Komatsu Specialtools

Measuring & Diagnostic
Assemble & Disassemble
Maintenance ＆ Others
Bond & Seal

INTRODUCTION
This booklet introduces items of tools and equipment that we have

carefully selected as being very useful for work in field service and
workshop.
1. The top column explains the characteristics of the item.
2. The central column explains the functions of each tool or equipment,

describing the features and expected effects of the functions.
3. A photograph of each tool or equipment (showing the appearance)

is given together with a photograph (or illustration) of it being used.
Thus, this booklet contains explanations on the features and benefits of

each tool and equipment, in addition to conventional tool guides, and we
are sure that it will be very helpful to our distributors and customers.
■ INDEX ■
■ Measuring & Diagnostic Page
PM KIT A & B & C 5

Mechatro-harness checker(T-junction adaptor) 7
T-junction adaptor KIT for deutsch connectors 9
Do-it-yourself KIT for deutsch connectors 10
070 connector (controller system) T-junction adapters 11
T-junction adapter and socket for common rail type engines (125&140) 12
TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (1) 13
TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (2) 14
T-junction adapter for Tier Ⅲ engines 15
Multi T-junction adapter 16
Tier Ⅳ interim engine-related inspection/diagnosis tool (1) 17
Tier Ⅳ interim engine-related inspection/diagnosis tool (2) 18
Tachometer KIT 19
Digital thermometer 20
Radiator cap tester 21
Engine compressive pressure measurement gauge KIT 22
Blowby pressure measurement KIT 23
Engine boost pressure measurement KIT 24
Analog type (Bourdon tube) oil pressure measurement KIT 25
Digital type oil pressure measurement KIT 26
Undercarriage wear measurement KIT 27
Oil leak tester (measurement and diagnosis of oil leak in the hydraulic circuit) 28
Flowmeter (for oil level measurement) 29
Contaminant checker (measurement of contaminants in the fuel or hydraulic oil) 30
Battery coolant tester 31
Pressure pick-up adapter and plug for face seal hose joint 32
FOWA checker KIT 33
Heat sensitive paper KIT 34
Handy smoke checker 35
Cable diagnosis device 36
Test bench for PPM & T/M 37
Test device for electronic T/M 38
TierⅠ Engine dynamo test device 39
TierⅡ Engine dynamo test device 41
TierⅢ Engine dynamo test device 42
Capacitor discharging device for hybrid 43
Disassembly/assembly tool for hybrid 44
■ Assemble & Disassemble Page
Power wrench 45
Socket wrench KIT (for 12 point bolts) 46
Angle tightening wrench 47
Guide bolt KIT 48
Nut wrench KIT 49
Sling chain KIT 50
Recoil spring disassembly/Assembly tool 51
Cylinder round head wrench 52
Manual/Electric hydraulic pumps 53
Electric hydraulic pump 54
Tool for disassembling and assembling track-shoe master pin 55
Hydraulic cylinder and puller (For press fitting and pulling out) 59
Component repair stand (Torque converters, PPMs, deferential gears, etc.) 60
Engine repair stand 61
Hydraulic cylinder repair stand 63
■ Maintenance ＆ Others Page
Eco-drain valve 65
Brake release pump 66
Quick coupler for oil pressure measurement 67
Oil feeder with filter 68
Vacuum pump (negative pressure generator) 69
Pump for oil lubricated track shoe (vacuum/hydraulic pump) 70
Suspension tool（Oil & N2 gas filling） 71
Gas pressure inspection and filling for accumulators 72
Heat gun for heating heat shrink tubes 73
Hub nut retightening tool for HD rear wheel flange type 74
Nut and bolt KIT 75
Connector repair KIT 76
Repair kit for Deutsch connectors 78
Connector repair KIT for Common rail engine & HPI engine 79
Connector repair KIT for Tier Ⅲ engine 80
Connector repair KIT for 070 connector (controller) 81
Harness repair KIT 82
■ Bond & Seal Page
Liquid gasket 83
Anaerobic adhesive locktight 84
Instant adhesive & heat resistant seal material 85
Seal KIT 86
Required for repair of aluminum radiators 87
5
Required as tools for preventive maintenance services
These tools provide high level services
PM KIT
PM KIT A PM KIT B PM KIT C
(Parts No. 799-401-2301) (Parts No. 799-201-1104) (Parts No. 799-201-1904)
PM tune-up
■ Features ■
・ Devices required for preventive maintenance are integrated into a compact size for portability
in the field.
・ Pressure measurement related devices are integrated into PM kit A, and other required
devices are integrated into PM kit B for ease of use, more efficient diagnosis, prevention of
device damage, and single item supply in case of damage.
・ PM kit C includes devices for PM tune-up services such as hydraulic excavator dash 6 / 7 / 8.
■ Major measurement item ■

Applicable KIT
Device Measurement item Unit
A B C
Engine speed rpm ○ ○
Blowby pressure kPa ○ ○
Engine Lubricating oil pressure MPa ○ ○
Boost kPa ○
Exhaust temperature ℃ ○
Torque converter inlet/outlet oil pressure MPa ○ ○
Transmission relief oil pressure MPa ○ ○

Transmission lubricating oil pressure MPa ○ ○
Other
Transmission modulating lubricating oil pressure MPa ○
Time sec ○
※
Hydraulic oil relief oil pressure 1
MPa ○ ○
Work equipment speed sec ○ ○
Work equipment hydraulic drift mm ○ ○
※
Control pump pressure MPa ○ 2 ○
※
TVC output oil pressure MPa ○ 2 ○
Hydraulic ※
MPa ○ 2 ○
oil CO. NC output oil pressure
※
Jet sensor differential pressure 2
MPa ○ ○
※
1 ： A "60MPa (600kn/cm2)" pressure gauge is required for a hydraulic excavator.
※
2 ： A quick coupler may be used for some measurement locations.
6
Required as tools for preventive maintenance services
These tools provide high level services
■ Component parts ■
No. Part No. Part name Remarks K I T- A K I T-B K IT-C
1 799-401-2311 Gauge -101 to +200kPa 1
2 799-401-2320 Gauge 1Mpa ( 10.2kg/cm2 ) 1 1
3 799-101-5140 Gauge 2.5Mpa ( 25.5kg/cm ) 2
2 2
4 799-101-5130 Gauge 6Mpa ( 61.2kg/cm2 ) 2 1
5 799-101-5120 Gauge 39.23Mpa ( 400kg/cm2 ) 2
6 799-101-5110 Gauge 60Mp ( 612kg/cm2 ) 2
7 799-101-2280 Gauge （ 60kg/cm2 （
5.88Mpa ) w/o glycerrol ) 1
8 799-401-2330 Nipple No. 1 to No. 5 8
9 799-401-2340 Coupling No. 1 to No. 5 8
10 799-401-2350 Washer No. 1 to No. 5 8
11 799-401-2530 Holder Gauge holder "5in1" 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 5m ( straight coupler ）: purple tape 1 1
19 799-401-2220 Hose 5m ( straight coupler ）: w/o tape 1 1
20 799-401-2550 Hose 5m ( 90 coupler ）: red tape 1
21 799-401-2560 Hose 5m ( 90 coupler ）: yellow tape 1
22 799-401-2570 Hose 5m ( 90 coupler ）: white tape 1
23 799-101-5160 Nipple PT1/8 ( quick coupler ) 3 3
24 799-101-5220 Nipple M10 1.25 ( quick coupler ) 6
25 799-101-5230 Nipple M14 1.5 ( quick coupler ) 1
26 07002-11023 O-irng For No.24 6
27 07002-11423 O-ring For No.26 1
28 790-301-1530 Elbow PT1/8 ( 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-262-1970 Sensor For measureing the surface temperature 1
36 79A-262-1930 Sensor For measureing the oil&water temperature 1
37 79A-262-1940 Adapter For securing (PT1/8) 1
38 799-201-1110 Cable For measureing THE EXHAUST temperature 2
39 799-201-1511 Nozzle For measureing the engine blow-by 1 1
40 799-201-1450 Adapter For measureing the engine blow-by 1 1
41 799-201-1591 Gauge 1000mmAg ( 10Kpa ) 1
42 79A-262-1910 Meter Thermometer 1
43 799-205-1201 Tachometer 1 1
44 799-205-1221 Prove Tachometer set 1 1
45 799-203-8301 Magnet stand 1 1
46 799-201-1571 Tube Sillcone tube 4m 1 1
47 799-203-8870 Stopper For fixing the bulldozer steering lever 1
48 799-201-1120 Watch For measuring various time data 1 1
49 799-201-1542 Gauge 500mmAg 1
50 795-790-1900 Nozzle For measureing the 102 Engine blow-by 1
51 799-401-2510 Case Ass y Case for containing kit A 1
52 799-201-1141 Case Ass y Case for containing kit B 1
53 799-201-1911 Case Ass y Case for containing kit C 1
7
Easy and quick checking of mechatronics components
and wire harness
Mechatro-Harness Checker (T-junction adaptor)

