Ass’y Case for containing KIT A 1
69 799-201-1140 CASE Ass’y Case for containing KIT B 1
70 799-201-1910 CASE Ass’y Case for containing KIT C 1
3
Simple and speedy checks of wiring harnesses.
MECHATRO-HARNESS CHECKER
(Parts No. 799-601-2500) (Parts No. 799-601-7100)
(Parts No. 799-601-7400) (Parts No. 799-601-6000)
Example of use
Dimension of case Weight

Part No.
(mm) N {kg}
799-601-2500 445 x 335 x 95 38.25 {3.9}
799-601-7100 500 x 400 x 110 39.23 {4.0}
799-601-7400 500 x 400 x 110 45.11 {4.6}
799-601-6000 500 x 400 x 170 68.65 {7.0}
799-601-7500 – 4.90 {0.5}
799-601-7600 – 4.90 {0.5}
799-601-8000 – 24.52 {2.5}
FEATURES
• Wiring harnesses with many terminals are used on the recent Komatsu products. It is hard to find
out a correct pin position of the wiring harness and it takes time. This checker enables easy and
speedy testing of the wiring harness.
• This checker has terminals for multimeter test leads and the numbers are the corresponding
terminal, so electronic circuit troubleshooting is easy and sure.
4
Ass’y P/No 799-601-7100 799-601-7400

. 799-601-2500
Sub ass’y
P/ No. 799-601-2800 799-601-7300 799-601-6000 799-601-7500 799-601-7600 799-601-8000
---------------------- 799-601-2900
P/NAME PIN P/NO. 799-601-2700 799-601-7000 799-601-7000 799-601-7200
CHECKER 21 799-601-2600 Q q q q
37 3100
37 3200
24 3300 Q
ECONO 2 799-601-2750 Q Q
3 2760 Q Q
4 2770 Q Q
8 2780 Q Q
12 2790 Q Q
MIC 5 799-601-2710 Q Q q
9 2950 q q q
13 2720 Q Q q
17 2730 Q Q q q q
21 2740 Q Q q q q
DLI 8 799-601-2810 Q Q
12 2820 Q Q
16 2830 Q Q
MS 6 799-601-3510 Q
5 3450 Q
10 3460 Q
14 2910 Q
14 3520 Q
17 3430 Q
17 3440 Q
19 3530 Q
24 3410 Q
24 3420 Q
040 8 799-601-7180 q
12 7190 q q
16 7210 q q q
20 7220 q q q
X 1 799-601-7010 q q
2 7020 q q q
3 7030 q q q
4 7040 q q q
2 7230 q q
SWP 6 799-601-7050 q q
8 7060 q q
12 7310 q
14 7070 q q
16 7320 q
M 1 799-601-7080 q q
2 7090 q q q
3 7110 q q q
4 7120 q q q
6 7130 q q q
8 7340 q
S 8 799-601-7140 q q q
10 7150 q q q
12 7160 q(Blue) q(Blue)
16 7170 q(Blue) q(Blue) q
12 7350 q (White) q
16 7330 q (White) q
REL 5 799-601-7360 q
6 7370 q
EXTENSION 799-601-2840 Q Q
CASE 799-601-2850 Q
3470 Q
7240 q q
PLATE 799-601-3360 Q
3370 Q
3380 Q
E : Not interchangeable between the blue and white onse of S12 and S16, (Even same pin No. structure is different.)
5
Kit applicable to all DEUTSCH connectors Kit applicable to HD30 connectors

(Parts No. 799-601-9000) (Parts No. 799-601-9100)
FEATURES FEATURES
• This kit consists of 22 adapters and boxes • This kit consists of 9 adapters and boxes
and is applicable to all DEUTSCH connec- and is applicable to all HD30 connectors.
tors. • HD30 connectors are used as intermediate
connectors for harness.
Kit applicable to DT connectors • Since the harness reliability has been im-
(Parts No. 799-601-9200) proved, its frequency of use is expected to
have been reduced.
• So this kit number has been set so that the
products will be stored at main service sta-
tions.
Kit parts number

No. 799-601 799-601 799-601 Parts number Name Applicable connector
-9000 -9100 -9200
1 ¡ ¡ 799-601-9010 Adapter (*1) DTM 2 ways
2 ¡ ¡ 799-601-9020 Adapter (*1) DT 2 ways
3 ¡ ¡ 799-601-9030 Adapter (*2) DT 3 ways
4 ¡ ¡ 799-601-9040 Adapter (*1) DT 4 ways
5 ¡ ¡ 799-601-9050 Adapter (*1) DT 6 ways
6 ¡ ¡ 799-601-9060 Adapter (*1) DT 8 ways (gray)
7 ¡ ¡ 799-601-9070 Adapter (*1) DT 8 ways (black)
8 ¡ ¡ 799-601-9080 Adapter (*1) DT 8 ways (green)
FEATURES 9
10 ¡
¡ ¡
¡
799-601-9090
799-601-9110
Adapter (*1)
Adapter (*1)
DT 8 ways (brown)
DT 12 ways (gray)
• This kit consists of 13 adapters, and is ap- 11 ¡ ¡ 799-601-9120 Adapter (*1) DT 12 ways (black)
12 ¡ ¡ 799-601-9130 Adapter (*1) DT 12 ways (green)
plicable to all DT connectors.
13 ¡ ¡ 799-601-9140 Adapter (*1) DT 12 ways (brown)
• These connectors have 2 to 12 ways. In 14 ¡ ¡ 799-601-9210 Adapter (*2) HD30, 18-8
addition to the X and SWP conventionally 15 ¡ ¡ 799-601-9220 Adapter (*2) HD30, 18-14
used for sensors and intermediate connec- 16 ¡ ¡ 799-601-9230 Adapter (*1) HD30, 18-20
tors, this kit covers the greater part of trouble 17 ¡ ¡ 799-601-9240 Adapter (*1) HD30, 18-21
18 ¡ ¡ 799-601-9250 Adapter (*2) HD24, 24-9
diagnosis, and is essential.
19 ¡ ¡ 799-601-9260 Adapter (*2) HD30, 24-16
• This kit number has been set so that the 20 ¡ ¡ 799-601-9270 Adapter (*2) HD30, 24-21
products will be stored at all service sta- 21 ¡ ¡ 799-601-9280 Adapter (*3) HD30, 24-23
tions. 22 ¡ ¡ 799-601-9290 Adapter (*3) HD30, 24-31
23 ¡ ¡
• The conventional box (799-601-2600) can 799-601-9310 Plate for HD30
24 ¡ ¡ 799-601-9320 Box
be used directly; therefore, the box is not 25 ¡ 799-601-9330 Case -9000 storage case
included. 26 ¡ 799-601-9340 Case -9100 storage case
6
T-junction adaptor for use with the 24-pin and Do-it-yourself kit of the T-junction adaptor or
40-pin DEUTSCH connector the DEUTSCH connectors
(Parts No. 799-601-9300) (Parts No. 799-601-9500
FEATURES
• Starting from the hydraulic excavators of
Model PC58-3, PC78-6 and PC200-7, the
controllers with the common name of “NGI
controller” are being used.
• To these controllers, 1 unit of 24-Pin
DEUTSCH Connector and 2 units of 40-
Pin DEUTSCH Connectors are being con-
nected.
• When using the T-junction adaptor for use
with the 40-Pin DEUTSCH connector, it is
necessary to use two boxes of the new box
799-601-9320 and the currently using box
799-601-2600. At this time, apply the plate
(Part No.: 799-601-9310) on the current box
799-601-2600. FEATURES
• Types of the T-junction adaptors which can
be fabricated using the above do-it-your-
Component parts of the KIT 799-601-9300 self connector kit:
Part numbers Q’ty Part name Remarks • T-junction adaptors (5 different types) for
799-601-9310 1 Plate use with the DTM2, DT2, 3, 4 and 6 pole
799-601-9320 1 Box types.
799-601-9350 1 T-adapter for 40-pin
799-601-9360 1 T-adapter for 24-pin
Contents of the do-it-yourself connector kit:
Part numbers Part names Applicableconnectors
799-601-9010 Adaptor DTM 2 poles
799-601-9020 Adaptor DT 2 poles
7
T-adaptor for use with the AMP make 070 Connector

(Kit No. : 799-601-7500)
Part numbers of the component parts:

No. Component part number Part name Q’ty Number of pins of the applicable connector
1 799-601-7510 Adaptor 1 10 pin
2 799-601-7520 Adaptor 1 12 pin
3 799-601-7530 Adaptor 1 14 pin
4 799-601-7540 Adaptor 1 18 pin
5 799-601-7550 Adaptor 1 20 pin
FEATURES
• This connector is being installed to important electronics equipments and devices like the monitor
panel, VHMS controller and engine controller.
• Although the T-adaptor for use with this connector has already been introduced in the Shop Manual
and the Tool Guide, this Parts & Service Operation Tips will introduce the aforementioned
T-adaptor once again.
8
T-junction Adaptor and Socket for use with the Common Rail Type Engines
Part numbers Applicable sensors and solenoids
799-601-9410 NE sensor and G. sensor
799-601-9420 Boost pressure sensor and

fuel pressure sensor
799-601-9430 PCV solenoid
FEATURES
• Common Rail type engines are being equipped with sensors and solenoids characteristic to com-
mon rail type engines such as the G. sensor, fuel pressure sensor and PCV solenoid.
• These sensors and solenoids are important parts of the common rail system and if their terminal
pins are directly touched by the probe of a circuit tester when conducting trouble shooting, the
terminal pin may be deformed to cause imperfect contact.
• To repair such imperfect contacts, it becomes necessary to replace the sensor or the solenoid
themselves and, in some cases, it becomes necessary to replace the fuel pump in whole.
Example of use
NE sensor Fuel pressure sensor
9
T-junction adaptor for the HST controller
Part No. Applicable model
799-601-9710 WA250-5
799-601-9720 WA320-5
799-601-9730 WA100-5
FEATURES
• The .-5. type middle sized wheel loaders are being equipped with the HST controller and, to this
controller, a new type connector is being connected.
• We now registered a T-junction adapter matching to the aforementioned connector.
Example of use
Since the connector of the controller is with
26 pins, when conducting trouble shooting of
pins after the No. 22 pin, connect the black
connector to the measuring box.
10

(for Tier 3 Engine)
T-adapter kit
(Part No. 799-601-4100
FEATURES
• T-adapter which is necessary for failure diagnosis of engine-related sensor or harness.
Component part
No. Part number Description 6D140 6D125 6D170 12V140 6D107 4D107 6D114 Way
1 799-601-4330 Socket New G sensor 3
2 799-601-4130 Adapter New CAM sensor 3
NE sensor 3
3 799-601-9420 Adapter ----- Rail pressure sensor 3
4 799-601-4190 Socket New Rail pressure sensor 3
5 799-601-4140 Adapter New Barometric air pressure 3
sensor
6 799-601-4240 Socket New Ambient air pressure sensor 3
7 799-601-4250 Socket New Intake manifold pressure sensor 3
8 799-601-4230 Socket New Intake manifold pressure/ 4
temperature sensor
9 799-601-4180 Adapter New EGR gas 3
pressure sensor
10 799-601-4160 Adapter New Oil pressure switch 2
11 799-601-4150 Adapter New Oil pressure sensor 3
12 795-799-5530 Socket ----- Coolant, Fuel, Oil temperature sensor 2
13 795-799-5540 Socket ----- Intake/Boost temperature sensor 2
14 799-601-9030 Adapter ----- By-pass/EGR valve 4
stroke sensor
15 799-601-4210 Adapter New ECM 50
16 799-601-4220 Adapter New ECM 60
17 799-601-4260 Adapter New ECM 4
18 799-601-9020 Adapter ----- Injector 2
19 799-601-4340 Socket New Pump actuator / Injector 2
20 799-601-9430 Socket ----- PCV 2
21 799-601-4350 Box New 1
22 799-601-4360 Case New 1
11
Almighty to measure rotating

speed!
TACHOMETER KIT TACHOMETER KIT
(Parts No. 799-205-1100) (Parts No. 799-205-1600)
FEATURES
• Various types of pick-up enable to measure rotating speeds, such as the speeds of any type
engines, cooling fan and drive shaft.
• Photo electric pick-up enables to measure engine speed without contact and injection line pick-up,
799-205-1600 is also available.
• The liquid crystal digital display has HOLD function to prevent from miss of reading.
SPECIFICATIONS Component parts:

Part number 799-205-1100 799-205-1600 No. Part number Part name
1) Duration of display - 1.0 seconds - 799-205-1000 Tachometer set
2) LCD display Measuring data: Measuring data:
6 Digits 7 segments 5 Digits 7 segments
- 799-205-1100 • Tachometer kit
LCD 8.00 mm 1 799-205-1200 •• Tachometer
Battery alarm Battery alarm “B”
Reflective light input Signal indicater “LED” 2 799-205-1300 •• Bracket
Units: r/min
3) Accuracy ± 0.01% ± 1 digit r/min ± 1 r/min
3 799-205-1220 •• Probe
4) Operating temperature 5 to 40°C 0 to 40°C 4 799-203-8300 •• Stand
5) Storage temperature –10 to 60°C –10 to 55°C 5 799-203-8230 •• Nut
6) Power supply AAA Alkaline battery: AM3 Manganese battery: 6 799-203-8240 •• Nut
4 pcs. 3 pcs.
7 799-205-1400 •• Case
7) Continuous operation 20 hours continuous use 10 hours continuous use - 799-205-1600 • Tachometer kit
(20°C)
8) Method of measurement Non contact, Contact 8 799-205-1700 •• Tachometer
Contact (with adapter) Fuel injection pipe-mounted
type sensor
9 799-205-1800 •• Detector
9) Measurement range 6.0 rpm to 99999.9 rpm 400 rpm to 10000 rpm - 799-205-1900 •• Case
10) Resolution 0.1 rpm 1 rpm