(Parts No. 799-601-2500) (Parts No. 799-601-7100)
(Parts No. 799-601-7400) (Parts No. 799-601-6000)
■ Example of use ■
Dimension Weight
Part No.
of case (mm) N (kg)
799-601-2500 445 335 95 3.9
799-601-7100 500 400 110 4.0
799-601-7400 500 400 110 4.6
799-601-6000 500 400 170 7.0
■ Features ■
・ Komatsu products use many types of wire harnesses with terminal.
It is difficult and time-consuming to find the correct pin position for a wire harness. This
checker allows you to conduct a wire harness test easily and quickly.
・ This checker has tester lead wire terminals whose numbers correspond to terminals. This
makes trouble diagnosis of electric circuits easy and precise.
8
Easy and quick checking of mechatronics components
and wire harness
■ Applicable model/Component parts ■

Ass y P/No. 799-601-7100 799-601-7400
Sub ass
y P/ No.
799- 799- 799- 799-601-7300 799- 799- 799- 799-
P/NAME PIN P/NO. 799-601-2700 601-2500 601-7000 601-2800 799-601-7000 799-601-7200 601-2900 601-6000 601-7600 601-8000
CHECKER 21 799-601-2600
37 3100
37 3200
24 3300
ECONO 2 799-601-2750
3 2760
4 2770
8 2780
12 2790
MIC 5 799-601-2710
9 2950
13 2720
17 2730
21 2740
DLI 8 799-601-2810
12 2820
16 2830
MS 5 799-601-3510
5 3450
10 3460
14 2910
14 3520
17 3430
17 3440
19 3530
24 3410
24 3420
040 8 799-601-7180
12 7190
16 7210
20 7220
X 1 799-601-7010
2 7020
3 7030
4 7040
2 7230
SWP 6 799-601-7050
8 7060
12 7310
14 7070
16 7320
M 1 799-601-7080
2 7090
3 7110
4 7120
6 7130
8 7340
S 8 799-601-7140
10 7150
12 7160 （Blue) （Blue)
16 7170 （Blue) （Blue)
12 7350
16 7330 （White)
REL 5 799-601-7360 （White)
6 7370
EXTENSION 799-601-2850
CASE 799-601-2840
3470
7240
PLATE 799-601-3360
3370
3380
Caution：Not interchangeable between the blue and white onse of S12 and S16, (Even same pin No. structure is different.)
9
Introducing Deutsch connectors!
T-junction adaptors for trouble diagnosis are ready (1)
Instead of the electric connectors currently used such as the X, SWP connectors, the
DT,HD30 connectors of Deutsch will be adopted in all models.
These connectors have higher reliability with waterproof performance and better electric
characteristics. Harness repair can be done easily such as replacement of connectors and
pins. For the future models to be introduced to the market such as the WA1200-3, they
will be adopted sequentially. The T-junction adaptor for diagnosis of these connectors is
introduced here.
T-junction adaptor KIT for Deutsch connectors

(Parts No. 799-601-9000）
■ Features ■
・ This kit consists of 22 adapters and boxes and is
applicable to all DEUTSCH connectors.
KIT applicable to connectors for HD30

(Parts No. 799-601-9100）
■ Features ■
・ This kit consists of 9 adapters and boxes and is
applicable to all HD30 connectors.
・ HD30 connectors are used as intermediate connec-
tors for harness.
・ Since the harness reliability has been improved, 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 stations.
KIT applicable to DT connectors

(Parts No. 799-601-9200）
■ Features ■
・ This kit consists of 13 adapters, and is applicable
to all DT connectors.
・ These connectors have 2 to 12 ways. In addition to
the X and SWP conventionally used for sensors and
intermediate connectors, this kit covers the greater
part of trouble diagnosis, and is essential.
・ This kit number has been set so that the products
will be stored at all service stations.
・ The conventional box (799-601-2600) can be used
directly; therefore, the box is not included.
10
Introducing Deutsch connectors!
T-junction adaptors for trouble diagnosis are ready (2)
Do-it-yourself KIT
(Parts No. 799-601-9500） ■ Types of T-junction adaptors
manufactured with the Do-it-yourself KIT ■
T-junction adaptors for DTM2,

DT2, 3, 4, 6-pole (5 types)
※Adapters frequently used for
trouble diagnosis are collected.
■ Features ■
・ The Do-it-yourself kit has wires with terminal so that anyone can manufacture T-junction
adaptors easily.
・ It takes one to three hours to manufacture the five types of T-junction adaptors.
■ KIT part number ■

KIT part number
Component Applicable
No. 799- 799- 799- Part name Remarks
part number connector
601-9000 601-9100 601-9200
1 ● ● 799-601-9010 Adapter DTM 2 ways
2 ● ● 799-601-9020 Adapter DT 2 ways Do-it-
yourself kit
3 ● ● 799-601-9030 Adapter DT 3 ways 799-
601-9500
4 ● ● 799-601-9040 Adapter DT 4 ways
5 ● ● 799-601-9050 Adapter DT 6 ways
6 ● ● 799-601-9060 Adapter DT 8 ways（gray）
7 ● ● 799-601-9070 Adapter DT 8 ways (black)
8 ● ● 799-601-9080 Adapter DT 8 ways(green)
9 ● ● 799-601-9090 Adapter DT 8 ways（Brown）
10 ● ● 799-601-9110 Adapter DT 12 ways（gray）
11 ● ● 799-601-9120 Adapter DT 12 ways (black)
12 ● ● 799-601-9130 Adapter DT 12 ways (green)
13 ● ● 799-601-9140 Adapter DT 12 ways (brown)
14 ● ● 799-601-9210 Adapter HD30, 18-8
15 ● ● 799-601-9220 Adapter HD30, 18-14
16 ● ● 799-601-9230 Adapter HD30, 18-20
17 ● ● 799-601-9240 Adapter HD30, 18-21
18 ● ● 799-601-9250 Adapter HD24, 24-9
19 ● ● 799-601-9260 Adapter HD30, 24-16
20 ● ● 799-601-9270 Adapter HD30, 24-21
21 ● ● 799-601-9280 Adapter HD30, 24-23
22 ● ● 799-601-9290 Adapter HD30, 24-31
23 ● ● 799-601-9310 Plate for HD30
24 ● ● 799-601-9320 Box
25 ● 799-601-9330 Case -9000 storage case
26 ● 799-601-9340 Case -9100 storage case
11
Controller-related T-junction adapters
070 connector (controller system) T-junction adapters

(Parts No. 799-601-7500)
■ Features ■
・ In the PC-7, HD465/605-7, WA-5, and D275AX/375A-5
series, the 070 connector is adopted in all models from
small to large-sized models.
・ This connector is installed in important electronic
equipment such as the monitor panel, VHMS controller,
and engine controller.
■ Part numbers of the component parts ■

Number of pins of
No. Component part number Part name Q ty
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
T-junction adapter for the NGI controller

(Parts No. 799-601-9300)
The controller commonly called NGI controller is installed in the models from PC-58-3,
PC78-6, and PC200-7. One Type 24 and two Type 40 Deutsch connectors are connected
to this controller. The -junction adapters for these connectors are installed.
■ Component part ■
Part No. Q ty Remarks T-junction adapter for 40-pole
799-601-9310 1 Plate
799-601-9320 1 BOX（24-pole）
799-601-9350 1 40-pole
799-601-9360 1 24-pole T-junction adapter for 24-pole The box of 799-601-9320
T-junction adapter for medium size wheel loader HST controller

(Parts No. 799-601-9710，799-601-9720，799-601-9730)
799-601-9710
■ Applicable model ■
799-601-9730 WA250-5
799-601-9720
WA320-5
WA100-5
12
Trouble diagnosis tool for common rail type engines
T-junction adapter and socket for common rail type engines (125&140)
(Parts No. 799-601-9410 , 799-601-9420 , 799-601-9430 , 799-601-9440)
■ Features ■
NE sensor and G. sensor
799-601-9410
Common rail type engines have common
rail-specific sensors and solenoids such as
the G sensor, fuel pressure sensor, and PCV
solenoid. These sensors and solenoids are
799-601-9420 critical parts of the common rail system. If
the tester lead comes into contact with the
pin contact during diagnosis, the pin contact
Boost pressure sensor and may deform resulting in defective contact.
fuel pressure sensor
A repair requires replacement of the
sensor/solenoid, or replacement of the fuel
PCV solenoid pump in some cases.
799-601-9430 The T-junction adapter and socket are
provided for protection of connectors and
pins from damage during diagnosis and for
easier diagnosis work.
Socket for boost sensor

(Parts No. 799-601-9440)
■ Applicable sensor/solenoid ■
Part No. Applicable sensor / solenoid It was found that the boost sensor con-
nector and fuel pressure sensor connec-
799-601-9410 NE sensor、
G sensor
tor are not common. Therefore, a new
799-601-9420 Fuel pressure sensor
socket (part number: 799-601-9440)
799-601-9430 PCV solenoid used for diagnosis of the boost sensor is
799-601-9440 Boost pressure sensor provided.
NE sensor PCV solenoid

G sensor
The lead rod of

the tester is connected here.
13
TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (1)
The D375A-5 through 170 series engines have been changed to Type 3 engines that
comply with the second exhaust gas regulation.In the future models to be introduced to the
market, Type 3 of the 170 series engines will be installed. The injector, fuel pump, sensors,
and controller comprising the fuel system (commonly called **HPI) of this engine use the
same units and parts with Cummins engines. Therefore, some of the diagnosis devices are
common with Cummins. The diagnosis devices used for the 6D170-3 series engines are
introduced here. **HPI：High pressure injection
Heat gun (universal contact free thermometer)