11) Distance from object
being measured 50 to 300 mm
(with reflective tape) -
12) Outer dimensions 122 x 58 x 28 mm 157 x 60 x 38 mm
13) Weight Approx. 130 g Approx. 400 g
12
Easy and accurate temperature measure-

ments from –99.9°C to 1299°C.
DIGITAL THERMOMETER
(Parts No. 799-101-1502) Example of use
FEATURES
• This meter is a digital one, so you do not have to be nervous to keep the body horizontally as a
conventional analog one.
• Wide range, from –99.9°C to 1299°C can be measured.
• You can read four places temperature at the same time, changing the channel, on the liquid crystal
digital display.
• V type engine requires adjustment of fuel balancing between L.H. and R.H. banks. two exhaust
gas sensors are added, so this adjustment can be done.
SPECIFICATIONS
1) Indicated temperature range –99.9 to 1299°C
2) Accuracy ±0.2% (read value)
3) Usable temperature 0 to 40°C
4) Usable humidity 20 – 80% R.H.
5) Temperature sensor K (Chromel-Alumel) thermocouple
79A-262-1920 Flexible sensor (-50°C to 280°C)
79A-262-1930 Bar sensor (-50°C to 350°C)
6215-11-8180 Exhaust sensor (-50°C to 700°C)
79A-262-1970 (Option) Surface sensor (-50°C to 400°C)
6) Display LCD (Liquid crystal)
7) Power supply 3V [LR6 (AA) x 2]
8) Continuously usable time 80 hours
9) Dimensions 352 (W) x 146 (L) x 90 (H) mm
10) Weight 13.73 N {1.4 kg}
13
Essential tool for checking operation

of injection nozzle.
FUEL INJECTION NOZZLE TESTER
FEATURES
• This tester can check the cracking pressure and spray condition of the injection nozzle easily.
• It is compact and lightweight, so it is easy to carry around.
SPECIFICATIONS
1) Applicable engine All models (Excl. cummins engine)
2) Pressure gauge 0.00 to 49.03 Mpa {0 to 500 kg/cm²}
3) Min calibration 980.67 kPa {10 kg/cm²}
4) Overall length Approx. 410 mm
5) Fuel reservoir 600 cc
6) Weight 71.59 N {7.3 kg}
Components parts:
No. Part No. Parts Name Q’ty Remarks
1 799-203-7700 Nozzle tester 1 71.59 N {7.3 kg}
2 799-203-7750 Tube ass’y 1 0.43 N {0.044 kg}
3 799-203-7760 Tube ass’y 1 0.41 N {0.042 kg}
4 799-203-7770 Tube ass’y 1 0.78 N {0.080 kg}
5 799-203-7780 Tube ass’y 1 8.24 N {0.084 kg}
6 799-203-7810 Tube ass’y 1 0.48 N {0.049 kg}
7 799-203-7820 Tube ass’y 1 0.85 N {0.087 kg}
14
For pressure test of cooling system

RADIATOR CAP TESTER
FEATURES SPECIFICATIONS
1 Pump DC 12 V
• This tester confirm functioin of the pres- Max 588.40 kPa {6 kg/cm²}
sure valve and checks the cooling system
2 Pressure With 0.00 – 196. 13 kPa
for water leakage.
gauge {0 – 2 kg/cm²} regulator
• The tester is composed of a manually op-
erated air pump for pressurizing and an 3 Dimensions 360 x 190 x 200 mm
adapter. 4 Weight 88.26 N {9 kg}
Types of radiator caps:

Type A The cap type in that the radiator cap and water pouring cap are built into a single unit (for automobile use)
(Four sizes by diameters are available, i.e., ø54, ø50, ø41, and ø31)
Type B The cap type that has a single unit of pressure valve
(Two sizes by the thread pitch of water pouring cap are available)
Type C The cap type made by WISCO and that has a plug hole in the upper tank
Types of combinations:
A type B typ C type
Checking
pressure valve
operations
Checking for
water leak from
cooling system
15
Essential! Quick coupler-type pressure gauge

kit with adapters for all hydraulic circuits
ANALOG HYDRAULIC TESTER
FEATURES
• Hydraulic pressure take-out adapters necessary for measurement (Various adapters for each
hydraulic port are prepared).
• Filled with glycerin to improved durability of the gauge, prevent breakage of the gauge and prevent
jitter of the pointer.
• A rubber protective cover is installed to the outside of the gauge.
• Quick couplers are used for easy connection of the gauge, hoses and adapters.
SPECIFICATIONS (799-101-5002)
1) Pressure gauge Component of gauge
1. 2.45 MPa {25 kg/cm²} 3. 39.23 MPa {400 kg/cm²}
2. 5.88 MPa {60 kg/²} 4. 58.84 MPa {600 kg/cm²}
2) Pressure hose 5 1600-mm long hoses (Resistance to 58.84MPa {600kg/cm2})
with quick couplers (sockets and nipples) and caps
3) Adapter Each adapter
4) Dimensions 395 W x 330 D x 85 H (Outside dimensions of storage case)
5) Weight 98.07 N {10 kg}
(Option)
No. Part No. Part Name Remarks
1 799-401-2530 Holder Used to install and hang up five pressure gauges.
2 799-401-2320 Gauge 980.67 kPa {10kg/cm²} pressure gauge filled with glycerin
3 799-401-2280 Gauge 5.88 MPa {60kg/cm²} pressure gauge without glycerin
4 790-261-1130 Coupling Female quick coupler (For bleeding air from hose)
5 799-101-5210 Nipple Quick nipple PT 1/4
6 799-101-5220 Nipple Quick nipple M10 x P1.25 (For O-ring boss)
7 799-101-5230 Nipple Quick nipple M14 x P1.5 (For O-ring boss)
8 799-101-2210 Flange Flange with pressure measuring port for split flange of nominal size of 06
9 799-401-2220 Hose 5.0m hose (With straight coupling)
Other hoses are available, too.
16
Only one pressure gauge can measure all

types of pressure.
DIGITAL HYDRAULIC TESTER
FEATURES
• All the adapters and hoses are interchangeable with those for an analog hydraulic tester.
• Only one digital gauge of 0 – 60 MPa {0 – 612 kg/cm²} can substitute for analog hydraulic testers
of four types.
• Indication by LCD.
SPECIFICATIONS
Material: Wet material: SUS630eq. SUS316
Case: ADC12
(max. operating pressure: 60 MPa {612 kg/cm²}
Operating range: 0 to 60 MPa {0 to 612 kg/cm²}
Electrical system: External type: 24 V DC

Battery type: LR6 x 3
Accuracy : ± 1%F.S. /°C ± 1digit

± 0.5%F.S. /°C ± 1digit (Range 1 to 50 MPa {0 to 510 kg/cm²}
Heat effect against span: 0.3% per 10°C
Weight: 47.07 kPa {480 g}
Outer dimensions (with case): 455(W) x 335(D) x 95(H)

Weight: 93.16 N {9.5 kg}
17
A temperature can be measured quickly and

accurately at a glance.
Heat gun
(Parts No. 795-799-5510)
FEATURES
• Ultra-wide range. Can be used for various purposes.
• The measured value holding function can hold one of a momentary temperature, the maximum
value and the minimum value.
• LCD with backlight
Since the LCD can be lighted up with a switch, the measured values can be checked securely
even in the dark.
• Various functions and indication patterns
The setting condition of the functions can be confirmed by various indication patterns of the large-
sized LCD panel.
SPECIFICATIONS
Model MX2
Measuring temperature range -30 – 900°C
Sighting system 3-point laser
Measurement accuracy ± 0.75% of reading or ±0.75°C (Lower than -5°C: 1 ±2°C)
Reproducibility ± 0.5% of reading or ±1°C
Responding speed (95%) 250 msec
Wavelength 8 to 14 µm
Emissivity revision 0.10 to 1.50 (0.01 step)
Using ambient temperature 0 – 50°C
Power source AAA Alkaline battery: 2 pcs
Weight Approx. 4.71 N {480 g}
Outer dimensions 50 (W) x 170 (D) x 200 (H)
18
Measure piston compression pressure be-

fore disassembling engine!
COMPRESSION GAUGE KIT
14.5 kg
FEATURES
• Intended to measure engine piston compression pressure.
SPECIFICATIONS
Compornent parts and applicable machines
No. Part No. Parts Name Specification and applicable model Q’ty Remarks
1 795-502-1590 Gauge ass’y 1
1a 795-502-1210 • Gauge 68.65 MPa (0 – 70 kg/cm²) 1
1b 795-502-1220 • Hose Length 390 mm 1
1c 799-502-1230 • Valve With a reset button 1
2 799-502-1240 Adapter 155-4 engine 1
3 799-502-1250 Adapter 92-1 engine 1
4 799-502-1260 Adapter 105-1, 2, 3 engine 1
5 799-502-1270 Adapter 120-11, 130-1 engine 1
6 795-502-1283 Case 410 x 300 x 127 mm 1
7 795-502-1291 Adapter 743 engine 1
8 795-502-1310 Adapter 94-1 engine 1
9 795-502-1320 Adapter 855 engine 1
10 795-502-1330 Adapter 105-1, 5, 110 engine 1
11 795-502-1340 Adapter KT1150 engine 1
12 795-502-1350 Adapter 6D, 8V, 12V170 engine 1
13 795-502-1360 Adapter 125 engine 1
14 795-502-1370 Adapter 95-1 (direct injection type) engine 1
15 795-502-1380 Adapter 95-1 (squish chamber type) engine 1
16 795-502-1500 Adapter ass’y 140-1 engine 1
16a 795-502-1510 • Adapter 1
16b 795-502-1520 • Plate Plate for 795-502-1510 1
17 795-502-1530 Adapter ass’y 3D78 engine 1
17a 795-502-1540 • Adapter 1
17b 795-502-1550 • Plate Plate for 795-502-1540 1
18 795-101-1580 Adapter ass’y 3D72, 75, 84 engine 1
18a 795-101-1560 • Adapter 1
18b 795-101-1570 • Joint 1
19 795-502-1610 Name plate 1
20 795-502-1560 Packing 1
21 795-502-1570 Packing 1
22 795-502-1580 Packing 1
19
Measure piston compression pressure be-

fore disassembling engine!
Note 1) Number 23 to 36 are not included in 795-502-1205
SPECIFICATIONS
Parts and applicable machines
No. Part No. Parts Name Specification and applicable model Q'ty Remarks
23 795-111-1110 Adapter 84-2 (Necessary tool: 795-101-1571) 1
24 790-553-1110 Adapter 2D94-2, 4D94-2, 4D95l, 4D95W 1
4D130-1
24a 790-553-1120 • Adapter Length 390 mm 1
24b 790-553-1130 • Adapter With a reset button 1
24c 790-553-1140 • Packing 155-4 engine 1
25 790-471-1090 Adapter 16V170-1 engine 1
26 790-471-1110 Plate 16V170-1 engine 1
27 790-472-1370 Adapter SA6D108 engine 1
28 795-502-1390 Adapter 1D75-1, 1D84-1 (Necessary tool: 1
795-553-1130, 795-553-1140)
29 795-502-1700 Adapter ass'y 102 engine 1
30 795-111-1120 Adapter 3D68E-3 engine 1
31 795-471-1410 Adapter 125E-3 engine 1
32 6217-71-6110 Gasket 125E-3 engine 1
33 795-471-1310 Adapter 140E-3 engine 1
34 795-611-1210 Adapter 170E-3 engine 6
35 795-790-3610 Gauge 114 engine 1
36 795-790-3710 Tester 114 engine 1
Necessary tool: 795-502-1590 Gauge assembly

20
Easy blow-by pressure measurement

of all engine models.
BLOW-BY CHECKER
FEATURES
• The engine blow-by pressure can be read on the gauge directly.
• Four in long vinyl tube enables measurement safely and remotedly such as sitting in the operator
seat while operating the machine.
SPECIFICATIONS
1) Applicable engine All models
2) Pressure gauge Chamber type pressure gauge
Measuring gauge 0 to 5 kPa {0 to 500 mmAq}
Minimum graduations 20 mmAq
Accuracy ±2%
3) Vinyl tube ø5 x ø6 x 4000 m
4) Dimensions 415 x 300 x 60 mm
5) Weight 44.13 N {4.5 kg}
OPTION
Part No. Discription Remarks
795-790-1950 Tool (Body) For 102 engine
799-201-1590 Gauge 0 to 10 kPa {0 to 1000 mmAq}
21
Digital display of fuel consumption in the field

without calculation.
FUEL CONSUMPTION METER
FEATURES
• Two in-line fuel flow sensors (supply and return) and a microcomputer provide the followings
measurement values on the digital liquid crystal display.
1) Accumulated fuel consumption (L): Total fuel consumption from start to finish
2) Measurement time (H.M.S.): Total measurement time from start to finish
3) Accumulated fuel consumption ratio
•• (Km/L): Mileage (kilometers) per one liter
•• (L/H): Hourly fuel consumption ratio
4) Spot fuel consumption ratio (L/H): Hourly fuel consumption ratio converted from one second
sampling
5) Mean vehicle speed (Km/H): Kilometers per hour
• Measurement data can be print out.
SPECIFICATIONS
1) Measurement range
Items A type sensors B type sensors
(L) 0.01 – 9999.99 liters (Accumulated)
(H.M.S.) 99 hours 59 minutes 59 seconds at the maximum (external battery connected)
10 hours (internal battery connected)
(Km/L) 0.1 – 99.9 Km/L
Ratio (Traveling distance can be input up to 9999.9 Km)
Ratio (L/H) 0.1 – 99.9 L/H
Spot ratio (L/H) 0.1 – 300 L/H 0.1 – 40 L/H
(Km/H) 0.1 – 999.9 Km/H
(Traveling distance can be input up to 9999.9 Km)
2) Power source 2-way power supply

3) Temperature range Operation temperature 0 to +50∞C
(Preservation temperature ñ20 to +70∞C)
4) Printer Mechanical dot-matrix, one way (left to right)
Normal size 40/line width 1.2 mm x height 2.4 mm
5) Dimensions 488 x 345 x 133 mm
6) weight 73.55 N {7.5 kg}
Note) This meter is not applicable on the Cummins ENGINES.