(Parts No. 795-799-5512)
■ Features ■
● Identification of defective injectors with a heat gun ●
○Diagnosis method:
・ Start with the engine in a cooled state.
・ Measure the temperature of each cylinder on the
exhaust manifold surface for 10 minutes immediately
after the start. A cylinder with little temperature
increase is regarded as abnormal.
※ The covers of the exhaust manifold have a structure
that allows easy surface temperature measurement.
■ Characteristics ■
［ Temperature characteristics ［ Temperature characteristics
when the second cylinder is abnormal ］ when all the cylinders are normal ］
Caution：A heat gun of Komatsu is specified. However, this is not a special item but a general commercial item.Therefore,
if you already have a heat gun, you don't need to purchase a new one.
■ Specified devices ■
Komatsu part Cummins
No. Part name Application
number part number
1 795-799-5512 ー Heat gun Used for trouble diagnosis of the injectors
2 795-799-5550 3376859 Adaptor Used for fuel pump pressure measurement
3 795-799-5560 ー Oil pressure Used for fuel pump inlet pressure measurement
gauge
4 795-799-5520 ー Socket(S) Used for trouble diagnosis of the rotation sensor
Used for trouble diagnosis of the water temperature sensor,

5 795-799-5530 ー Socket(C) intake air temperature sensor, and exhaust temperature sensor
6 795-799-5540 ー Socket(A) Used for trouble diagnosis of the temperature sensor
Used for trouble diagnosis of the barometric pressure sensor,

7 795-799-5460 3824774 Cable
fuel pressure sensor, and actuator pressure sensor
8 795-799-5470 3824775 Cable Used for trouble diagnosis of lubricating oil pressure
Used for trouble diagnosis of the timing pressure sensor,

9 795-799-5480 3824776 Cable
manifold pressure sensor, and pump pressure sensor
14
TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (2)
Adaptor Oil pressure gauge for negative

(Parts No. 795-799-5550） pressure measurement
(Parts No. 795-799-5560）
Adaptor
Used for inlet pressure

measurement of the fuel
Quick coupler for fuel pump
inlet pressure measurement pump.The measurement
range is 0 to -0.1Mpa.
■ Features ■
A quick coupler for pump inlet/outlet pressure measurement is installed to the fuel pump.
This coupler cannot be connected to the couplers used by Komatsu, so an adapter that
allows connection is specified. This allows you to use the existing quick coupler. Pump
outlet pressure measurement can be done easily with the existing pressure gauge.Because
pump input pressure is negative, a vacuum gauge is required.
Diagnosis of the electronic control system

1）Socket ■ Operating Instructions ■
(Parts No. 795-799-5540 , -5520 , -5530) An example of diagnosis of the intake
air temperature sensor
795-799-5540
795-799-5520
795-799-5530
The HPI has various sensors. Simple sockets

Connected to the sensor for diagnosis of
and cables for connection to these sensors
disconnection and short circuit in the sensor.
for diagnosis are specified. The cables are
common with the ones used for Cummins.
２）Cable ■ Operating Instructions ■

(Parts No. 795-799-5460 , -5470 , -5480) An example of diagnosis of
the barometric pressure sensor
795-799-5460
795-799-5470
795-799-5480
Used similarly as the T-junction adapter to measure output voltage of the

sensor.Also used diagnosis of disconnection and short circuit in the sensor.
15
T-junction adapter for trouble diagnosis of Tier Ⅲ engines
T-junction adapter for Tier Ⅲ engines

(Parts No. 799-601-4100 , 799-601-4200) ■ Example of use ■
■ Features ■
In SMP-630, the T-junction adapter kit for Tier Ⅲ engines (part number 799-601-4100) was
introduced. As requested from the field, a kit for low-end models focusing on adapters
assumed to be used frequently is specified.
This kit is connected from the 799-601-4100 kit to the connector of the engine controller.
The 50/60-pole T-junction adapter, measurement box, and housing case are excluded. The
50/60-pole T-junction adapter may be required depending on the failure. This kit does not have
a measurement box, but the existing 799-601-9320 or 799-601-3300 can be used.
Part number of Part 6D 6D 6D 12V 4D 6D 4D 6D Number 799- 799-

No.
IT adapter socket name 140 125 170 140 95 107 107 114 of pins 601-4100 601-4200
1 799-601-4330 Socket G sensor 3 ○ ○
CAM sensor 3 ○ ○
2 799-601-4130 Adaptor
NE sensor 3 ○ ○
3 799-601-9420 Adaptor Rail pressure sensor 3 ○ ○
4 799-601-4190 Socket CAM sensor 3 ○ ○
Barometric air
5 799-601-4140 Adaptor pressure sensor 3 ○ ○
6 799-601-4240 Socket Barometric air pressure sensor 3 ○ ○
7 799-601-4250 Socket Intake manifold
pressure sensor 3 ○ ○
Intake manifold
8 799-601-4230 Socket pressure sensor 4 ○ ○
EGR boost
9 799-601-4180 Adaptor sensor 3 ○ ○
10 799-601-4160 Adaptor Oil pressure switch 2 ○ ○
11 799-601-4150 Adaptor Oil pressure switch 3 ○ ○
12 795-799-5530 Adaptor Coolant, Fuel, Oil temperature sensor 2 ○ ○
13 795-799-5540 Adaptor Boost temperature sensor 2 ○ ○
14 799-601-9040 Adaptor By-pass/EGR valve 4
stroke sensorr ○ ○
15 799-601-4211 Adaptor Controller Controller 50 ○
16 799-601-4220 Adaptor Controller 60 ○
17 799-601-4260 Adaptor Controller 4 ○ ○
Injector Pump
18 799-601-9020 Adaptor actuator 2 ○ ○
19 799-601-4340 Socket Pump actuator 2 ○ ○
20 799-601-9430 Socket PCV 60 ○ ○
21 799-601-4350 Box 2 ○
22 799-601-4360 CASE ○
23 799-601-9040 Adaptor 4
Intake
24 799-601-4110 Adaptor manifold
pressure sensor
Boost 4
Boost
25 799-601-4380 Adaptor sensor 4
26 799-601-4390 Adaptor Controller 60
Caution）
799-601-9420,795-799-5530,795-799-5540,799-601-9040, 799-601-9020,799-601-9430,799-601-9460
Common with TierⅡ engines
16
Introduction of a multi T-junction adapter
for trouble diagnosis
Multi T-junction adapter

(Parts No. 799-601-9890）
DT 2 pin DTM 2 pin DT 3 pin DT 4 pin
■ Features ■
Many types of T-junction adapters for trouble diagnosis of sensors and harnesses have been
manufactured. However, limited types of connectors are used daily.
A multi T-junction adapter that integrates 2-, 3-, and 4-pin connectors frequently used for the
main body is provided.
By having only this type at hand, you can deal with trouble diagnosis of almost all sensors.
※ When storing or carrying it, keep the male and female parts together to avoid foreign materials from
accumulating in the pin part.
17
Tier Ⅳ interim engine-related inspection
/diagnosis tool (1)
T-junction adapter
(Parts No. 799-601-4600)
Parts No.799-601-4620
Parts No.799-601-4630
No.799-601-4630
Parts No.799-601-4640
No.799-601-4640
Parts No.799-601-465
No.799-601-4651
No.799-601-4651
Parts No.799-601-4660
No.799-601-4660
Number
Part No. Part name of pins Usage location
799-601-4620 T-junction adapter 4 MAF sensor & KDPF junction connector
799-601-4630 T-junction adapter 2 KDOC & KDPF temperature sensor
799-601-4640 T-junction adapter 2 Exhaust temperature sensor
799-601-4651 T-junction adapter 24 Engine harness
799-601-4660 T-junction adapter 3 Turbo speed sensor
Blowby measurement tool

(Parts No. 799-201-1501 Others)
■ Features ■
・To measure blowby pressure, the CCV filter must be bypassed.
・To achieve this, remove horses and apply blind plugs with plugs and caps before
measurement.
Part No. Part name Q ty Remarks

Plug
Blowby checker
799-201-1501 1
kit
Cup
Commercial items Clamp
799T-201-3210 Plug 1
can be used. Blowby
tool
Commercial items
799T-201-3220 Cap 2
can be used.
Commercial items
078281-00359 Clamp 2
can be used.
Plug Cap Clamp

18
Tier Ⅳ interim engine-related inspection
/diagnosis tool (2)
Tools required for injector trimming

■ Features ■
Injector trimming is writing the injection timing correction data of each injector to the engine
controller after the injectors are replaced.This is required from the Tier Ⅳ interim to comply
with the strict exhaust gas regulation.
Komatsu Cummins
No. Part name part number part number Q ty Remarks
1 Insite 3886388 1 Lite ver.7.4

2 Kit data link adapter 4918416 1 Deutsch 9pin and 6pin USBterminal
3 PC 1 Commercial items can be used.

Main body
4 connection cable 799-601-4510 1
5 QR scanner (AT10Q-HM) 1 Selling agency：Denso Wave
6 Software for QR scanner

USB-COM port driver 1
Injector
Insite PC Kit data link adapter 799-601-4510

Lite ver7.4 （INLINE5&Cable） QR code
QRscanner
HC dozer nozzle cleaning equipment

(Commercial items can be used.)
■ Features ■
Light oil is injected from the HC dozer nozzle as auxiliary fuel to
burn and eliminate carbons clogging in the KDPF. The nozzle part
is stained with carbon, so it must be removed and cleaned every
4500 hours. For cleaning, use light oil and soft waste or nylon
brush.
HC dozer nozzle
During cleaning
After cleaning
Before cleaning
Good condition
No residual soot
on the nozzle tip
＜Caution!!＞
Never use a wire brush because it damages the nozzle part.
19
Various types of engine speed can be measured
for versatility
Tachometer KIT (Parts No. 799-205-1002)

Laser type tachometer Vibration detection type tachometer
(Parts No. 799-205-1101) (Parts No. 799-205-1601)
■ Features ■
・ A contact free tachometer using laser beam is adopted as a service tool for improved safety
of inspection and adjustment.
・ Due to the significant expansion of detection distance, inspection/diagnosis work can be
performed more easily and safely than before.
■ Component parts ： 799-205-1101 ■
No. Part No. Part name Q ty Remarks

ー 799-205-1002 Tachometer KIT 1 799-205-1101＆799-205-1601
ー 799-205-1101 ・Tachometer KIT 1 Laser type tachometer
1 799-205-1201 ・・Tachometer 1 6.0 to 99999.9 rpm
2 799-205-1221 ・・Probe 1 Photoelectric pickup, cable length of about 5 m
3 799-203-8301 ・・Stand 1
4 799-205-1401 ・・Case 1 Fuel injection tube mounting type sensor
ー 799-205-1601 ・・Tachometer KIT 1 Vibration detection type tachometer
5 799-205-1701 ・・Tachometer 1 400 to 10,000 rpm
6 799-205-1800 ・・Detector 1 Fuel injection tube mounting type sensor
■ Specifications ： 799-205-1002 ■ ■ Specifications ： 799-205-1601 ■
Model TM-7030-008 Applicable 4-cycle diesel engine

Beam used Laser beam engine （Injection pump specification）
Probe Remote (5 m) Detection Detects vibration of the injection pipe

Measurement method generated during fuel injection.
Reflection tape type
method
Class 2 laser (1 mW), Measurement Within 1s+1 cycle time
Light source wavelength 650 nm (red) time
480 to 8008 r/min
Detection 50 to 1000 Measurement
((r/s is in the range of r/min
distance range
measurement divided by 60))
Detection angle 40
AAA alkaline battery x4

Accessory
Scotchlite tapes x10
20
Easy and accurate temperature measurements
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 to 80% R.H.
5) Temperature sensor K (Chromel-Alumel) thermocouple
6) Display LCD(Liquid crystal)
7) Power supply 3V [LR6 (AA) x 2]
8) Continuously usable time 80H
9) Dimensions 352(W)Ｘ146(L)X90(H)mm
10) Weight 1.4kg

21
For pressure test of cooling system
Radiator cap tester

■ Features ■
・This tester confirm functioin of the pressure valve and checks the cooling system for water
leakage.
・The tester is composed of a manually operated air pump for pressurizing and an adapter.
■ Types of radiator caps ■

■ Specifications ■ The cap type in that the radiator cap and water pouring
Type cap are built into a single unit (for automobile use)
DC 12 V A (Four sizes by diameters are available, i.e., ø54, ø50, ø41,
1) Pump
Max 588.40 kPa {6 kg/cm²} and ø31)
2) Pressure With 0.00 to 196. 13 kPa Type The cap type that has a single unit of pressure valve
gauge {0 to 2 kg/cm²} regulator (Two sizes by the thread pitch of water pouring cap are
B
available)
3) Dimensions 360 190 200mm Type The cap type made by WISCO and that has a plug hole in
C the upper tank
The kind of
No. Part No. Part name Remarks
radiator cap
1 799-202-9002 ・Radiator cap -
1- 1 799-202-9201 ・Hand pump -
1- 2 799-202-9211 ・Cap B M80,P=1.5
1- 3 799-202-9221 ・Cap B M80,P=2 (Two-article screw)
1- 4 799-202-9231 ・Adapter A Rubber outside diameter φ38
1- 5 799-202-9240 ・Joint A φ41 φ41 H=73
1- 6 799-202-9250 ・Joint A φ50 φ41 H=62
1- 7 799-202-9260 ・Joint A φ54 φ41 H=54
1-10 799-202-9311 ・Hose - L=1m
2 799-202-9330 ・Joint A ・Option φ31 φ41 H=78
3 799-202-9340 ・Joint A ・Option Rubber outside diameter φ27.5
4 07041-13633 ・Plug C ・Option 36 P1.5, PT1/8
5 07002-03634 ・O-Ring C ・Option
6 799-202-9360 ・Nipple C ・Option CEJN 10-220-5151
Q ty：1 piece each
22
Measure piston compression pressure before
disassembling engine!
Engine compressive pressure measurement gauge KIT

(Parts No. 795-502-1205)
■ Features ■
・ A compression measurement adapter for Komatsu engines are
provided as a kit. Cummins 743 series (NH220, NTO6) and
855 series KT1150 engines can also be measured.
■ Specification and applicable model ■

Specification and
No Part No. Parts name Q ty
applicable model
1 795-502-1590 Gauge ass y 1

1a 795-502-1210 ・Gauge 0 to 70kg/cm2 1
1b 795-502-1220 ・Hose Length 390 mm 1
1c 795-502-1230 ・Valve With a reset button 1
2 795-502-1240 Adapter 155-4 engine 1
3 795-502-1250 Adapter 92-1 engine 1
4 795-502-1260 Adapter 105-1、2、3 engine 1
5 795-502-1270 Adapter 120-11、130-1 engine 1

■ Option ■
6 795-502-1283 Case 410 300 127ｍｍ 1
Specification and
No Part No. Parts name Q ty
applicable model
7 795-502-1291 Adapter 743 engine 1
84-2(Necesary tool:
23 795-111-1110 Adapter 1
795-101-1571)
8 795-502-1310 Adapter 94-1 engine 1
2D94-2, 4D94-2, 4D95L,
24 790-553-1110 Adapter 1
4D95W 1,4D130-1
9 795-502-1320 Adapter 855 engine 1
24a 790-553-1120 ïAdapter length 390 mm 1
10 795-502-1330 Adapter 105-1、5、110 engine 1
24b 790-553-1130 ïAdapter With a reset button 1
11 795-502-1340 Adapter KT1150 engine 1
24c 790-553-1140 ïPacking 155-4 engine 1
12 795-502-1350 Adapter 170 engine 1
25 790-471-1090 Adapter 16V170-1 engine 1
13 795-502-1360 Adapter 125 engine 1
26 790-471-1110 Palette 16V170-1 engine 1 95-1
14 795-502-1370 Adapter （direct injection type） 1
27 790-472-1370 Adapter SA6D108 engine 1 engine
95-1
1D75-1, 1D84-1(Necesary 15 795-502-1380 Adapter (squish chamber type) 1
28 795-502-1390 Adapter tool:795-553-1130, 1 engine
795-553-1140)
16 795-502-1500 Adapter ass y 140-1 engine 1
Adapter
29 795-502-1700 102 engine 1
Ass ｙ
16a 795-502-1510 ・Adapter 6Ｄ140 engine 1
30 795-111-1120 Adapter 3D68E-3 engine 1
16b 795-502-1520 ・Plate Plate for795-502-1510 1
31 795-471-1410 Adapter 125E-3 engine 1
17 795-502-1530 Adapter ass y 1
32 6217-71-6110 Gasket 125E-3 engine 1
17a 795-502-1540 ・Adapter 3D78 engine 1
33 795-471-1310 Adapter 140E-3 engine 1
17b 795-502-1550 ・Plate Plate for 795-502-1540 1
34 795-611-1210 Adapter 170E-3 engine 1
18 795-101-1580 Adapter ass y 3D72, 75, 84 engine 1
35 795-790-3610 Gauge 114 engine 1

18a 795-101-1560 ・Adapter 3D72、
75、84 engine 1
36 795-790-3710 Testa 114 engine 6

18b 795-101-1570 ・Joint 3D72、
75、84 engine 1
37 790-472-1370 Adapter SA6D108 engine 1 Packing 1

19 795-502-1560
38 790-471-1090 Adapter SA16V170 engine 1 20 795-502-1570 Packing 1
39 790-471-1110 Plate Plate for 790−471-1090 1 21 795-502-1580 Packing 1

23
Easier blowby pressure measurement of engines
Blowby pressure measurement KIT (Parts No. 799-201-1506)

KITⅡ (Parts No. 799-201-3101)
■ Features ■
・Engine blowby pressure can be
directly read from the pressure gauge.
・When the vinyl tube is extended,
measurement can be done easily and
safely while operating the machine in
the operator's seat.
・Low-end model Kit Ⅱ (799-201-3101)
is also provided.
■ Specification of blowby measurement tool new kit part number ■

8
10
6D
0、
43
T
C7
11
KI
6D
rd
NT
50（ s KT 855
o
da
0
rb
A）
ins
15
、S
an
tu
43
55
T
1
m
（
05
KI
St
N7
N8
NT
0
m
30
No
17
D1
0）
01
06
No. Part number Part name