22
Easy measurement of BOOST PressURE!

Prevent turbo. and engine failure!
BOOST GAUGE KIT
FEATURES
• Simple measurement same as hydraulic pressures.
• Quick coupler connection, speedy preparation!
• Vaccum range is available till 760 mmHg.
Component parts:
No. Part No. Parts Name Qíty Remark
1 799-101-5160 Nipple 1 PT 1/8
2 799-401-2311 Gauge 1 -760ñ1500 mmHg
3 799-401-2610 Hose 1 58.84 MPa
{600 kg/cm≤}
23
Undercarriage parts wear measuring tool

kit for your parts business expansion
UNDERCARRIAGE MEASURING TOOL
Photo. 1
1. Kit Part Number and Vendor
Part Number: CK40-25
Vendor: Komatsu South Africa (PTY) LTD
Undercarriage Division
E-Mail: [email protected]
: [email protected]
2. Components
This tool is composed of three layers, and there are
two kinds of outside calipers on the upper layer as
Photo. 2
shown in Photo. 1, there are three kinds of scales,
two kinds of depth gauges and one kind of outside
caliper on the middle layer as shown in Photo. 2,
and there are one kind of vernier caliper and brushes
on the lower layer as shown in Photo. 3.
Example of use
Photo. 3
Measurement of Link Height

1) Use the depth gauges to measure link height.
2) Read the scales to determine the depths mea-
sured with the depth gauges.
FEATURES
• Three kinds of calipers are available suitably for parts to be measured.
• The calipers are fitted with screw and enables you to measure accurately because it prevent
positions from changing at the measuring time. In addition, the caliper tips are shaped, enabling to
measure easily.
• The depth gauges enable you to measure link heights and grouser heights accurately.
24
Compressed air detects seal damage easily.
OIL LEAK CHECKER

FEATURES
• Damaged seals can not keep pressure leaving it drop down quickly. Using this mechanism, the
following parts checking can be done easily.
1) Floating seals on track roller, idler and final drives,
2) Clutch piston of automatic transmission.
• Various adapters are available, so as to be used for all Komatsu products.
• Compressed air can be supplied by the compressed air source in the shop or by any commer-
cially available hand-operated pump (bicycle pump).
SPECIFICATIONS
Gauges 196.13 kPa {2 kg/cm²} and 980.67 kPa {10 kg/cm²}
Regulator adjustment 0.0 to 980 kPa {10 kg/cm²}
pressure
* Depending on the use, the tester can be bought in separate parts under the following kit part numbers.
• Tester for checking operation of automatic transmission clutch piston: 799-301-1600
• Tester for checking oil leakage from final drive case (field use): 799-301-1800
25
One scale to measure both the pushing

and pulling force.
PUSH-PULL SCALE
(Parts No. 79A-264-0021 (0 to 30 kg))
79A-264-0091 (0 to 50 kg)
Accessories
FEATURES
• This scale can measure both the pushing and pulling force, using various adaptors, so it has a
wide range of uses in maintenance and inspection, or adjustment when assembling levers and
pedals.
• The pointer is held at the maximum indicated value.
• With a kg-N scale.
SPECIFICATIONS
Item Parts No. 79A-264-0021 79A-264-0091
1. Measurement range 0 – 300 N {0 to 30 kg} 0 – 500 N {0 to 50 kg}
2. Minimum scale 0.25 N {0.25 kg} 5 N {0.5 kg}
3. Stroke 10 mm 10 mm
4. Dimensions (with case) 224 x 64 224 x 64
5. Weight (with case) 17.65 N {1.8 kg} 17.65 N {1.8 kg}
26
Indispensable one for troubleshooting of hydraulic circuit.

Flowmeter and adapters kit for Komatsu machine.
FLOWMETER KIT
FEATURES
• This kit enables to test the performance of the hydraulic equipment (mainly the hydraulic pump) by
connecting the flowmeter into the hydraulic piping.
• This meter indicates the oil flow, oil pressure and oil temperature at the same time.
• Adapters are available to allow checking the performance of the hydraulic pumps on all Komatsu
models.
SPECIFICATIONS
1) Measuring range Flow: 15 to 350l/min. (±1%)
(accuracy in parentheses) Pressure: 0 to 39.23 MPa {400 kg/cm²} (±1%)
Temperature: 0 to 150°C (±1%)
2) Power source Dry batteries: 1.5V single 3 x 3 pcs.

1.5V single 1 x 2 pcs.
3) Weight (body only) 62.76 N {6.4 kg}
4) Weight (total) 264.78 N {27 kg}

27
Measure the sound level and maintain the

environment quiet!
SOUND LEVEL METER
FEATURES
• This is a hand-held integrating sound level meter it is ideally suited for measuring factory and
community noises especially for noise with large level fluctuation.
• Four kinds of display mode can be selected by pressing the mode selector.
SPECIFICATIONS
Performance IEC Pub. 60804 Type 2, JIS C 1502-1990 Ambient Temperature: –10 to +50°C
standards: conditions: Humidity: Approx. 10 to 90% RH
Microphone: 1/2-inch prepolarized condenser type UC52 Power: IEC R6 or ANSI AA battery x 4
LR-6: 34 hour, R6P: 14 hour
Measurement 28 to 130 dB (A)
ranges: 33 to 130 dB (C) Dimensions: 260 (H) x 76 (W) x 33 (D) mm
Six ranges: 10 dB step
Frequency range: 20 – 8000 Hz Weight: Approx. 400 g (including batteries)
Weightings: A and C, Flat Standard Windscreen x 1, Battery R6P x 4, Jack cover x 1,

accessories: Carrying case x 1, Hand strap x 1
Dynamic Fast and Slow
characteristics:
Measurement Lp (Instantaneous/Maximum level), Leg/LE

modes (display): (Manual/Preset measurement time:
10 s, 1 min., 5 min., 10 min., 15 min., 30 min.,
1h, 8h, 24h)
Sensitivity adjust- Electrical calibration by internal 1000 Hz sinu-

ment (calibration): soidal wave signal
Maximum level Provided

hold:
Display: 128 x 62 dot
Outputs: AC & DC
28
Contamination control with ISO and NAS

classification by yourself in the field!
CONTAMINATION CHECKER
(Parts No. 79A-851-1000) CM20 Compornent
FEATURES
• Using the optical scanner head system, it is possible to categorize into 4 ranges of particle diam-
eter (5 — 15, 15 — 25, 25 — 50, and over 50 microns) to measure.
• Taking of samples from on-liine is made by simply connecting to a quick coupler ring.
• Operation is simple, and tests can be carried out completely automatically in only 4 minutes.
• The result is shown immediately on the monitor, and it is also possible to print out a hard copy.
• The number and class of particles for each range of particle diameter can be displayed in NAS or
ISO.
SPECIFICATIONS
Principle of measurement Light blocking-type automatic particle No. Part No. Part Name Q’ty
measuring
method 79A-851-1000 Check ass’y 1
Measurement ranges of 4 ranges (Over 5, over 15, over 25 and over
particle diameter 50 microns) 79A-851-1200 • Check subass’y 1
International grain ISO Grade 7 – 24, NAS Grade 0 – 12 1 79A-851-1210 • • CM20 1
measurement standard
Calibration Conformed to ISO 4402
2 79A-851-1220 • • Sample 1
Recalibration Unnecessary 3 79A-851-1230 • • Hose ass’y 1
Accuracy/Reproducibility 5% max.
4 79A-851-1240 • • Ribbon 1
Viscosity range of 2 – 100cSt (Up to 500cSt of single point
sampler)
5 79A-851-1250 • • Lamp 1
hydraulic oil
Using temperature range +5°C — +80°C 6 79A-851-1260 • • 1
Ambient temperature range +5°C — +40°C 7 799-101-5150 • • Hose 1
Applicable hydraulic Mineral oil, synthetic oil
oil/lubricating oil 8 79A-851-1270 Bottle sample 1
Max. using pressure 4118.79 N (420 kgf/cm²)
Max. flow rate 400 l/min 1) As the power source, a battery power supply or an
Operating condition Min. using pressure of 2kgf/cm² AC100V power supply is used.
Test time 4 minutes 2) Option: Bottle sampler: 79A-851-1270
Waiting time for re-test 4 minutes each
Battery life 150 tests
Storage capacity Data of 300 tests
Output to printer 16-column printer
Output to external device RS232C
Power source Battery (Alkaline dry battery of R20PU size x
6 pcs.)
or DC12V
29
Reduced Cylinder Checking Tests for use with the

WA500-3 wheel loaders after the minor change
Switch box
(Parts No. 799-607-4200)
Example of use
Connect the connector of the switch box.
FEATURES
• The WA500-3 wheel loaders after the minor change are being equipped with the common rail type
engines.
• Since the monitor panel is the same as that on the machines before the minor change, it becomes
necessary to use the switch box when conducting reduced cylinder checking tests.
• To carry out reduced cylinder checking tests, a circuit tester is necessary in addition to this switch
box.
30
Measurement with one drop.
Specific gravity tester

(Parts No. 795-500-1001)
(Parts No. 795-500-2000)
Example of use
FEATURES
• Used to measure the specific gravity of the
battery liquid and the charging condition of
the battery.
• Used to measure the freezing temperature
when anti-freeze is use.
Specifications:
795-500-1001 795-500-2000
Gravity of the Reading 1.100 to 1.300 1.00 to 1.30
battery liquid range
Measurement Reading
freezing range -5 to -50°C -8 to -50°C
temperature
Type of the anti-freeze AF-PT, AF-ACL NON AMINE
31
Adapter and Plug for Face seal hose joint
Adapter Plug
(Parts No. 799-401-3100 and others) (Parts No. 07376-70210 and others)
02 03 04 05 06 10
FEATURES Example of use

• Adapter with measuring port.
6 Type (Nominal Number (KES) 02 to 10)
Choose one by hose size.
• O-ring for face seal joint.
Choose one by face seal joint size.
Example : Connect with pressure gauge

FEATURES
• 6 Type (Nominal Number (KES) 02 to 10)
Cap
(Parts No. 02789-00210 and others)
Example of use
FEATURES
• When no inner presure is applied.
• 6 Type (Nominal Number (KES) 02 to 10)
Adapter with measuring port.

32
Troubleshooting Unit for HPI Engine, 6D170E-3
Heat gun Pressure gauge

(Parts No. 795-799-5510) (Parts No. 795-799-5560)
FEATURES
• To be used for measuring pressure at fuel
FEATURES pump inlet. (Measuring negative pressure)
• To be used for troubleshooting of injector. • The measuring range is from 0 to -0.1 MPa.
Adapter
(Parts No. 795-799-5550)
Cummins part No. 3376859)
FEATURES
• To be used for measuring pressure of fuel
pump.
33
Troubleshooting Unit for HPI Engine, 6D170E-3

Socket Cable
(Parts No. 795-799-5520 to 795-799-5540) (Parts No. 795-799-5460 to 795-799-5480)
795-799-5460 795-799-5470 795-799-5480
795-799-5520
795-799-5530
795-799-5540
FEATURES
• 795-799-5460 Cable
(Cummins Part No. 3824774)
FEATURES To be used for troubleshooting of atmo-
• 795-799-5520 Socket (S) spheric pressure sensor, fuel pressure
To be used for troubleshooting of engine sensor and actuator pressure sensor.
speed sensor. • 795-799-5470 Cable
• 795-799-5530 Socket (C) (Cummins Part No. 3824775)
To be used for troubleshooting of water To be used for troubleshooting of lubricat-
temperature sensor, air intake temperature ing oil pressure sensor.
sensor and exhaust gas temperature sen- • 795-799-5480 Cable
sor. (Cummins Part No. 3824776)
• 795-799-5540 Socket (A) To be used for troubleshooting of timing
To be used for troubleshooting of tempera- pressure sensor, air intake pressure sen-
ture sensor. sor and pump pressure sensor.
34
FOWA (Fuel, Oil, Water and Air) Program of

New Checker
FOWA Checker Assembly
(Parts No. 799-609-2000)
FEATURES
• Measurement of TBN (Total Base Number)
Sulfur is contained in fuel, when burnt, changes to sulfur dioxide and then to sulfuric acid, which
is molten in oil, oxide and deteriorates the fuel as chemical change. To restrain this chemical
change, alkaline additives like detergent dispersant are added in oil.
The measurement of TBN is for measuring how much alkaline additives to restrain oxidation and
deterioration is remained.
• Measurement of TAN (Total Acid Number)
Oil is oxidized or deteriorated when used, and the acidity increases. TAN is for measuring the
acidity. TBN decreases as oil is deteriorated, but TAN increases to the contrary.
• Judgment of Viscosity
While oil is used, soot resulted from imperfect combustion is hardened to sludge. When sludge
is produced, oil viscosity increases. Deterioration of oil due to sludge can be judged by measuring
the viscosity. When fuel mixes in oil, the viscosity decreases, and dilution by fuel can be judged as
well.
• Measurement of Moisture in Oil
When cooling water mixes in oil, the oil film is broken and a lubrication failure occurs. Conse-
quently, early seizure will result in a serious accident.
• Measurement of Water Hardness Value
When river water is used as the cooling water and the hardness is high, scale adheres to the
inside of the radiator water tube. Consequently, the water flow decreases and the engine is over-
heated. So, it is very important to manage water harness.
• Measurement of Water pH Value
In case river water is used as the coolant, if the water is not neutral, it will cause a chemical
reaction. Therefore it cannot be used as the normal cooling water. So, it is important to measure
pH value of water.
Component parts
No. Part Number Description Q’ty Remarks
1 799-609-2100 TBN checker assembly 1 set For 50 times
2 799-609-2200 TAN checker assembly 1 set For 25 times
Note: This assembly includes the hardness checker
3 799-609-2300 Viscosity checker assembly 1 set -
4 799-609-2400 Water checker assembly 1 set For 50 times
for 10 times, but if the hardness checker is
5 (799-609-2500) Hardness checker 2 packs For 10 times
ordered under the Part No. 799-609-2500, the
6 799-609-2600 Litmus paper 1 pack For 100 times harness checker for 50 times will be supplied.
35
Anyone can measure exhaust gas color easily

and says same value!
Handy smoke checker
(Parts No. 799-201-9001)
Example of use
FEATURES
• Best for judging of engine deterioration and maintaining of environment
• Handy Smoke Checker (exhaust gas color meter) is on sale as a renewal.
• Compact, portable, and you can easily measure and instantly judge the exhaust gas color in fields!
• The newly installed smoke scale was approved by the department of commerce in United States.
New scale parts number: 799-201-9340
Component parts:
No. Part number Description Q’ty Remarks
1 799-201-9310 Pump 1
2 799-201-9320 Probe 1 Pump ass’y
3 799-201-9330 Nipple 1
1 Manufactured by
4 799-201-9340 Smoke scale BACHARACH
(See above)
5 799-201-9020 Filter paper 1set Containing 300 sheets
6 799-201-9350 Case 1
36
Torque multipliers ... Maximum output from mini-

mum input through planetary reduction gears.
POWER WRENCH
(Parts No. Refer to Specifications) Example of use
FEATURES
• When tightening parts with a large tightening torque, a large output torque can be obtained with a
small input torque.
• Planetary type reduction gears offer compact sizes. These multipliers are supplied in steel cases
with their adapters so as to be transported and sometimes indispensables for large size ma-
chines service.
SPECIFICATIONS
Max. working torque
Part No. Reduction ratio Weight N {kg)
Nm {kgm}
790-102-1000 1471 {150} 1 : 4.8 84.34 {8.6}
790-102-1100 4413 {450} 1 : 16 171.62 {17.5}
790-102-1200 11768 {1200} 1 : 43 664.89 {67.8}
37
Powerful socket wrench kit for 12 point bolts.
SOCKET WRENCH KIT (for 12 point bolts)

(Parts No. 79A-212-4201)
FEATURES
• This is used for tightening or removing 12 point bolts mainly used on engines.
• Compared with hexagonal bolts, the head of 12 point bolts is smaller, and the load is larger. The
structure of this sockets give increased wear resistance and strength.
• This kit can cover a range of bolts with width across flats of 10 mm - 24 mm (bolt diameter 10 - 22
mm).
COMPONENT PARTS AND SPECIFICATIONS
No. Part No. Part name Width across Permissible

Insertion angle B torque Nm {kgm} Remarks
flats A
1 • 79A-212-4210 Socket 10 mm • 12.7 mm (1/2”) 105.91 {10.8}
2 • 79A-212-4220 Socket 12 • 12.7 (1/2) 182.40 {18.6}
3 • 79A-212-4230 Socket 14 • 12.7 (1/2) 290.28 {29.6}
4 • 79A-212-4240 Socket 17 • 12.7 (1/2) 423.65 {43.2}
5 • 79A-212-4250 Socket 19 • 19.1 (3/4) 604.09 {61.6}
6 • 79A-212-4260 Socket 22 • 19.1 (3/4) 878.68 {89.6}
7 • 79A-212-4270 Socket 24 • 19.1 (3/4) 1126.78 {114.9}
8 • 79A-212-4180 Case – – –
9 • 79A-212-4291 Packing – – –
• 19.1 (Female) x
10 • 79A-212-4310 Adapter – • 12.7 (Male)
–
Hexagonal bar (with
11 • 79A-472-1030 Adapter 17 – – across flats: 17 mm)
38
Essential special tool for tightening bolts by

angle method Angle tightening wrench.
ANGLE TIGHTENING WRENCH
FEATURES
• The snug torque can be pre-setted simply with the torque scale, and can be carried out over a
wide range.
• It is both possible to read the angle value and to make pre-set.
• After the snug torque is reached, the angle scale plate rotates, so even if the ratchet is applied to
return the torque wrench, and angle scale plate does not return.
• If the flexible tube is removed, it can be also used as a normal torque wrench.
SPECIFICATIONS
Scale kgf.m Unit for Dimensions (mm)

Part No.
min – max Unit on angle L’ L a b c d h m n A t
scale
790-331-1120 4 – 28 0.2 2° 684 600 3/4 = 19.05 20.5 10.2 30 40.1 37.9 16.1 73.6 33.5
790-331-1110 6 – 42 0.3 2° 984 900 3/4 = 19.05 20.5 10.2 34 43.2 43.7 17 76.7 33.5
39
Guides for aligning holes.

GUIDE BOLT KIT
FEATURES
• Use of these guide bolts can reduce the time taken to install parts, and can prevent seals from
damage.
• A simple idea makes big effect.
SPECIFICATIONS
Size (mm)
No. Part No. Q’ty
Dia. Pitch Long
1 790-201-3110 3 ø8 1.25 70
2 790-201-3120 3 ø 10 1.5 110
3 790-201-3130 3 ø 12 1.75 155
4 790-201-3140 3 ø 14 2.0 180
5 790-201-3150 1 Case
40
Quality assurance, reducing manhour for removal

and installation of bearing lock nut!
NUT WRENCH KIT
FEATURES
• Removal and installation of the bearing locknut takes time, but with this wrench, the time can be
reduced by approx. 50%, and damage to the part is prevented, so working efficiency can be im-
proved and the quality can be assured.
• By using a torque wrench at the same time, it is possible to measure the preload.
SPECIFICATIONS AND APPLICABLE NUTS

No. Part No. Tool Square
Q’ty drive Circular nut Dimension Number Dimension Dimension
description (mm) Part No. A (mm) of claws B (mm) C (mm)
1 790-102-1820 Nut wrench 1 12.7 01530-03310 42 4 48 7
2 790-102-1831 Nut wrench 1 12.7 01530-03610 46 4 52 7
3 790-102-1841 Nut wrench 1 12.7 01530-03912 49 4 55 7
4 790-102-1851 Nut wrench 1 19.05 01530-04212 53 6 60 7
5 790-102-1861 Nut wrench 1 19.05 01530-04512 58 6 65 7
6 790-102-1871 Nut wrench 1 19.05 01530-04812 61 6 68 7
7 790-102-1881 Nut wrench 1 19.05 01530-05212 65 6 72 7
8 790-102-1891 Nut wrench 1 19.05 01530-05814 74 6 82 10
9 790-102-1911 Nut wrench 1 19.05 01530-06214 80 8 88 10
10 790-102-1921 Nut wrench 1 25.4 01530-06814 87 8 95 10
11 790-102-1931 Nut wrench 1 25.4 01530-07214 92 8 100 10
12 790-102-1941 Nut wrench 1 25.4 01530-07616 96 8 104 10
13 790-102-1951 Case 1 – – – – –
* 12.7 mm = 1/2 in, 19.05 mm = 3/4 in. 25.4 mm = 1 in.
41
Spanner for loosening and tightening round nuts.
ROUND NUT SPANNER KIT

FEATURES
• Round nuts can be loosened and tightened quickly and surely without damage.
SPECIFICATIONS
Applicable circular nut Weight
No. Part No. Tool description
Outer dia. (mm) Circular nut part No. N {kg}
1 09003-02022 Spanner 34 – 36 01530-02010 0.98 {0.1}

}
01530-02210
2 09003-02427 Spanner 38 – 42 01530-02410 0.98 {0.1}
01530-02710
3 09003-03033 Spanner 45 – 48 01530-03010 1.96 {0.2}
01530-03310
4 09003-03639 Spanner 52 – 55 01530-03610 2.94 {0.3}
01530-03912
5 09003-04245 Spanner 60 – 65 01530-04212 2.94 {0.3}
01530-04512
6 09003-04852 Spanner 68 – 72 01530-04812 3.92 {0.4}
01530-05212
7 09003-05560 Spanner 75 – 82 01530-05814 4.90 {0.5}
8 09003-06270 Spanner 88 – 95 01530-06214 6.86 {0.7}
01530-06814
9 09003-07280 Spanner 100 – 105 01530-07214 7.85 {0.8}
01530-07616
01531-08015
10 09003-08290 Spanner 112 – 120 01531-09016 9.81 {1.0}
11 09003-09200 Spanner 125 – 130 01531-09517 10.79 {1.1}
01531-01018
12 790-302-1650 Leather case – – –
42
No need for any special skill when removing

roller bearings (NJ type)
BEARING PULLER KIT
(Parts No. 790201-3400) Example of use
FEATURES
• Using common tool such as 2-JAW or 3-JAW puller, it has been impossible to pull out, without
damage, NJ type roller bearing, because the rollers remain on outer race where space does not
permit hooking, for example, on final drive housing of bulldozers.
• This puller kit enables to hook all rollers evenly so as to extract the outer race with the rollers.
Component parts
Bearing
Applicable bearing A B dimensions
Assy Part No. (Part No.) (mm) (mm)
dr (mm) d (mm)
103-27-21260, 06403-00308 6 3 53.5 40
06043-02309, 113-27-21270, 6 3.3 58.5 45

205-09-51120, 06043-00309,
790-201- 202-09-15110
3500
06043-00311, 130-09-13580 6 3.9 70.5 55
06043-02311, 145-27-41230
130-09-31490, 130-09-31231 6 4 77 60
790-201- 130-09-31491
3400
06043-02213 8 3.1 79.6 65
06043-00313, 06043-02313 8 4.3 83.5 65
06043-02314, 130-09-31331 8 4.8 90 70
145-27-41220, 154-27-15170
790-201-
3600 150-09-13260 8 4.4 95.5 75
140-09-13131 8 5.4 101 80
130-09-13560 8 4.8 108 85
195-27-12870, 06043-00318 8 5 115 90

170-09-13190 8 4.1 126.8 105
170-09-13230 8 4.5 132.5 110
43
The lifting equipment shows the level

of the repair shop.
SLING CHAIN KIT
(Parts No. 790-402-1001) FEATURES
• Chains have 10 – 20 times the durability of wire
rope, so even though the purchase cost is high,
total costs are low.
• When used in combination with shackles, they can
fulfil a wide variety of uses. (The length can be
changed freely, so they can be used as special
liftiing equipment.)
• Compared to wire rope, they are safe and do not
injure the worker’s hands.
• They do not twist out of shape, so they are easy to
handle and have long life.
• To reduce the distance that the lifting tools are car-
ried, the chains are designed to be hooked on a
sliing cart fitted with castors, thus allowing them to
be used anywhere inside the working area. The B
and D type chains, which are over 20 kg, are de-
signed to be hooked directly on a crane.
SPECIFICATIONS (Contents of Kit)

No. Part No. Tool description Q’ty Specifications Remarks
1 790-402-1101 Sling cart 1 –
2 790-402-1201 Sling A 1 Max. working load 2.5 ton (1.75 ton) 4-sling lifting
3 790-402-1301 Sling B 1 Max. working load 5.0 ton (3.5 ton) 3-sling lifting
4 790-402-1401 Sling C 1 Max. working load 3.2 ton
5 790-402-1501 Sling D 1 Max. working load 5.0 ton (3.5 ton)
6 790-402-1601 Sling E 1 Max. working load 2.0 ton
7 790-402-1701 Sling F 1 Max. working load 1.25 ton
8 790-103-1400 Sling G 1 Max. working load 1.0 ton Nylon sling
9 790-402-2110 Clamp 2 1 ton for dia. 6.3 mm With pin
10 790-402-2120 Clamp 3 2 tons for dia. 9.5 mm With pin
11 790-402-2130 Clamp 2 3 tons for dia. 11.1 mm With pin
12 790-402-2210 Joint 1 1 ton for dia. 6.3 mm With pin
13 790-402-2220 Joint 1 2 tons for dia. 9.5 mm With pin
14 790-402-2230 Joint 1 3 tons for dia. 11.1 mm With pin
15 790-402-2310 Pin 18 1 ton for dia. 6.3 mm With snap ring
16 790-402-2320 Pin 13 2 tons for dia. 9.5 mm With snap ring
17 790-402-2330 Pin 4 3 tons for dia. 11.1 mm With snap ring
18 04530-01222 Eyebolt 4 Permissible load 220 kg M12, P1.75
22 04530-03045 Eyebolt 4 Permissible load 1,500 kg MC30, P3.0
23 790-401-1510 Shackle 4 Permissible load 600 kg
24 790-103-1520 Shackle 4 Permissible load 1,200 kg
28 790-401-1420 Plate 4 Permissible load 100 kg
29 790-401-1430 Plate 4 Permissible load 2,000 kg
Note 1) In the case of direct winding mode, the values in ( ) shall be applied.
Note 2) The above loads are for the hanging angle of 60°.
44
Essential tool for fitting floating seal

securely in close contact.
INSTALLER
For mounting the floating seal Example of use
FEATURES
• With this tool it is possible to install the floating seals used for the final drive, track rollers, and
carrier rollers with uniform force to ensure that they are fitted properly and in close contact.
Tool No. and applicable model (Bulldozer)

Final drive idler
D155-2, 2A, D31, 37, 39EX, PX-21
D65-12, D41A, E, P-6, D65-15
D275A-2, 5, AX-5, D375A-1, 2, 3

D40, 45-1, 3, D55-3, D57-1
D37-5, D37A-2, D37P-2A
D75-5, D61 (No. 5 only)
D135A-2, D155A-2, 2A
D31A, P, S-18, D31-20,
D41A, E, P-6, D135-2,

D31, 37, 39EX, PX-21
No. Tool No.