5、
ins
ins
ins
A） 4D1
C
/6
in
/2
31
15
56
10
r
m
15
、4
Fo
-1
1-
1-
S
5
17
5、
um
um
um
um
40
95
D9
6D
94
20
20
A）
0
rC
rC
rC
rC
14
94
12
V1
11
6D
4D
/6
9-
9-
4
2
VT（
4、
6D
2D
6D
KT
S4
10
10
11
12
79
79
Fo
Fo
Fo
Fo
S（
3/
Tool 795-790-3300
1 799-201-1511 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 for Cummins
(main body)
Tool 795-790-1950
795-790-1900 1 1 1
(main body) for Japan-made
2 799-201-1541 Gauge 1 1 1 1 1 1 1 1 1 1 5kPa
Silicon tube
3 799-201-1571 Tube 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 m x Inner diameter
of 5 to 5.5 mm
4 799-201-1530 Nut 1 1 1 1 1
Oilhole mounting
adapter
5 799-201-1521 Adapter 1 1 1 1 1
6 799-201-1582 Case 1 1 Storage case

Joint diameter
7 799-201-1411 Adapter 1 1 1 1 1 1 φ14.5/16ｍｍ
Blind plug for
8 799-201-1460 Plug 3 3 3
N743 vent hole
Joint diameter
9 799-201-1450 Adapter 1 1 1 1 1 1 1 2 1 φ19/26mm
10 799-201-1630 Joint 1 1 1 1
φ20/φ26/
11 799-201-1470 Hose 1 1 1 Length 60ｍｍ
φ16/φ22/
12 799-201-1421 Hose 1 1 1 Length 60ｍｍ
φ14/φ20/
13 799-201-1480 Hose 1 1 1
Length 60ｍｍ
φ14/φ20/
14 799-201-1490 Hose 2 2 2 2
Length 100ｍｍ
15 07281-00289 Clamp 2 2 2
16 07281-00259 Clamp 1 1 1 1 1 1 1 1 1
17 799-201-1591 Gauge 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10kPa

U-type tube type
18 795-790-1610 Gauge 1 1 1 gauge (Cummins)
19 799-201-1640 Adapter 1
20 799-201-1430 Adapter
21 799-201-1440 Adapter
※For the blowby tool for Tier Ⅳ engines, refer to page 17.
24
Prevents failure of the engine and turbo
Engine boost pressure measurement KIT

■ Features ■
・Simple measurement same as hydraulic pressures.
・Quick coupler connection, speedy preparation!
・Vaccum range is available till 760 mmHg.
■ Application ■
Used to measure the air super charging pressure of an engine.
No. Part No. Parts Name Q ty Remark
1 799-101-5160 Nipple 1 PT1/8
2 799-401-2610 Hose 1
3 799-401-2311 Gauge 1 -760 to1500 mmHg

25
Required! Quick coupler type pressure gauge kit with all
hydraulic circuit adapters
Analog type (Bourdon tube) oil pressure measurement KIT

(Parts No. 799-101-5002)
■ 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.
1. 2.45 MPa (25 kg/cm²)

Pressure gauge Component 2. 5.88 MPa (60 kg/cm²)
of gauge 3. 39.23 MPa (400 kg/cm²)
4. 58.84 MPa (600 kg/cm²)
Pressure hose 1600mm long hoses (Resistance to 58.84MPa {600kg/cm2})
with quick couplers (sockets and nipples) and caps
Adapter Each adapter
Dimensions 395 W x 330 D x 85 H (Outside dimensions of storage case)

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.
2 799-401-2280 Gauge 5.88 MPa {60kg/cm²} pressure gauge without glycerin
3 799-261-1130 Coupling Female quick coupler (For bleeding air from hose)
4 799-101-5210 Nipple Quick nipple PT 1/4
5 799-101-5220 Nipple Quick nipple M10 x P1.25 (For O-ring boss)
6 799-101-5230 Nipple Quick nipple M14 x P1.5 (For O-ring boss)

Flange with pressure measuring port for split flange
7 799-101-2210 Flange
of nominal size of 06
5.0m hose (With straight coupling)
8 799-401-2220 Hose
Other hoses are available, too.
26
Digital type oil pressure measurement KIT
Digital type oil pressure measurement KIT

(Parts No. 790-261-1204)
■ Features ■
・All the adapters and hoses are interchangeable with those for an analog hydraulic tester.
・Only one digital gauge of 0 to 68.64 MPa {0 to 700 kg/cm²} can substitute for analog hydraulic
testers of four types.
・Indication by LCD.
１) Pressure sensor KH18 Pressure sensor
2) Pressure port PF1/4
3) Pressure range 68.64Mpa (700 kg/cm2)
4) Accuracy 1%
5) Sampling speed Approximately 20 times / sec
6) Display 3-digit LCD, character height 12.7 mm
7) Power supply S-006P6F22 Dry-cell battery 1
8) Operating temperature range 0 to 55℃
9) Continuous operation time Approximately 10H
10) Temperature characteristic 0.1% / ℃
11) Hold time Approximately 5 minutes
12) Storage temperature range -20℃ to 60℃
Pressure gauge 110(W) 175(H) 63(D)mm

13) Dimensions
Housing case 45(W) 92(H) 340(D)mm
14) Weight 9.5Kg

27
Undercarriage parts wear measuring tool
kit for your parts business expansion
Undercarriage wear measurement KIT

Photo.1 Photo.2 Photo.3
■ Example of use ■ ■ KIT part number and order destination ■

Part number : CK40-25
Order destination : Komatsu south africa (PTY)LTD
Undercarriage Division
kevinn@komatsu.co.jp
■ Measurement of Link Height ■
1)Use the depth gauges to measure link height.
2)Read the scales to determine the depths measured with the
depth gauges.
■ Components ■
This tool is composed of three layers, and there are two kinds of outside calipers on the upper
layer as 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.
■ Features ■
・Three types of calipers are specified for different measurement targets.
・The calipers with screws allow precise measurement because measurement position does not
change.
・The shape of the tips of calipers allows easy measurement.
・Link height and grouser height can be measured precisely with the notch gauge.
No. Part No. Part name Q ty Specifications

1 P40-25 Case 1 400 x 250 x 100mm
2 PDG-34 Depth gauge
（large） 1 340mm
3 PDG-12 Depth gauge(small) 1 120mm
4 POC10-1 Outside calipers (small) 1 100mm
5 POC15-1 Outside calipers (medium) 1 150mm
6 POC30-1 Outside calipers (large) 1 300mm
7 PV200-1 Vernier calipers 1 200mm
8 PST300-1 Tape measure 1 3m
9 PSR300-1 Metal measure 1 300mm
10 PSR100-1 Metal measure 1 100mm
11 PWB-1 Wire brush 1
12 PS50-1 Wire brush 1 Width 50mm
28
Easily diagnoses oil leak in the hydraulic circuit
Oil leak tester (measurement and diagnosis of oil leak in the hydraulic circuit)
(Parts No. 799-301-1500)
■ Example of use ■ ■ An example of use in a track roller ■
■ 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).
Gauges 196.13 kPa {2 kg/cm²} and 980.67 kPa {10 kg/cm²}
Regulator adjustment pressure 0 to 102kg/cm2
※ 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
29
Indispensable one for troubleshooting of hydraulic circuit
Flowmeter and adapters kit for Komatsu machine
Flowmeter (for oil level measurement)

■ 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.
1） Measuring range Flow 15 to 350ℓ/min

（ 1%）
(accuracy in parentheses)
2
Pressure 0 to 400kg/cm（ 0.5%）
Temperature 0 to 150℃（ 1%）
2） Power source Dry batteries 1.5V single 3 x 3 pcs.
1.5V single 1 2 pcs.
3） Weight (body only) 62.76 N {6.4 kg}
4） Weight (total) 264.78 N {27 kg}

30
Contaminants in the hydraulic oil and lubricating oil can be
measured easily with ISO and NAS codes
Contaminant checker (measurement of contaminants in the fuel or hydraulic oil)

(Parts No. 79A-851-1200)
■ Features ■
・The optical scanning system allows measurement of 4 types
of particle size ranges of 5 to 15 micrometers, 15 to 25
micrometers, 25 to 50 micrometers, and 50 micrometers or
more.
To obtain samples online, just connect with a quick coupling.
・Operation is simple.Testing is completely automatic and takes
only 4 minutes.
・The result is displayed on the monitor in real time and can be
printed out.
CM20 Component ・The number of particles and class are displayed in NAS or ISO
for each particle size range.
・300 tests can be recorded in the memory.
・Transfer to a PC can be done.
・Battery-driven and portable.
・Testing can be done anywhere.
・It is easier to use than the previous contaminant checker and
affected less by air and dust contaminants.
Measurement ranges 4 ranges (Over 5, over 15, over 25 No. Part No. Part name Q ty
of particle diameter and over 50 microns)
79A-851-1000 Check ass y 1
International grain ISO Grade 7 to 24
measurement standard NAS Grade 0 to 12 79A-851-1200 ・Check subass y 1
Calibration Conformed to ISO 4402 79A-851-1210 ・・CM20 1
Recalibration Unnecessary 2 79A-851-1220 ・・Sample 1
Accuracy/Reproducibility 5% max. 3 79A-851-1230 ・・Hose Ass y 1
Viscosity range of 2 to 100cSt
4 79A-851-1240 ・・ Ribbon 1
hydraulic oil (Up to 500cSt of single point sampler)
5 79A-851-1250 ・・Lamp 1
Using temperature range ＋5℃ to ＋80℃
Ambient temperature range 6 79A-851-1260 ・・Paper 1
＋5℃ to ＋40℃
Applicable hydraulic oil 7 799-101-5150 ・・Hose（1.7ｍ 2） 1
/lubricating oil Mineral oil, synthetic oil
8 79A-851-1270 ・Bottle sample 1
Max. using pressure 41MPa (420 kg/cm2)
Max. flow rate 400 r/min. 1) As the power source, a battery power supply
or an AC100V power supply is used.
Operating condition Min. using pressure of 2kg/cm² 2) Option: Bottle sampler : 79A-851-1270
Test time 4 minutes
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
Battery (Alkaline dry battery of
Power source
R20PU size x6 pcs.)or DC12V
31
Measurement with one drop
Battery coolant tester

Pin
Lighting
plate
■ Scale ■ ■ Specifications ■
Part name Part No.

Pin 795-500-2020
Lighting plate 795-500-2010
■ Features ■
・ Can be used for measurement of the charging state of battery electrolyte and the freezing
point of antifreeze.
・ Measurement of both the regular type (AF-PT) antifreeze and supercraft (AF-ACL) can be
done.
・ In a battery electrolyte inspection, the specific gravity and charging state of the electrolyte
can be read.
・ The specific gravity at 20℃ is not affected by the outside air temperature so it can be read
with the built-in automatic compensation function.
■ Specifications ■ ■ Freezing point graph of super coolant ■
Reading range Temperature（℃）

10
・ Battery electrolyte 1.10 to 1.30 0

specific gravity
・ Freezing point -8 to 50℃ -10
Size （mm) 33.5(H)X31(W)X154(L) -20
Weight -30
250kg
-40
Super coolant
Applicable coolant AF-NAC -50
0 20 40 60 80 100
Ethylene glycol concentration（％）
32
Maintenance equipment used for oil pressure face seal joint
Pressure pick-up adapter and plug for face seal hose joint
(Parts No. 07976-70210 and others) ■ Example of use ■
02 03 04 05 06 10
■ An example of combination ■
■ Features ■
Pressure pick-up adapter six types from.
・02 to 10. Select it according to the size.
O-ring for face seal.
・Select an O-ring for each face seal from the table
of service mate (SMP-587).
Nut (cap) Blind plug

(Parts No. 02789-00210 and others) (Parts No. 07376-70210 and others)
B
B Blind plug O-Ring Face seal hose
■ Features ■
This nut (cap) is put on the end part
such as a face seal type union elbow
when the machine body is disassembled ■ Features ■
and transported or when the rubber This plug is put on the end part of the face seal
hose is transported alone to prevent oil type rubber hose as a blind plug when the
leak or intrusion of foreign materials. machine body is disassembled and transported
or when the rubber hose is transported alone to
prevent oil leak or intrusion of foreign materials.
Nominal Pressure pick-up Screw Bolt width

Nut (cap) Blind plug
code adapter dimensions (B)
02 799-401-3100 02789-1-0210 07376-7-0210 9/16UNF 19
03 799-401-3200 02789-1-0315 07376-7-0315 11/16UN 22
04 799-401-3300 02789-1-0422 07376-7-0422 13/16UN 27
05 799-401-3400 02789-1-0522 07376-7-0522 1UNS 32
06 799-401-3500 02789-1-0628 07376-7-0628 1・3/16UN 36
10 799-401-3600 ― ― 1・7/16UN 41
33
For checker FOWA (Fuel, Oil, Water, Air) program
FOWA checker KIT

(Parts No. 799-609-2000)
■ Features ■
Importance of maintenance of secondary materials
such as fuel, oil, water, and air has been emphasized
traditionally. Recently, engines have sophisticated
electronic control complex structure for exhaust gas
regulations and improved fuel economy. As a result,
slight insufficiency in maintenance often results in a
major accident.
This new checker is provided for customers to utilize a
correct maintenance method to prevent unexpected failure of major components. As a service
program that leads to expansion of sales of oil and antifreeze, the existing maintenance checker
has been reviewed completely. It allows you to analyze deterioration of engine oil, mixing of fuel,
mixing of moisture, and coolant water quality easily in the field.
■ Measurement items and target oil/fuel/coolant ■

Measurement items Engine Oil Face seal hose Coolant Hydraulic oil
TBN ○
TAN ○ ○
Viscosity ○
Moisture ○ ○ ○
PH ○
Water hardness ○
ＴＢＮ：Total Base Number
（Total alkalinity number）ＴＡＮ：Total Acid Number
（Total acid number）
No. Part No. Description Q ty Remarks

1 799-609-2100 TBN checker A ssy 1set For 50 times
2 799-609-2200 TAN checker A ssy 1set For 25 times
3 799-609-2300 Viscosity checker assembly 1set ー
4 799-609-2400 Water checker assembly 1set For 50 times
5 (799-609-2500) Hardness checker 2packs For 10 times
6 799-609-2600 Litmus paper 1set For 100 times
■ Judgment method (an example of TBN) ■

It is known that Komatsu genuine new oil has a TBN value of
11 and a checker reading of 2.5 to 2.8. Therefore, when only
used oil is measured, its TBN can be known from the reading
based on the right graph. The usage limit value of TBN is 5.
A reading of 1.5 or more is determined as useable with a
margin.
Typical oil has a TBN value of about 11. However, if heavy oil
is used as fuel, the TBN may be high because of additives. In
this case, TBN must be determined by measuring new oil with
this checker and comparing it with used oil. For this method,
refer to the Operation Manual. Basically, judgment is done by
comparing it with new oil, and replacement is required when
the TBN value of new oil decreases to the half. As the standard value of TBN,
TBN=5 or more is in the useable range.
34
Indicates temperature of high-temperature part at a glance
Heat sensitive paper KIT

■ Features ■
・The heat sensitive paper discolors sharply at a specific temperature.
・It is an irreversible thermosensitive material that won't go back to the original color once
discolored.
・For the discoloring thermal material element, a melting point of specially-refined stable melt-
ing pigments is utilized. The thermosensitivity is precise and shows high accuracy.
・The thermosensitive element is sealed with a heat-resistant film, so it is not affected by the
ambient atmosphere such as water, chemicals, or oil.
・Heat-resistant adhesive is applied on the back of the heat sensitive paper. It can be put on
the temperature measuring part after the backing sheet (exfoliate paper) is removed.
■ Used in the following places ■

It has high durability, and it is utilized in a wide variety of areas for heat generation/heating tem-
perature management indoors and outdoors.It is used for heating inspection of substation
equipment and machining facilities at power companies and factories to prevent accidents and
to streamline maintenance.
Original color Original color

Part No. Symbol Indicated temperature
/discoloration /discoloration
799-101-6710 5E-50 50-55-60-65-70
799-101-6720 5E-75 75-80-85-90-95

White → black 2℃
799-101-6730 5E-100 100-105-110-115-120
799-101-6740 5E-125 125-130-140-150-160
799-101-6750 5E-170 170-180-190-200-210 Light yellow → black 2 to 3℃
■ Structure ■
Polyester film
Thermosensitive element
15mm 4mmΦ Adhesive
Marking ink
Polyester film
43mm
Adhesive
20 sheets/case Exfoliate paper
35
Diesel exhaust smoke gas color can be measured
in the Bosch spot unit
Handy smoke checker

■ Features ■
・Suction exhaust gas using a handheld pump and catch exhaust gas by a paper filter.
・Compare the paper that has captured exhaust gas with a standard color sample and take the
degree of contamination that is closest to the color sample Nr.
・This handheld smoke checker has not obtained a type approval of the Ministry of Transport,
but has the following features, suitable for field use.
(1) Lightweight and compactness, (2) Ease of handling, (3) Low price and (4) Compliance
with KES.
・The smoke scale that has been installed is also a tool approved by the US Commerce Depart-
ment.
・Can be used in engines compliant to Tier IV Interim. (Heat resistant specification)
※Note: Should allow safe work after checking data such as the shop manua
■ Specifications ■ No.
Component
Part name Q ty Remarks
part number
0 to 70% 1 795-201-9310 Pump 1
1) Measurement
range (Degree of contamination)
2 795-201-9320 Nozzle Assy 1 Pump Ass y
2) Dimensions 410 X 300 X 65mm 3 795-201-9330 Nipple 1
4 795-201-9340 Smoke scale 1 Made in Bachrach
3) Weight 3kg
5 795-201-9020 Filter paper 1set
6 795-201-9350 Case 1
Smoke scale
Bosch spot unit.
(Parts No. 799-799-201-9340) 10
9
8
7
6
5
4
3
2
1
10 20 30 40 50 60 70 80 90 100
Degree of contamination (%)
■ Features ■
・Classification into ten levels in accordance with the Bosch spot unit
・Immediate judgment by judgment criteria of the shop manual
・The following two types of judgment values are used in measurement of diesel exhaust smoke
gas color (black smoke) depending on the measuring instrument used.
① Bosch spot unit, ② Degree of contamination (%)
This relation can be expressed by the graph shown above in accordance with the result of an
experiment by Komatsu.
When necessary, use after making a conversion. (The graph is cited from KES06.701.55)
36
Cable disconnection and short circuit can be detected
when it is connected to the end of a parallel cable
Cable diagnosis device

Disconnection Disconnection
part waveform
Disconnection
location
■ Target harness ■
All harnesses
(diagnosable lines are limited to two parallel lines)
■ Cable diagnosis device

（Harnesses checker）■
Maker BI COMMUNICSTIONS Ltd（Britain）
Mode TX6000 Ranger
■ Features ■
・Can measure failure locations precisely.
・Can determine if failure is disconnection or short circuit.
・Can change the measurement distance (range) according to the length of the electric cable.
・50 items of waveform data can be stored in memory.
・Oscillation signal (tone oscillation) is minimal and does not affect devices.
※In some conditions, insulation degradation failure can be determined.
■ Connection to various
■ Interpreting waveforms ■
electric cables ■
Disconnection Defective water

Coaxial cable insulation
Shielded cable Short circuit Corrosion
Twisted pair line

Wire
Water intrusion
connection
Multi-center line
Connector/strand
disconnection
Branch circuit
The figure above is a typical waveform indicating a trouble.