D155A, AX-3, AX-5
D155A, AX-3, AX-5
D475A-3, D575A-2
D65-12, D70LE-12,
Ring dia. Weight

D275A-2, 5, AX-5
D355A-5, D85-15
D375A-1, 2, 3, 5
D66S-1, D85-15
(mm) N {kg}
D20, 21-3, 5, 6
D85ESS-2, 2A,
D85-21, D95-2
D475A-1, 2, 3
D85A, P-21
D475A-1, 2
D575A-2E
D355A-5
D575A-2
D95-1, 2
1 790-431-1071 1 484 13.7 {1.40}

2 791-430-3230 74 3.92 {0.40}
3 791-515-1520 1 1 1 120 1.96 {0.20}
4 791-530-1510 1 1 132 4.90 {0.50}
5 791-542-1520 1 252 4.90 {0.50}
6 791-545-1510 1 328 8.83 {0.90}
7 791-545-1520 1 137 1.96 {0.20}
8 791-560-1520 1 1 1 1 151 3.92 {0.40}
9 791-575-1520 1 171 3.92 {0.40}
10 791-580-1510 1 1 1 1 1 368 8.83 {0.90}
11 791-580-1520 1 180 4.90 {0.50}
12 791-585-1510 1 548 1.96 {0.20}
13 791-627-1280 1 409 9.81 {1.00}
14 791-630-1780 141 13.3 {1.36}
15 791-651-1510 1 1 93.6 0.98 {0.10}
16 791-675-1510 1 100 0.98 {0.1}
17 791-827-1151 1 674 49.8 {5.1}
18 791-827-1180 1 674 44.1 {4.5}
19 791-830-1520 160 14.2 {1.45}
20 792-520-2121 1 289 9.80 {1.00}
21 796-230-1110 90 1.67 {0.17}
22 796-670-1010 122 1.98 {0.20}
23 796-670-1020 1 110 1.67 {0.17}
45
Essential tool for fitting floating seal

securely in close contact.
Tool No. and applicable model (Bulldozer)

Carrier roller Track roller Track roller
bogie
DD375A-1, 2, 3, 5, D275A-2, D475A-3
D41A, E, P-6, D31, 37, 39EX, PX-21
D85-21, D95-2, D155A-2A, D85-15
D155A, AX-3, AX-5, D41A, E, P-6

D135-2, D155A-2, D275A, AX-5
D475A-1, 2, D475A-3#10685~
D85-21, D95-2, D275A, AX-5
DD475A-3#10601~#10684
D355A-5, D155A, AX-3, 5
D70LE-12, D85ESS-2, 2A
No. Tool No. Ring dia. Weight

D475A-3#10601~#10684 (mm) N {kg}
D135-2, D155A-2, 2A
D31, 37, 39EX, PX-21
D61, 65-12, D65-15

DD61, D65-12, 15
D475A-3#10685~
DD155A, AX-3, 5
D375A-1, 2, 3
D275A, AX-5,
D475A-1, 2
D575A-2
D355A-5
D375A-5
D375A-5
D575A-2
D375A-3
D85-15
1 790-431-1071 484 13.7 {1.40}

2 791-430-3230 1 74 3.92 {0.40}
3 791-515-1520 1 1 1 1 1 120 1.96 {0.20}
4 791-530-1510 1 1 132 4.90 {0.50}
5 791-542-1520 252 4.90 {0.50}
6 791-545-1510 328 8.83 {0.90}
7 791-545-1520 137 1.96 {0.20}
8 791-560-1520 1 1 151 3.92 {0.40}
9 791-575-1520 171 3.92 {0.40}
10 791-580-1510 368 8.83 {0.90}
11 791-580-1520 180 4.90 {0.50}
12 791-585-1510 548 1.96 {0.20}
13 791-627-1280 409 9.81 {1.00}
14 791-630-1780 1 141 13.3 {1.36}
15 791-630-2310 1 98 7.85 {0.80}
16 791-651-1510 1 1 1 1 93.6 0.98 {0.10}
17 791-675-1510 1 1 100 0.98 {0.10}
18 791-827-1151 674 49.8 {5.10}
19 791-827-1180 674 44.1 {4.50}
20 791-830-1520 1 160 14.2 {1.45}
21 792-520-2121 289 9.80 {1.00}
22 796-230-1110 1 90 1.67 {0.17}
23 796-230-1120 1 80 4.61 {0.47}
24 796-670-1010 1 122 1.98 {0.20}
25 796-670-1020 1 110 1.67 {0.17}
46
Contribution to safety and ease of recoil

spring assembling and disassembling works.
RECOIL SPRING DISASSEMBLING/ASSEMBLING TOOL
(Parts No. 791-685-8006)
(Parts No. 791-600-2001)
FEATURES
• This tool allows disassembly and assembly works of the undercarriage recoil spring safely and
easily.
• Protective covers are installed at the top for more safety.
• Castors enable easy transportation as it is.
• This tool can also be used as a small press.
SPECIFICATIONS
Part No. 791-685-8006 791-685-8502 791-600-2001

Dimensions 1600 (L) x 610 (W) x 750 (H) mm 2300 (L) x 610 (W) x 750 (H) mm 1600 (L) x ¯ 480 mm
Weight 4756 N {485 kg} 5021 N {512 kg} 2085 N {212.6 kg}
47
Indispensable ones for nitrogen gas charging!
NITROGEN GAS CHARGER

(Parts No. 792-610-1700)
* The diagram shows the gas charging of suspension on

dump trucks.
FEATURES
• These tools are designed for nitrogen gas charging for the suspension cylinders on dump trucks
and motor scrapers and the accumulators on hydraulic excavators.
• The charging lines of 792-610-1200 are separated in two which lines are independents each other.
This structure enables to adjust left and right suspension cylinders at the same time.
SPECIFICATIONS
792-610-1200 (Dump truck and motor scraper) Q’ty 792-610-1700 (Hydraulic excavator) Q’ty
1) Valve assembly 2 1) Valve 1

(with pressure gauge: 14.71 MPa
2) Regulator assembly 1
{150 kg/cm²}
(with pressure gauge: 9.81 MPa {100 kg/cm²}
24.52 MPa {250 kg/cm²} 2) Hose (1.5 m) 1
3) Hose (7 m) 2 Additional adapter, 792-610-2190 is necessary to

4) Valve 1 charge accumulators on hydraulic excavators.
(with pressure gauge: 6.86 MPa {70 kg/cm²}
48
Round head wrench for removing

hydraulic cylinders.
CYLINDER ROUND HEAD WRENCH
FEATURES
• There is no need to prepare many types of wrenches to fit various O.D.
• Claws on the screw are tightened to the head to meet the notches. Thus, a large torque can be
applied evenly to each notch.
• Tightening to the normal torque is possible by setting the torque wrench.
Component parts
SPECIFICATIONS
Weight
No. Part No. Description Q’ty
Applicable head O.D. Up to 150 mm N {kg}
Number of claws 2 of 3
1 790-102-2380 Wrench 1 46.1 {4.7}
2 790-102-2390 Wrench 1 29.4{3.0}
3 790-102-2320 Screw 3 3.04 {0.31}
4 790-102-2330 Screw 3 3.14 {0.32}
5 790-102-2350 Screw 3 3.04 {0.31}
6 01582-12419 Nut 3 0.59 {0.06}
7 04020-00820 Pin 1 0.08 {0.008}
8 01010-62065 Bolt 2 2.22 {0.226}
9 01640-22032 Washer 2 0.27 {0.028}
10 01582-12016 Nut 2 0.34 {0.035}
49
Indispensable ones! Power source for

hydraulic cylinders and pullers.
MANUAL/ELECTRIC HYDRAULIC PUMPS
(Parts No. 790-101-1102 Manual) Example of use
(Parts No. Refer to specification)
Photo: 790-101-6000
FEATURES
Manual hydraulic pump
• This is a manual pump for use in the field, and can be used
as a power source for cylinders and pullers.
Electric hydraulic pump
• This pump is lightweight and compact, and is fitted with cas-
tors, so it is extremely easy to transport.
• The remote switch ensures safety.
• Compared to the manual hydraulic pump, the discharge is
larger, so the speed of the operation can be increased.
SPECIFICATIONS
790-101-1102
Tool No. 790-190-1200 790-190-1300 790-190-1400
1) Discharge flow/Dis- 4.6 cc/68.65 MPa
Max. operating pressure 68.6MPa {700 kg/cm²} 68.6MPa {700 kg/cm²} 68.6MPa {700 kg/cm²}
Pressure
charge pressure {700 kg/cm²}

(at/stroke) (at 129 cc/735.50 MPa Low pressure 4.1MPa {42 kg/cm²} 4.1MPa {42 kg/cm²} 4.1MPa {42 kg/cm²}
{75 kg/cm²} or less)
High pressure 68.6MPa {700 kg/cm²} 68.6MPa {700 kg/cm²} 68.6MPa {700 kg/cm²}
2) Valve type 4-way control valve
(push, pull) (push, pull) Pressure Flow rate, l/min
3) Handle operating 40.21 N {4.1 kg} MPa {kg/cm²} 50Hz 60Hz
force 0.7 {7} 8.9 10.7
Delivery
4) Tank capacity 5l 6.9 {70} 1.1 1.3
5) Oil used SAE10W 34.3 {350} 0.9 1.1
6) Weight 280.47 N {28.6 kg} 68.6 {700} 0.8 0.9
7) Overall length 1075 mm
Tank capacity 7.6 l 7.6 l 7.6 l
8) Overall height 305 mm
9) Overall width 210 mm AC 1 ph 100 V AC 1 ph 115 V Power source AC 1 ph 230 V Power source
110 – 120 V 220 V – 240 V
10) Hose length 2.5 m Electric motor 830W 830W 830W
50/60Hz 50/60Hz 50/60Hz
AC 1 ph 125V AC 1 ph 125V AC 1 ph 250V
Applicable plug 30 A 20 A 15 A
with ground wire with ground wire
Weight 40kg 40 kg 40kg
Size (mm) 305W x 430L x 550H 305W x 430L x 550H 305W x 430L x 550H
50
Hydraulic pushing and pulling power, 30 to 200 tons

(using with the former pumps)!
CYLINDER
Photo: 790-101-1300
FEATURES
• The cylinder specifications range from 287 kN {30 tons} to 2050 kN {200 tons}, so select the
cylinder to match the type of work.
• Pushing or pulling operations can be carried out with hydraulic pumps.
• When this tool is used, there is no need for hammering, pulling, or press fitting, so there is no
damage to any part.
SPECIFICATIONS
Part No.
790-105-1100 790-101-1300 790-101-1600 790-101-4000 790-101-4300 790-101-4500
Item
Max. capacity push 287 kN {29.3 t} 981 kN {100 t} 686 kN {70 t} 490 kN {50 t} 1557 kN {158.8 t} 2050 kN {209.1 t}
(at 68.6 MPa {700 kg/cm²})
Max. wroking pull 148 kN {15.1 t} 834 kN {85 t} 539 kN {50 t} — 1294 kN {132 t} 1563 kN {159.4 t}
(at 68.6 MPa {700 kg/cm²})
Stroke 209 mm 152 mm 152 mm 50 mm 350 mm 200 mm
Weight 191 N {19.5 kg} 510 N {52 kg} 304 N {31 kg} 1294 N {13.5 kg} 1451 N {148 kg} 1314 N {134 kg}
Overall length 372 mm 431 mm 353 mm 128.6 mm 717 mm 589 mm
Cylinder O.D. 100 mm 160 mm 128 mm 139.0 mm 216 mm 245 mm
This tool is used as a set with a hydraulic pump (790-101-1102)

An adapter may be necessary depending on the place of use.
51
Speed up track link pin removal and

installation operations.
REMOVAL, INSTALLATION TOOLS
Type A Example of use
Type B Example of use
FEATURES
• The track link pin can be removed and press fitted easily and speedily.
TOOL NO. AND APPLICABLE MODELS

Type A Type B
Tool number Applicable model Tool number Applicable model
791-615-7001 D20, 21-5, 6, 7, CD35-1, CD35C-1 791-616-1010 PC20-3, 6, PC30-3, 5, 6
PC38UU-1, PC40-5, 6, 7 791-616-1020 PC38UU-1, PC30-3, 5, 6, PC40-5, 6
PC45-1, PC58UU-3, PC40, 45R-8 PC40R, 45R-8, PC58SF-1, PC58UU-3
PC60, 60L, 60U-1, 2, 3, 5 BR100JG-2
PC75UU-1, 2, BC100-1, PC60-6, 7 791-616-1030 PC60-6, PC60, 70-7, PC75UU-1, 3
BR100JG-2, PC70-7, PC50UU-1, 2 PC78US-5, PC78US, UU-6
PC58SF-1, PC78US, UU-6 BR120T-1
791-620-7000 D30, 31-15, 16, D37A-2 791-616-1060 D20, 21-5, 6
D31-17, 18, 20, D37P-2A, D37-5 791-616-1040 PC80-3, PC90-1, PC100, 120-3, 5, 6
PC80, 90-1, PC80(LC)-3 PC120-6Z, PC128UU-1, 2
PC100N-6, PC100, 120-1, 2, 3, 6 D31-17, 18, D37-2, BZ210-1
PC100D-3, PC100L-6, PC130-6
PC128US-2
52

REMOVAL, INSTALLATION TOOLS Example of use
Type C
FEATURES
Type C Type C
(For dry type track ) (For lubricated type track )
791-620-3000 D31-18, 20, 21, D37A-2, P-2A 791-620-3500 D31-8, 20, D37-5, D37A-2
D37-5, 21, PC100, 120-3, 5 D37P-2A, D31, 37-21
PC100D-3, CD40-1, PF3-1 791-630-3500 D40, 45-1
791-630-3200 D41A, E, P-6, D39-21 791-645-3500 D60, 65-8, 12, 15
791-630-3000 D40, 45-1, D57-1, CD60-1, BP500-1 D85ESS-2, 2A, D66S-1, D70LE-12
BR480RG-1, PC100(L, U)-3 791-650-3500 D75-5, D95-2, D80, 85-21
PC120-3, PC150-1, 3, 5, PC150LC-3
PC158US-2, PC200, 220-3, 5
PC230-6, 6Z, CS360-2, PC228UU-1
PC228US-3, PC200, 210, 220, 230-7
791-640-3000 D55-3
791-646-3000 PC300(LC)-3, PC300-6, PC300, 350-7
PC400(LC)-3, PC400-5, 6
791-650-3000 D75-2, 3, D85-21, PC400-1, 7
791-665-3000 D95-1, 2
53

REMOVAL, INSTALLATION TOOLS
Type D
Type E
FEATURES
Type D Type E
791-675-9500 D135A-2, D150, 155A-1 791-832-1200 D575A-2, 2E
Master pin type
791-680-9501 PC650-1, 3, 5, PC750, 800-6 791-832-1500 D475A-2, 3

Dry type
D355A-3#9001 and up 791-832-1600 The additional part to adapt

796-832-1100 PC1100-6, PC1250-7 791-832-1200 to D475A-2, 3
796-632-1200 PC600-6
791-685-9500 PC1500-1, D455-1
791-675-9701 D155A-2, 2A, D155A-3, AX-3, 5
791-680-9700 D355-3, D355A-3#9001 and up
791-680-9802 D375A-1, D275A-2, 5, AX-5
Lubricated type
Master link type
791-685-9700 D455-1
790-434-1502 D475A-1, 2, 3
PC1600-1, PC1800-6
790-434-2600 PC1000-1
791-632-1100 D375A-2, 3, 5
54
Oil refresher for efficient hydraulic oil

changing or cleaning.
OIL CLEANER
FEATURES
• This REFRESHER is designed for filtrating of hydraulic oil so as to allow reuse by removing
contamination such as wear particles, dust, dirt, etc.
• This REFRESHER is powered by gasoline engine and mounted on a cart, so it is portable and can
be used in the field.
• Changing or cleaning of hydraulic oil can be easier and more speedy. You can reduce manhour
and also make sure preventing from contamination.
Component parts: (790-601-3000) SPECIFICATIONS:

1) Engine 1.8 PS/1,800 rpm
No. Tool No. Description Q’ty
2) Pump capacity 35 l/min (max.)
1 790-601-3300 Pump assembly 1 3) Filter element 0.5 um
4) Starting method Recoil starter (manual type)
2 790-601-3400 Filter assembly 1
5) Size 860 x 460 x 897 mm
6) Weight 813.95 N {83 kg}
ATTACHMENTS (For oil cleaner)

790-601-4002 Component parts: (790-601-4002)
No. Part No. Tool description Q’ty
1 790-601-2101 Hose ass’y 1

2 790-601-2401 Tube ass’y 1
3 790-601-2601 Hose ass’y 1
4 790-601-2704 Tube ass’y 1
5 790-601-3100 Hose ass’y 1
6 790-601-3200 Hose ass’y 1
7 790-601-2910 Case 1
55
Save the earth for next generation!

Recovery and recycling of Chlorofluorocarbons.
CFCs:
CHLOROFLUOROCARBONS
FEATURES
RECOVERY-RECYCLING EQUIPMENT
• Safe, easy operation for efficient, high-speed refrigerant recovery.
• Easy moving anywhere with large-size wheel.
• It is high-purity recycling function.
CHARGING EQUIPMENT
• It be used for charging an air conditioner with CFCs gas as well as for recharging it with the CFCs
gas recovered by a recovery-recycling equipment.
• Also, easy moving anywhere with large-size wheel.
• It is quick charging function.
SPECIFICATIONS:
cou cable
ia
st As
a
ntry
trali
Sou e &
li
thea
App
USA
0 Europ
Aus
g}
N {k
No. Part No. Part description Remarks

0
P/N
-138
-137
ght
-136
Ass’y
Wei
-702
-702
-702
799
799
799
1 799-702-1110 CFCs recovery-recycling equipment 1 666.85{68} AC100 to 115V (w/recovery tank)

799-702-1120 CFCs recovery-recycling equipment 1 666.85{68} AC220 V (w/recovery tank)
799-702-1130 CFCs recovery-recycling equipment 1 666.85{68} AC220 V (w/o recovery tank)
2 799-702-1220 Charging equipment (Smart cart) 1 426.59{43.5} AC115 V
799-702-1230 Charging equipment (Smart cart) 1 1 426.59{43.5} AC220 V
3 799-702-1140 Control valve 2 2 2 0.59{0.06} for low pressure (7/16 – 20 UNF)
4 799-702-1150 Control valve 1 1 1 0.59{0.06} for high pressure (3/8 – 24 UNF)
56
Innovation of engine oil change !
ECO-DRAIN VALVE
(Parts No. Refer to specification) Exsample of use (Elbow type)
Standard type Short type
FEATURES
• Hose joint can be separated and connected with threaded nut.
• The joint with hose can be disconnected or connected by one hand easily.
• Retro-fit on the machines in the field improves customer satisfaction.
• Good for the Earth :Direct hosing into a can prevents from oil spillage by wind without any
drop on the earth.
• Good for human :Free from dirtiness and hot oil on hand and clothes.
• Better job efficiency :Oil drainage can be done with ONE TOUCH opening valve.
:During winter warmer oil can be done quicker.
:A forced oil changing device can be connected.
Specification (Standard type)

Standard type d x p Part No. dxp do Installable engine
07705-01100 16 x 1.5 7.5 YANMAR, KUBOTA
795-999-1210 18 x 1.5 9.0 MITSUBISHI
795-999-1410 20 x 1.5 9.0 ISUZU
07705-01200 22 x 1.5 7.5 Light type desined for YANMAR
07705-01300 22 x 1.5 12.5 KOMATSU, HINO, KUBOTA
07705-01400 24 x 1.5 12.5 KOMATSU, CAT
do 795-999-1610 24 x 2.0 12.5 ISUZU, NISSAN DIESEL
21T-01-31490 36 x 1.5 21.0
Short type dxp
Specification (Short type)
do Part No. dxp do Installable engine
07705-21100 16 x 1.5 7.5 YANMAR, KUBOTA
795-999-1110 18 x 1.5 9.0 MITSUBISHI
795-999-1310 20 x 1.5 9.0 ISUZU
07705-21400 24 x 1.5 12.5 KOMATSU, CAT
Elbow type 795-999-1510 24 x 2.0 12.5 ISUZU, NISSAN DIESEL
dxp
Specification (Elbow type)
Part No. dxp do Installable engine
07705-11100 16 x 1.5 7.5 YANMAR, KUBOTA
do 07705-11400 24 x 1.5 12.5 KOMATSU, CAT
57
Reduce manhours and make sure high tightening

nut torque of rebuilding hydraulic cylinders.
CYLINDER REPAIR STAND
(Parts No. 790-502-1003) Example of use:
FEATURES
• These stands are designed for removal and installation of piston nylon nuts and screw type heads
on hydraulic cylinders.
• Loosening and tightening are carried out by a crank structure using a high pressure hydraulic
cylinder. The straight movement of the cylinder rod is converted into rotating movement and this
lever ratio makes a high torque.
• A hydraulic pressure gauge is installed and the scale indicates the torque, calculated by the lever
ratio, for the control of torque.
SPECIFICATIONS FRAME EXTENSION

Component parts:
Part No. 790-502-1003 No. Part No. Description Q’ty Weight Remarks
1 790-445-2730 Frame 1 62.9 L=1,000mm
Driving torque Max. 39227 Nm {4000 kgm} 2 01010-31265 Bolt 3 0.07
[at max. pressure 68.65 MPa {700 kg/cm2}] 3 01580-01210 Nut 3 0.01
Driving method Hydraulic cylinder (30 t), 4 790-445-2740 Plate 3 0.10
Stroke 180 mm 5 790-445-2710 Frame 1 16.1 Common use
with S.T.D
Work length 3067 mm 6 01010-31230 Bolt 4 0.08 Common use
Dimensions 900(W) × 3570(L) × 1790(H) mm with S.T.D
7 01580-01210 Nut 4 0.04 Common use
Weight 492 N {662 kg} with S.T.D
8 01643-31232 Washer 4 0.08 Common use
This cylinder repair stand requires a hydraulic pump 68.6 MPa with S.T.D
{700 kg/cm2}. (Recommended pump: 790-101-1102)
Require the extension for PC1500-1, PC1600-1.
58
Repair stand improves working efficiency

and safety!
UNIT REPAIR STAND
⎧Parts No. 790-501-5200 ⎫ Example of use
⎩ 790-501-5000 ⎭
FEATURES
• As the stand is driven by an electric motor with brake and reduction gear, forward and reverse
rotations and stopping at any desired rotation angle can be performed easily and safely with the
respective button switches.
• The rotary head can be lifted and lowered with a hydraulic jack.
• A plate provided at the top of rotary head is useful for putting disassembled parts and service tools
on it.
• The castors facilitate carrying of the stand on flat ground.
• The 100V – 110V AC, 110 – 120V AC and 220V – 240V AC, single phase, power source can easily
be available in the shop.
SPECIFICATIONS
Item Part No. 790-501-5000 790-501-5200
1)Dimensions 1140(H) × 1660(W) × 1530(L) mm

2)Weight 2892.96 N {295 kg}
3)Rotating shaft permissible moment 8825.99 Nm {900 kgm}
4)Max. shaft torque 804.15 Nm {82 kgm}
110 – 120 V AC motor
5)Drive source 100 – 115V AC motor or
220 – 240V AC motor
* Each unit needs a bracket, please check on the SERVICE TOOL GUIDE in detail.
* For 790-501-5200 110 – 120V, 220 – 240V specifications, provide the applicable transformer
when requested by the customer.
59
Reduce time when disassembling or assembling

the engine!
ENGINE REPAIR STANDS
FEATURES
790-501-2001
• The turnover mechanism is different from the normal perpendicular rotation. In order to make
horizontal rotation possible, the overall height has been reduced. Work can be carried out safety
and efficiently in a comfortable working posture.
790-501-4000
• Quick and safe set-up due to electric motor driven system.
• Both way turning is available.
• Limit switch completely stops the motor from turning while locked.
• Large sized engine up to V16 49033.25 N {5000 kg} engine can be mounted.
• Manual handle allows fine adjustment for easy pull out and inserting the lock pin.
• Caster and draw bar pull for easy transportation are available as option.
SPECIFICATIONS
Item Part No.

790-501-2001 790-501-4000
1) Service capacity 29419.95 N {3000 kg} 5295.91 N {5400 kg}
2) Service torque capacity 13729.31 Nm {1400 kgm} 26477.96 Nm {2700 kgm}
3) Turning angle 360° 90°
2
4) Power source Air 686.47 kPa {7 kg/cm } Motor, 2.2 kw, 3 phase
5) Dimensions (L × W × H) 1055 × 1200 × 1300 mm 4380 × 1570 × 1320 mm
6) Weight 3677.49 N {375kg} 16671.31 Nm {1700kg}
* Various voltages are available upon request.
60
For quality assurance of hydraulic systems.
HYDRAULIC TEST STAND EPC valve controller

(Parts No. 799-402-6000) (Parts No. 799-610-1210)
FEATURES FEATURES
• This stand is an essential piece of equip- • EPC valve controller for a bench test of the
ment when carrying out troubleshooting on hydraulic pump.
hydraulic components and for confirming
performance when repairing or rebuilding. • The frequency for the new controller is set
to the standard dither signal for the EPC
• A complete set of attachments is available valve currently in use.
together with judgement standards based
on abundant experience and results with
the hydraulic components used on Necessary tools
Komatsu construction equipment. Part number Part name Q'ty Main specification
799-552-3710 Cable (1) 1 Bipolar ECONO type (male),
• The publications of the testing method sup- Length = 5 m
799-552-3720 Cable (2) 1 Bipolar ECONO type (female),
plied by Komatsu are made based on this bipolar X type (female)
test stand specification. 799-552-3730 Cable (3) 1 Bipolar ECONO type (female),
bipolar ECONO type (female)
799-610-1410 Cable (4) 1 Bipolar ECONO type (female),
bipolar DT type (female)
799-608-2510 Power
or supply 1 Output : 24VDC (4.5 A) Input :
commercially unit 85 to 135 VAC, 170 to 264 VAC
SPECIFICATIONS
1. MAIN SYSTEM Part number: 799-610-1210
TERM 799-402-6000 799-402-1003 <Main specifications>
Weight (Main Unit) {6600 kg} {5100 kg} Number of outputs 1
Weight (Work Bench) {1800 kg} {1800 kg}
Display function 2 (Output current 1, output
Dimension (Main Unit) 2000× 3360× 1900 mm 1750× 3400× 1800 mm
voltage 1)
Dimension (Work bench) 3150× 1770× 525 mm 3150× 1770× 525 mm
Types of dithers 3 (see the dither waveforms
Output of Electric 132 kW 75kW
Motor for main pump 3P 200 V – 140 V 3P 200 V – 440 V below)
Main Pump HPV95+95 Output current 0 to 1000 mA
Displacement 20 – 190 cm3/rev 14 – 112 cm3/rev
Delivery (50 Hz) 30 – 275 l/min (50 Hz) 18 – 148 l/min (50 Hz) Output voltage 0 to 5 V
Delivery (60 Hz) 30 – 330 l/min (60 Hz) 22 – 177 l/min (60 Hz)
Rated Pressure {420 kg/cm2} {350 kg/cm2} Power supply Non. Supply 24 VDC (Constant-
Main Motor A6V225 voltage power supply connection)
Displacement 65 – 336 cm3/rev 30.8 – 107 cm3/rev
Rated Pressure 34.32 kPa {350 kg/cm2} 34.32 kPa {350 kg/cm2} Dimensions 260 x 230 x 100 mm
Output Torque 0 – 1127.76 kPa {115 kgm} 0 – 539.37 Nm {55 kgm}
Output Speed 0 – 3000 rpm 0 – 3000 rpm Weight Approx. 2.3 kg
61
Create new business opportunities and profits
Portable bore re-builder