Refer to it when identifying a trouble.
37
Introducing tools for a bench test of electronic transmission
(T/M)
Test bench for PPM & T/M Pump tester

(Parts No. 799-402-6000) (Parts No. 799-610-1211)
Dither waveform
■ Features of the pump tester ■

・Can conduct a test according to Komatsu's design specifications.
・It supplies control current to the EPC valve that controls the discharge flow rate of the pump.
・In the test bench, a dither waveform required for a test can be generated.
■ Specifications ■ ■ Specifications ■
（Test bench main part）（Pump tester）
AC440V 60Hz Output to 1 channel P.OUT.

1 Power supply
160ｋｗ
（MAX） Power 0 to 1000mA
2 Control circuit AC200V Voltage 0 to 24V

1 Output
3 Coolant 100 to 150L/min Dither 3 types, switched with a selector.
Fixed internally
Main Pump 132kw
Current setting 0 to 1000mA
Boost Pump 11kw
4 Motor Accuracy Within 1%
Pilot Pump 3.7kw
Output to CURR MONI.
Monitor For monitoring the output current
Pump for T/M 18.5kw 2 output
For 0 to 1000 mA
Current
5 Test oil pressure 0 to 372Mpa Voltage output of 0 to 1 V
6 Test flow rate 15 to 340L/min Voltage range AC100V to 240V 10％

Input power
3 supply Frequency range 50 to 60Hz
Input terminal AC inlet 3-pole
210
（W） 160
（D） 66
（H）※Projection part not included
4 Dimensions
Weight 1.8Kg
Temperature range -5 to 35℃

Operating
5 environment
Humidity range Within 10 to 85% (no condensation)
■ Tool used for connection to the EPC value of the pump ■
Part NO. Part name Q'ty Main specification

799-552-3710 Cable1 1 Bipolar ECONO type (male),Length 5 m
799-552-3720 Cable2 1 Bipolar ECONO type (female),bipolar X type (female)
799-552-3730 Cable3 1 Bipolar ECONO type (female),bipolar ECONO type (female)
799-610-1410 Cable4 1 Bipolar ECONO type (female),bipolar DT type (female)
commercially Power supply unit 1 AC INLET 3-poles
38
Easily diagnoses oil leak in the hydraulic circuit
Test device for electronic T/M

(Parts No. 799-607-6100)
No. Part No. Parts name Q'ty Remark
1 799-607-6110 Switch Box 1 Common
2 799-607-6120 Harness 1 X connector
3 799-607-6130 Harness 1 German connector
4 799-607-6140 Harness 1 Mitsubishi connector
for D375A-5
5 799-607-6150 Adapter 1
(Option)
■ Connection of electric wiring ■

Connection of electric wiring is common among all models. The T/M main body is connected
directly to ECMV. Normally, the T/M has 6-10 ECMV's. From the testing controller, three signals
of Lo, TM1, and TM2 can be output simultaneously. Therefore, change the connection to ECMV
for different test items.
○Basic connection
・ECMV for Lo-lockup
・ECMV for TM1-F, R clutch
・ECNV for TM2-1st, 2nd, 3rd, and 4th (for details, refer to the test check sheet of the model.)
The connector for the parking brake solenoid (indicated as B/K) is also provided. Connect this
connector for the parking brake built into the T/M. For a power unit with the T/M and steering
integrated as in the D155AX-3, use two units each of controllers and switch boxes to conduct a
test.
■ Connection method for the ■ Connection method for the
T/M for bulldozers/dump trucks/graders T/M for wheel loaders
Controller
Controller
for T/M test
for T/M test
Switch box Switch box
■ Connection method for the power unit for the

D155AX-3: Use two controllers and switch
boxes for the transmission and steering clutch brake.
Controller and
switch box
for transmission
Controller and
switch box for
steering clutch brake
39
For equipment for dynamo test of the exhaust gas regulation
engines dedicated equipment is provided for quick support (1)
■ Dynamo test Tier Ⅰ & Ⅱ & Ⅲ ■

TierⅠ TierⅡ TierⅢ
Engine Engine Fuel Engine Dynamo Fuel Engine Dynamo Fuel Engine Dynamo
displacement model injection test device injection test device injection test device
Ltr Pump controller tool Pump controller tool Pump controller tool
Bosch Cummins Cummins

3.3 ４D95 ーーーーーー CRI CM2150 Tool+1
3.9 ４D107 ーーーーーー
CRI CM850 Tool
5.9 ６D107 ーーーーーー
CRI CM850 Tool
8.3 ６D114 ーーーーーー Cummins Cummins Cummins

HPI CM850 Tool
ーーー Denso Komatsu Komatsu Denso Cummins Cummins

11.0 6D125
CRI Controller Tool CRI CM850 Tool
ーーー Denso Komatsu Komatsu Denso Cummins Cummins

15.2 6D140
CRI Controller Tool CRI CM850 Tool
Komatsu Komatsu Cummins Cummins Cummins Denso Cummins Cummins

23.0 6D170 Komatsu Tool
Controller Tool HPI CM500 Tool CRI CM850
Komatsu Komatsu Denso Cummins Cummins

30.5 12V140 Komatsu ーーー
Controller Tool CRI CM850 Tool
■ TierⅠ Engine dynamo test device ■

The following describes the harness connection method and engine starting method for a
dynamo test of the electronic governor engine of Tier Ⅰ engine.
Throttle box
(Parts No. 799-605-5011)
Throttle box
Rack position voltage

output (connect a tester)
Connecting
harness Engine speed display
（−）（＋）
Battery
SI display
connector is black.
スロットルダイアル
Throttle dial
Engine controller
Power harness Throttle box

（799-605-5040）（799-605-5011） Key switch
■ Equipment required for a dynamo test Loading model

Engine controller Controller
part number connecting harness
of the electronic governor engine ■
PC1100-6 7834-22-6004 799-605-5150
D475A-3 7830-33-3403 799-605-5160
Parts name Part No. Remark
D475A-5 7830-33-3409 799-605-5160
Throttle box 799-605-5011 799-605-5210
Common
HD465A-5 (4625 up to) 7818-52-1003 799-605-5110
Power harness 799-605-5040 among all
models HD465-5 (4625 up to) 7818-52-4001 799-605-5130
Battery
HD785-3 7818-51-1601 799-605-5020
The connecting harness for the model is used HD785-5 7818-52-3001 799-605-5140
for the above.The XEP checker is used for
HD700-1 7823-38-5001 799-605-5120
obtaining various data.
WA700-3 7823-38-6001 799-605-5130
WA800/900-3 7823-38-7001 799-605-5180
799-605-5160
D575A-3 7830-22-3400
799-605-5190
40
■ TierⅠ Engine dynamo test device ■
The XEP checker is used for conducting a performance test of the fuel injection pump of
Komatsu's electronic governor engines.
XEP checker
(Parts No. 799-605-3000)
■ Test description ■
1）The governor command current and rack sensor output voltage values are checked.
From this checker, the command current value for the indicated fuel injection pump supply
current and rack sensor output voltage values is measured.
2）Rack sensor prestroke range check
The command current value to the fuel injection pump from this checker and the oil pressure
are measured.
Weight
No. Part No. Parts name Q'ty
(kg) 1
ー 799-605-3000 Checker Ass y 1 3.9
1 799-605-3010 ・Checker 1 3.7
2 799-605-3020 ・Harness 1 0.2

AC Power
3 ー 1 ー 2
Cable
799-605-4000 AC100V
（50/60Hz）
Input voltage
799-605-3001 AC170 to 264V
（47-440Hz）
Operating temperature range -10 to 50℃
Storage temperature range -20 to 60℃
Dimension 250 210 102ｍｍ
Weight 3.9ｋｇ
■ Function ■
・Governor command current: 0 to 1 A (variable)
Output signal ・ Prestroke control current ： 0 to 1A (variable)
・Rack sensor voltage: 5 VDC (fixed)
・Measures the current across the resistors with the potentiometer.