(Part No. 799-704-1100)
Welder
(The gas cylinder is not included.)
(Part No. 799-704-2410)
* Welder is not necessary if you already
possess it.
FEATURES
• It has now become possible to easily repair the pin holes of the work equipment which have been
worn and loose by high load operations.
• Taking advantage of its feature of being a portable device, use it in the service shops and in fields,
we suggest you to “create new job opportunities”.
• Build-up welding and cutting processes for pin holes of the work equipment can be made by use of
this single equipment.
Main specifications
1. Portable bore re-builder 2. Semi-automatic welder
Type S-2 hi-tech Part No. 799-704-1100 Type MIG 190 Part No. 799-704-2410
(1) Processing capacity (1) Power supply: AC220V (3P) 4.5KW 50/60Hz
1 Bore cutting range: ø 50 ~ ø 250 mm (2) Current range: 15 ~ 220A
2 Build-up welding range: ø 25 ~ ø 300 mm In the meantime, by use of the cable adaptor (Part
3 Additional applications: This equipment is also No. 799-704-2420), Panasonic’s welder can also be
usable for drilling work and tapping work. used.
(2) Main spindle motor 3. End face processing adaptor
1 DC servo motor: 500W Type KIT2000 0 40 Part No. 799-704-2210
2 Continuous output torque: 3.5Nm 1 End face processing range: ø 35 ~ ø 320 mm
3 Revolution of the motor: 0 ~ 4,000 rpm
(3) Feeding device Optional devices
1 DC servo motor: 300W * End face processing adaptor
2 Continuous output torque: 1.3Nm Part No. 799-704-2210
3 Revolution: 0 ~ 3,000 rpm * Cable adaptor
(4) Power supply: AC100 ~ 220V (2P) 8A 50/60Hz (For use with the Panasonic’s welder)
Part No. 799-704-2420
62
For confirmation of performance after engine

overhaul
Dynamo test kit Dynamo test kit
(Parts No. 799-607-4001) (Parts No. 795-799-5600)
FEATURES FEATURES
• Used to dynamo test of CRI engine. • Used to dynamo test of HPI engine.
(CRI: Common Rail Injection) (HPI: High Pressure Injection)
Applicable model: SA(A)6D125E-3 (CRI Type) Applicable model: SA(A)6D170E-3 (HPI Type)
SA(A)6D140E-3 (CRI Type)
Component parts: Component parts:

No. Parts No. Parts name Q’ty Weight (kg) No. Parts No. Parts name Q’ty Weight (kg)
1 799-607-4001 Dynamo test kit 1 8.25 1 795-799-5600 Dynamo test kit 1 10.20
2 799-607-4010 · Box 1 1.20 2 795-799-5610 · Controller 1 4.60
3 799-607-4020 · Harness 1 3.50 3 795-799-5620 · Harness 1 3.10
4 799-607-4030 · Harness 1 0.05 4 795-799-5630 · Harness 1 2.50
5 799-607-4050 · Harness 1 3.50
63
Profitable nut and bolt kit for field service.
NUT AND BOLT KIT
FEATURES
• The typical sizes of nuts and bolts used on
Komatsu products are now available as a
kit.
• The case is divided into compartments for
each item for ease of use.
No. Description Part No. Q’ty Main application

1 Nut & bolt kit 09941-00000 1
2 • Bolt 01010-30820 10
3 • Bolt 01010-30825 10 For tightening electrical
components (These are
4 • Bolt 01010-30830 10 contained in the same box).
5 • Bolt 01010-30835 10
6 • Bolt 01010-31020 10
7 • Bolt 01010-31025 10 For tightening outer fittings
(There are contained in the same
8 • Bolt 01010-31030 20 box).
9 • Bolt 01010-31035 20
10 • Bolt 01010-31220 5
12 • Bolt 01010-31230 10 box).
13 • Bolt 01010-31240 5
14 • Bolt 01010-31430 2
16 • Bolt 01010-31440 2 box).
17 • Bolt 01010-31640 2
18 • Bolt 07372-00830 10
19 • Bolt 07372-01030 10 For hydraulic hoses, split flange,
etc. (There are contained in the
20 • Bolt 07372-01235 10 same box).
21 • Bolt 07372-01240 10
22 • Nut 01580-00806 20
23 • Nut 01580-01008 15
24 • Nut 01580-01210 15
25 • Nut 01580-01411 5
26 • Nut 01580-01613 3
27 • Washer, flat 01643-30823 15
28 • Washer, flat 01643-31032 20
29 • Washer, flat 01643-31232 20
30 • Washer, flat 01643-31445 10
31 • Washer, flat 01643-31645 5
32 • Washer, spring 01602-00825 20
33 • Washer, spring 01602-01030 25
34 • Washer, spring 01602-01236 30
35 • Washer, spring 01602-01442 10
36 • Washer, spring 01602-01648 5
37 • Case 09941-00090 1
64
Wiring harness connector repair kit to meet needs of

electronic technology epoch.
CONNECTOR REPAIR SET
FEATURES
• Komatsu products are innovated by electronic technology and lots of electronic devices and har-
ness connections are installed on them. This kit provides all kinds of connectors and terminals
used on all Komatsu products.
• All connectors are available in a case in sets for each type, and special tools are provided, so
repairs can be carried out easily.
SPECIFICATIONS
.
2000
2001
rt No
y Pa
222-
222-
ht
on
Weig
Ass’
Opti
790-
790-
Part No. Part Name Outline (main uses, structure)

Set 1
Set 2
N
*1 *2 {kg}
790-222-2100 Repair kit-tool 1 1 — 16.67 Three types of crimping tools and a bag to hold them (For
{1.7}crimping and stripping covers from electric wiring)
790-222-2800 Repair kit-connector 1 1 — 9.81 Plug type connectors (KES parts), terminals for DLI connec-
{1.0}tors, bodies, drawing tools, and plastic storage case
790-222-3100 Repair kit-connector 1 1 — 10.30 Terminals for CN (KES parts, lock type) connectors, bodies,
{1.05}drawing tools, and plastics storage case
790-222-2200 Repair kit-connector 1 1 — 22.56 Round terminals (crimping terminals held by screws, 28
{2.3}types, applicable wire: 0.5 – 15), and plastic storage case
790-222-3000 Repair kit-connector 1 1 — 12.75 Terminals for Econoseal (KES parts) connectors, bodies,
{1.3}inserting, drawing tools, and plastic storage case
790-222-2600 Repair kit-connector 1 1 — 11.77 Terminals for MIC connectors, bodies, drawing tools, and
{1.2}plastic storage case
790-222-3200 Repair kit-connector 1 1 — 11.08 Crimping connectors with insulation covers (3 types), clamp
{1.13}bands, vinyl tape, and plastic storage case
790-222-3300 Repair kit-connector — 1 — 15.20 New X (made by Yazaki), 040 (made by AMP) housings used
{1.55}on new models, terminals with cable, metal-plated MIC
terminals, and plastic sotrage case
790-299-1100 Case (OP) (2) (2) 1 21.57 Carrying case for holding above kits 1 – 8 (any 4 kits in one
{2.2} case) (W485 × D345 × H133 mm)
*1 The new Set 2 consists of the present Set 1 with the addition of repair parts for connectors used on new models.
*2 Case P/N 790-299-1100 is available as an option, so it is not included in the part number for Set 1 or Set 2.
65
Wiring harness connector repair kit to meet needs of

electronic technology epoch.
CALLED X AND SWP CONNECTOR FOR
CONVENIENCE
(Parts No. 790-222-3500)
The photograph does not show blind plugs (27) and
(28), extraction tools (29), (30) and (31), and part (33)
which appear in the instruction manual.
Note:
With the S type connectors, if the color of the 12-pin connectors is different (white or blue), the connector
cannot be connected even if the number of pins is the same.
• Use the crimping tool kit (part number 790-222-2100) when crimping the terminal and wire.
CALLED M AND S CONNECTOR FOR

CONVENIENCE
(Parts No. 790-222-3600)
The photograph does not show part (32) which ap-

pears in the instruction manual.
Note:
The connector assembly includes the connector body, terminal, rear and grommet.
The quality cannot be guaranteed when crimping the terminal and wire using a hand tool, so please use
terminals No. 19–26 (with wire). These terminals (with wire) are supplied in units of 20.
* The cables (AEX wire: 0.85–2 mm²) of the terminals (with wire) are supplied in units of 20.
• The terminals with cables for X type are as follows:
1) 0.85 mm² = with black rubber plug (both male and female)
2) 2.0 mm² = with red rubber plug (both male and female)
3) 1.25 mm² = with red rubber plug (both male and female)
66
Repair Kit of New Connector

(DEUTSCH DT and HD30 Connectors)
Repair kit (A) Repair kit (B)
(Parts No. 790-222-4000) (Parts No. 790-222-4100)
FEATURES FEATURES
• For repair of connectors at repair shop. • For repair of connectors in the field.
• All parts of DT connector and required tools • Mainly the parts of frequently used 2-, 3-, 4-
are included in a kit. , and 6-ways DT connectors are available
• Separately get a HD30 connector body only as a compact kit.
and the kit is applicable to every connector. • Like the repair kit (A), the repair kit (B) also
• This kit does not include a case. Obtain one includes a terminal crimp tool and terminal
if necessary. pull-out tool.
• As for HD30 connector bodies, more than • Therefore, it is well serviceable in the field.
100 types are provided and not used very • This kit does not include a case (P/N: 799-
frequently. 601-7910 and 7920), either. Obtain one if
• For this reason, no repair kit is available for necessary.
the HD30 connector bodies.
• You must place an order separately when
you need it.
Case (Option)
Medium size: Part No. 799-601-7920 Large size: Part No. 799-601-7910
Size: 410 x 240 x 325mm Size: 550 x 325 x 365mm
Weight: 2.9Kg Weight: 6.0Kg
67
Connector repair kit for sensor and solenoid

(For common rail engine and HPI engine)
Connector repair kit
Parts No. 790-222-5000
FEATURES
• Many sensors such as engine speed sensor and boost pressure sensor indispensable for the
system are used on the common rail system loaded on 6D125E-3 and 6D140E-3 and the HPI
system loaded on 6D170E-3.
• If connectors fitted to these sensors are broken, the engine will come not to work.
• We have just set the repair kit that enables to repair such important connectors easily and would
like to introduce the kit.
Component parts:
No. Component Description Numb- Q’ty Clas- Name of Remarks
Part No. er of sific- Sensor to be connected (Maker Name and
Poles ation Connector Type)
- 790-222-5000 Repair kit - 1 - -
1 790-222-5010 · Connector 2 2 C NE sensor, G sensor Yazaki 7223-1324-90
2 790-222-5020 · Connector 3 2 C Fuel pressure sensor AMP 174357-2
3 790-222-5030 · Connector 2 2 C PVC solenoid valve Sumitomo 6189-0039
4 790-222-5040 · Connector 3 2 C Boost pressure sensor Sumitomo 6189-0099
5 790-222-5050 · Connector 2 2 H Engine speed sensor Packard 12015792
6 790-222-5060 · Connector 2 2 H Cooling water temperature sensor Packard 12162193
Fuel temperature sensor
7 790-222-5070 · Connector 2 2 H Intake air temperature sensor Packard 12162197
8 790-222-5080 · Connector 3 2 H Timing pressure sensor Packard 12065287
Intake air pressure sensor
Fuel pump pressure sensor
9 790-222-5090 · Connector 3 2 H Atmospheric pressure sensor Packard 12162182
Fuel pressure sensor
Timing rail actuator
10 790-222-5110 · Connector 3 2 H Pump actuator Packard 12162280
Lubricating oil pressure sensor
Rail actuator
11 790-222-5120 · Tool - 1 - - -
12 790-222-5130 · Case - 1 - - -
Note 1: Classification C is the connector mounted on 6D125/140E-3 engines.
2: Classification H is the connector mounted on 6D170E-3 engine.
68
070 Connector Repair Kit
Connector repair kit

Parts No. 790-222-6000
FEATURES
• The following introduces repair kit of the 070 connectors used in controllers and monitors.
• The previously introduced 79A-222-2030 is used as a terminal crimping tool; if necessary, prepare
it separately.
• The previously introduced 79A-222-2170 is used as a terminal extraction tool; if necessary, prepare
it separately.
• Pin and socket terminals are supplied on a 50-unit basis.
Component parts
No Part Number Part Name Way Q’ty/Set Maker’s Number
1 790-222-6010 Connector (Cap) 10 2 174932-1
2 790-222-6020 Connector (Cap) 12 2 174933-1
3 790-222-6030 Connector (Cap) 14 2 174934-1
4 790-222-6040 Connector (Cap) 18 2 174935-1
5 790-222-6050 Connector (Cap) 20 2 174936-1
6 790-222-6060 Connector (Plug) 10 2 174465-1
7 790-222-6070 Connector (Plug) 12 2 173851-1
8 790-222-6080 Connector (Plug) 14 2 173852-1
9 790-222-6090 Connector (Plug) 18 2 173853-1
10 790-222-6100 Connector (Plug) 20 2 174952-1
11 790-222-6110 Contact (Pin) - 50 175030-1
12 790-222-6120 Contact (Socket) - 50 175027-1
69
Wiring harness simple repair

Harness repair kit
Parts No. 799-601-9600
5
2 1 4
6
7
FEATURES
• Simple repair
• Fix the loose electric wiring and repair robbed parts.
• For machines in long-term operation, this service is aiming at preventing accidental failure or fire
breakout due to the deteriorated or loose electric wires or the harness.
Component part:
No. Parts No. Parts name Q'ty Weight (kg)
- 799-601-9600 Repair kit 1 0.80
1 799-601-9610 · Pliers 1 0.60
2 08058-11040 · Clip 2 0.03
3 08058-00825 · Clip 3 0.01
4 08034-20823 · Band 10 0.03
5 08034-20519 · Band 10 0.02
6 08034-20414 · Band 10 0.01
7 08024-91920 · Tape 1 0.10
70
Liquid gasket, Bowding agent, Polyurethane

paint for profit in field service.
Sealants and adhesives for repair (1)
Part Name Features Main use
Liquid gasket • Anaerobic liquid sealant containing • Used to seal pipe joints,
Parts No. 790-129-9080 Teflon but no solvents. flanges, tapered parts,
• Since this is anaerobic sealant, it etc.
is hardened between metallic parts.
• High setting speed and high
resistance to chemicals and heat.
• Using temperature range is –40 —
+130°C.
Liquid gasket • Silicone sealant (White). • Sealing of threads of

Parts No. 790-129-9090 • Liquid sealant having silicone as stainless steel pipes
main part and no solvents. • Sealing of various flanges
• Hardened to form rubber-type • Repair of engines
elastic material when exposed to
air at normal temperature.
Loctite High strength. High resistance to • Use to prevent loosening

Parts No. 79A-129-9110 chemicals and heat (–55 —175°C). of bolts, plugs and
threaded parts and seal
them.
Sealant • Sealant used to seal fitting parts • Used as heat-resistant

Parts No. 790-129-9120 and joints, durable at 1000°C. sealant for repair of
• This is directly applied to cleaned engines.
fitting surfaces, then dried up. • Can be used to repair
exhaust pipes, mufflers,
and other high-tempera-
ture parts.
* When the heat resistance at -40 —

400°C is required, sealant 790-129-
9070 is available.
71
Sealants and adhesives for repair (2)

Part Name Features Main use
Bonding agent • Main element is α-cyanoacrylate • Used to stick rubber, plas-
Parts No. 790-129-9130 monomer (liquid). tic and metallic parts.
• If this agent is thinly applied to
surfaces of parts to be stuck and
they are pressed against each
other, slight moisture in air works
as hardener to stick parts together
strongly.
Bonding agent • Instantaneous adhesive made of • Used to stick rubber, plas-

Parts No. 790-129-9140 cyanoacrylate. tic, metallic, wooden and
• If this agent is thinly applied to ceramic parts.
surfaces of parts to be stuck and
they are pressed against each
other, slight moisture in air works
as hardener to stick parts together
strongly in several seconds or
several minutes.
Polyurethane paint 1. Type: Two-part weather-resistant For large-scale repair of

Parts No. 790-129-9210 polyurethane paint, the main PC100 – 350-6
elements of which are acrylic • Work equipment
polyol and non-discoloring • Revolving frame
polyisocyanate • Counterweight
2. Features • Outside parts of door
• High weatherability.
• High workability in spray paint- * For touchup, use acrylic
ing. enamel paint.
• Smooth and gloss finished Parts no. 790-129-9230
surface.
• Short drying time.
• Sticks well to various materials.
Polyurethane paint drying at normal tem- 1. Type: Two-part weather-resistant For large-scale repair of
perature polyurethane paint, the main PC100 – 350-6
Parts No. 790-129-9220 elements of which are acrylic • Inside of machine cab
polyol and non-discoloring Plate
polyisocyanate Cover
2. Features
• Refined finish, luster and excel- * For touchup, use acrylic
lent gloss are maintained. enamel paint.
• Smooth finished surface. Parts no. 790-129-9230
• Short drying time.
• Paint film performance higher
than baked paint.
Note: When using adhesive, take care that it will not stick to your skins, eyes, etc. (Before using it, read the
instruction manual carefully.)
72
Sealant repair kit for profit in field service.
SEALANT REPAIR KIT

(Parts No. 09940-10000)
FEATURES
• This is a kit consisting of the sealants and
O-rings frequently used for field service of
Komatsu products.
• Individual items have their own part num-

bers, so it is also possible to purchase in-
dividual items.
SPECIFICATION (Component)
No. Description Part No. Q’ty Capacity Main use

1 Sealant repair kit 09940-10000 1
2 • Liquid gasket 09940-00011 2 250 g/pc • Used as a seal for all types of flange
surface or threads.
• Oil pan, final drive case, etc.
3 • Thread tightener 09940-00030 3 50 g/pc • Used for prevention of loosening of bolts,
plugs, screws, and for seals.
4 • Moly-lubricant 09940-00040 1 200 g/pc • Prevention of seizure when press fitting
bearings, keys, and pins.
• Initial settling and lubrication of sliding
surfaces of bearings.
5 • Rust proof oil 09940-00051 2 60 g/pc •Sliding parts of control levers, etc.
6 • O-ring kit 09940-00061 1
7 •• O-ring 07002-12434 10 pcs.
8 •• O-ring 07002-13634 10 pcs.
9 •• O-ring 07000-13075 10 pcs.
10 •• O-ring 07000-13060 10 pcs.
11 •• O-ring 07000-13048 10 pcs.
12 •• O-ring 07000-13038 10 pcs.
13 •• O-ring 07000-13032 10 pcs.
14 •• O-ring 07000-13028 10 pcs.
15 •• O-ring 07000-13025 10 pcs.
16 •• O-ring 07000-13022 10 pcs.
17 • Case 09940-00161 1
18 • Seal tape 09940-00070 1
19 • Case 09940-00081 1
73
Repair procedure for aluminum radiators

“The repair methods which can be carried out by yourself and also at the job site” using your existing repair techniques
and easily attainable new techniques, we are introducing the following two methods:
FEATURES
Item Features Main objects for repair
Brazing repairs Repairs using aluminum brazing filler material. Aluminum oil coolers, etc, which are
It is possible to obtain a similar strength to the being used under higher-pressure
aluminum base material. applications.
Repairs using Repairs using two-component type epoxy resins. Brass and aluminum radiators,
resins Handling is easy since the mixture ratio of the two Resin made covers, etc.
component fluids can be determined automatically. Also applicable to temporary repairs
(An exclusive tool should be used.) at the job site.
It is also possible to increase the strength by the
use of a fiber net. Finishing the surface by coating
is also easy.
Using material for implements

Aluminum brazing filler material
Part No.: 790-760-1100 Flux (1 set: 6 cases)
Part No.: 790-760-1200 Brazing filler material

(1 set: 5 kg) (wire diameter: ø1.6)
Part No.: 790-760-1300 Epoxy resin kit
Part No.: 790-760-1310 Epoxy resin cartridge
Part No.: 790-760-1320 Fiber net
Part No.: 790-760-1330 Mixing nozzle (A set of 10 paces

is necessary when being supplied as a single spare part)
Brush (Although it is included in the kit, it will not be supplied
as a single spare part.)
Propane burner (An article on the

market)
Cartridge (An article on the mar
ket)
74
Periodic Maintenance Record Book Program

Periodic Maintenance Record Book Program Form No. SEZS100100P
Operational manual Form No. SEZS100100M
Outline of Periodic Maintenance Record Book
This program is written by Microsoft Excel 97 and we have developed so as to be able to create a digital data
sheet ( work sheet ) or print material at site. We have been issuing the books and this one will substitute the
books and upon request we create them in digital way using this.
In this program two kinds of file are used , one is of the creating program and another is master data.
One file , the creating program , PM Record Book.xls and master data file for each model are used.
The creating program is to be installed in a specific folder on the hard disc “C”. And the master data files, CSV
text files can be stored in any folder as required.
This program is developed for whom knows Microsoft Excel 97 well and therefore when somebody is not good
in Excel program and use this , this program may be damaged by improper operation.
Please ask somebody who is a good Excel program operator.
Hardware circumstance
A PC is required in order to be usable with Microsoft Excel 97.
This is only applicable in Excel 97 circumstance.
75
KUC Inspection Reporting Program
Form No. SELA195000
Purpose
Undercarriage Inspection Reporting Program has been released to create the KUC report with automate wear
percent calculation and graphical function. You are requested to utilize this program to boost undercarriage parts
sales in your territory.
FEATURES
The program
• Can be processed by only clicking its menu bar,
• Has all standard value and wear criteria,
• Automatically calculate wear life percent with formula “y=aXk”,
• Automatically calculate second wear life after bushing turn basing on the first measurement.
• Create colored report rapidly,
• Create wear percent graphs automatically
for not only standard measurement but also ultrasonic measurement.
76
VHMS Technical analysis tool box
Service Kit (Contains two parts as below) 799-608-3101

VHMS Technical analysis tool box • 799-608-3210
PC download cable • 799-608-3220
FEATURES
• Automatically measured and recorded data can be downloaded, as well as machine data that has
been collected over an extended period of time.
• Compared with the conventional Pm-CLINIC system, which requires approximately two hours, the
VHMS system requires only 10 minutes.
• Quick and accurate report creation and recommendations based on information downloaded to a
PC
Downloading to a PC
An example of Hydraulic Excavator
Items monitored on
a large excavator
F, R: Engine speed
F, R: Governor voltage
F, R: Coolant temperature
F, R: Engine oil temperature
F, R: Engine oil pressure
Atmospheric temperature
Main pump pressure 1-5
Gear pump pressure
Hydraulic oil temperature
F, R: TVC current
F, R: Throttle voltage
F, R: PTO oil temperature
Oil pressure switch
(on/off signal)
Solenoid valve
(on/off signal)
77
WebCARE Version 2.0
What is WebCARE?
WebCARE is database of machine vital information and history of machine operation that can be monitored 24hrs -
365days in anytime and anywhere with the latest technology such as Satellite communication and Internet.
Since today, machine condition data is gathered by using many kinds of diagnosis tool such as PM clinic, oil analysis
along with repair and maintenance history taken by field service.
By using VHMS (Vehicle Health Monitoring System), machine vital information can be measured in digital and orga-
nized automatically by model / serial number to be stored in WebCARE database.
Purpose
Following items to be monitored in WebCARE.
A. VHMS data (Vehicle health Monitoring System)
B. KUC data : Undercarriage measurement results stored in KUC Program
C. PM Clinic data : PM Clinic measurement data stored in PM Clinic reporting program
D. KOWA data : KOWA oil analysis data: Link to Komatsu Australia (KAL) Oil database
Above data to be uploaded to WebCARE system via Satellite (Orbcomm), FTP (File Transfer protocol) or direct
uploading to WebCARE.
FEATURES
New features of WebCARE new version
• Displayed by multiple language
• Improvement of VHMS data analysis functions
• Accumulate field data in WebCARE : KUC measurement data and PM-Clinic data
• SMAP, CSS-Net (For Japan only)
In addition to gather machine condition data, we had made a link to SMAP system.
78
Optimum Fleet Recommendation
JOB ANALYSIS AND OPTIMUM MACHINE SELECTION PROGRAM
OFR is an activity of KOMATSU to support our customers when they select machines and decide fleet for
a certain job site.
And also OFR is the name of software programme to carry out this activity quickly and professionally.
OFR programme is reviced constantly and the latest version is 6.2.
FEATURES
Main Function of OFRv6.2
• Shovel and Dump Truck simulation
• O&O cost calculation
• Bulldozers simulation
• Load & Carry simulation
• Loading Machine simulation
• Job Site Analysis (Cycle Time, Haul Road Measurement, Weight Measurement)
79
KIRD
(Komatsu Information on Reliability & Durability)
KIRD is a software program for Komatsu and Komatsu distributor to support our customers when they
need R & M contract, FMC (full Maintenance Contract) and so on, whatever the name is, any life cycle
cost support.
KIRD program has several functions to realize this such as;
FEATURES
• Repair & Maintenance cost estimation
(R&M Cost Estimator)
• Repair or machine replacement recommendation
(Field Data / Inquiry, Input/ Edit, Maintenance Cost Report)
• Actual repair cost and major components life database etc
(Field Data / Inquiry, Component Records)

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Form No.

1. One item each is introduced on one page.

No. Part No. Part Name Remarks KIT A KIT B KIT C

Simple and speedy checks of wiring harnesses.

(Parts No. 799-601-7400) (Parts No. 799-601-6000)

Dimension of case Weight

Ass’y P/No 799-601-7100 799-601-7400

Simple and speedy checks of wiring harnesses.

Kit applicable to all DEUTSCH connectors Kit applicable to HD30 connectors

Kit parts number

Simple and speedy checks of wiring harnesses.

Simple and speedy checks of wiring harnesses.

T-adaptor for use with the AMP make 070 Connector

Part numbers of the component parts:

Simple and speedy checks of wiring harnesses.

Part numbers Applicable sensors and solenoids

799-601-9410 NE sensor and G. sensor

799-601-9420 Boost pressure sensor and

799-601-9430 PCV solenoid

Simple and speedy checks of wiring harnesses.

T-junction adaptor for the HST controller

Part No. Applicable model

Simple and speedy checks of wiring harnesses.

Almighty to measure rotating

SPECIFICATIONS Component parts:

10) Resolution 0.1 rpm 1 rpm

Easy and accurate temperature measure-

Essential tool for checking operation

For pressure test of cooling system

Types of radiator caps:

Essential! Quick coupler-type pressure gauge

Only one pressure gauge can measure all

Electrical system: External type: 24 V DC

Accuracy : ± 1%F.S. /°C ± 1digit

Heat effect against span: 0.3% per 10°C

Weight: 47.07 kPa {480 g}

Outer dimensions (with case): 455(W) x 335(D) x 95(H)

A temperature can be measured quickly and

Measure piston compression pressure be-

Measure piston compression pressure be-

Note 1) Number 23 to 36 are not included in 795-502-1205

Necessary tool: 795-502-1590 Gauge assembly

Easy blow-by pressure measurement

Digital display of fuel consumption in the field

2) Power source 2-way power supply

Note) This meter is not applicable on the Cummins ENGINES.

Easy measurement of BOOST PressURE!

• Quick coupler connection, speedy preparation!

• Vaccum range is available till 760 mmHg.

Undercarriage parts wear measuring tool

Measurement of Link Height

Compressed air detects seal damage easily.

OIL LEAK CHECKER

One scale to measure both the pushing

Indispensable one for troubleshooting of hydraulic circuit.

2) Power source Dry batteries: 1.5V single 3 x 3 pcs.

4) Weight (total) 264.78 N {27 kg}

Measure the sound level and maintain the