Signal
measurement
・Measures the rack sensor output current.
・Displays on the 1/2 digit digital display.

Measurement
display method ・The governor command current, prestroke control current, and rack sensor
output voltage can be switched with the select switch and displayed.
41
■TierⅡ Engine dynamo test device ■
Tools used in a dynamo test of the common rail type engine of TierⅡ engines and harness
connection method
Applicable engine SA6D140E-3 , SAA6D140E-3 , SAA6D125E-3
1) Dynamo test KIT

(Parts No.799-607-4001)
No. Part No. Parts name Q'ty Remark
1 799-607-4010 Throttle box 1
2 799-607-4020 Wire harness 1 For type A controller
3 799-607-4030 Power harness 1
4 799-607-4050 Wire harness 1 For type A controller
2) Engine controller
Use type A or type B depending on the engine controller.
Select type A or type D from the model controller part number table below.
Type Applicable model Controller part No.

A HD325-6 7872-10-2304
A WA500-3 7872-10-5205
A PC600-6/PC800-6 7872-10-4105
A D155AX-5 7872-10-3106
A HM400-1/HM350-1 7872-10-2103
D WA470-5 7872-20-5104
D WA480-5 7872-20-5104
D D275AX-5 7872-20-3201
D D65EX-12 7872-20-3301
D PC1800-6 7872-20-4202
42
■TierⅢ Engine dynamo test device ■
Tools used in a dynamo test of the common rail type engine of TierⅢ engines and harness
connection method
We introduce dynamo test equipments that can be used for all TierⅢ Engines
（4D95/6D107/6D1146D125/6D140/6D170）and 12V140-3 Tier2 Engine
■ Required equipment ■
Cummins
No. Part No. Parts name Q'ty part No. Remark
1 795-799-5610 Controller 1 3163890
2 795-799-5650 Harness 1 3164242 Use to all TierⅢ engine and 12V140-3
3 795-799-5660 Wire 1 ー 12V140-3
4 795-799-5670 Harness 1 ー 12V140-3
5 799-601-4410 Harness 1 ー 4D95LE-5
6 795-799-5732 Inline5 1
7 795-799-5720 9 pin Cable 1
8 795-799-5742 Cable 1
１．795-799-5610 ２．795-799-5650 ３．795-799-5660 ４．

795-799-5670
５．799-601-4410 ■ Example of use ■
■ Cummins dedicated tool ■
No. Part No. Parts Name Q'ty
9 3886388 Insite DVD-ROM KIT 1
■ Connection method ■
Engine
1 ECM
2
6，7，
8
Controller
Adapter
Battery PC（Insight）
43
Dedicated equipment for hybrid construction machinery (1)
Capacitor discharging device for hybrid

(Parts No. 796-426-1800)
■ Connection to the main body ■
Capacitor
■ Discharging of hybrid construction machinery■

This device is a tool to discharge the electric charge in the capacitor used in hybrid construc-
tion machinery. High-voltage electric charge is charged in the capacitor. To prevent an electric
shock, damage to the device, and fire due to a short circuit, electric charge in the capacitor
must be discharged before the work (disassembly, repair, etc.) related to machine body service.
Normally, the discharging function of the machine body is used. Use this device if the function
is not working due to failure.
■ Features ■
・This device converts electric charge charged in the capacitor to heat by flowing it through
the internal resistor to consume it.
・Heat generated internally is emitted to the outside by the cooling fan.
・It operates automatically from the start until electric charge is completely discharged. In the
end, the START LED goes off and the device stops.
■ Specifications ■ Operating voltage (ring voltage)
Operating voltage
DC24V 4V
(ring voltage)
Maximum load voltage Max DC400V
Residual voltage after

DC24V 4V
discharging
Outer diameter
dimension （mm） 556（W） 229（D） 519（H）※Protrusions included/cables not included
Weight Approximately 24.5kg（Cable included.）
*1 Operation time varies depending on the capacitor state (temperature, secular charge, etc.).
Caution) No discharging is performed when the capacitor voltage is 30 VDC or lower.
44
Dedicated equipment for hybrid construction machinery (2)
Disassembly/assembly tool for hybrid
1）Engine stand
The engine stand is used to install the generator motor to the 4D107 engine.
■ Engine stand ■
Part No. Part name Q ty
795T-401-1210 Stand 1
795T-401-1220 Plate 1
2）Centering tool
It is used for disassembling and installing the rotor of the generator motor.
The centering tool is used because the gap between the rotor and housing is small (0.6 to 0.8 mm).
■ Centering tool ■
796-410-1000 Guide 1
796-410-1040 Bar 1
796-410-1050 Plate 1
3）Bracket
It is used to maintain the engine position when the engine assembly is installed or removed on
the machine body.
■ Bracket ■
795T-280-1030 Bracket 1
795T-280-1040 Bracket 1
45
Torque multipliers ... Maximum output from minimum
input through planetary reduction gears
Power wrench
(Parts No. Refer to Specifications) ■ Example of use ■
Removal and installation of the

nylon nut of the hydraulic cylinder
■ Features ■
・When tightening parts with a large tight- 1）Insert the socket with the head bolt width dimen-
sion of the bolt or nut to remove/install into the
ening torque, a large output torque can output side of the wrench, insert a lock pin, and
be obtained with asmall input torque. insert an O-ring to prevent removal of the pin.
・Planetary type reduction gears offer 2）Fit it into the head of the bolt/nut.
3）Ensure safety in the place where the normal
compact sizes.
position lever is to be placed.
・These multipliers are supplied in steel 4）Especially use a torque wrench for the final tight-
caseswith their adapters so as to be ening torque check to ensure accuracy of tighten-
transported and sometimes indispens- ing work.
5）When removing the switching clutch, apply force in
ables for large size machines service.
the input direction to remove it smoothly.
A
C
L
B
Max. working A B C D Fixed position

Standard Weight
No. Part No. torque Dimension Dimension Dimension Dimension Reduction lever L
ratio input (kg)
Nm {kgm} Φ(mm) (mm) (mm) (mm) dimension
1,471 Nm 333 Nm
1 790 -102 -1000 80 153 19 25.4 1 : 4.8 194 6.9
(150 kgm) (34 kgm)
4,413 Nm 343 Nm
2 790 -102 -1100 104 215 19 38 1 : 16 300 12.9
(450 kgm) (35 kgm)
5,884 Nm 343 Nm
3 790 -102 -3500 140 225 19 38 1 : 16 370 18.0
(600 kgm) (35 kgm)
11,768 Nm 343 Nm
4 790 -102 -1200 210 255 19 38 1 : 43 515 41.6
(1,200 kgm) (35 kgm)
46
Powerful socket wrench KIT for 12 point bolts
Socket wrench KIT (for 12 point bolts)

(Parts No.79A-212-4201)
Weight：2kg
■ 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 to 24 mm
(bolt diameter 10 to 22mm)
■ Component parts and specifications ■ ■ Applications ■

Used for removal and installation of
twelve-point head bolts.
B
All engines
S B Permissible
No. Part No. Part name Dimension Dimension torque Nm Remarks
（mm） mm(inch) {kgm}
1 ･79A-212-4210 Socket 10 □ 12.7(1/2 ） 10.8
2 ･79A-212-4220 Socket 12 □ 12.7(1/2 ） 18.6
3 ･79A-212-4230 Socket 14 □ 12.7(1/2 ） 29.6
4 ･79A-212-4240 Socket 17 □ 12.7(1/2 ） 43.2
5 ･79A-212-4250 Socket 19 □ 19.1(3/4 ） 61.6
6 ･79A-212-4260 Socket 22 □ 19.1(3/4 ） 89.6
7 ･79A-212-4270 Socket 24 □ 19.1(3/4 ） 114.9
8 ･79A-212-4310 Adapter ー *1 ー
Hexagonal bar
9 ･79A-212-1030 Adapter 17 ーー (withacross flats: 17 mm)
10 ･79A-212-4180 Case ーーー
11 ･79A-212-4291 Packing ーーー
*1 No.8 Adapter 12.7mm(1/2 ）

female、
19.1mm(3/4 ）male
47
Essential special tool for tightening bolts by
angle method Angle tightening wrench
Angle tightening wrench

(Parts No. Refer to Specifications) ■ Example of use ■
■ Features ■
・Snug torque can be set easily with the torque scale for a variety of purposes.
・An angle value can be read from snug torque or can be preset in advance.
・The angle scale plate rotates after snug torque is reached, so the angle scale plate does
not return.
・The standard clip is an alligator clip that can be put on anywhere.
・When the fixing nut of the standard clip is removed, the tip of the flexible tube can be
connected to a commercially available magnet base.
・When the flexible tube is removed, it can be used as a normal torque wrench.
・When the ratchet lever is switched, it can be used for loosening a bolt.
Wrench (angle tightening wrench)

(Parts No. 790-331-1110 , 790-331-1120)
■ Component parts and specifications ■ ■ Locations where tightening by
angle method is adopted ■
Force
application ○ For reference, locations where the bolt is
point
tightened using the plastic range rotation
Total length L
angle method are as follows.
Effective length L
466
Locations where tightening

Model by angle method is adopted
Flexible tube
（ l =600mm） Ratchet lever Model part name
1）Cylinder head bolt
A
Clip
2）Connecting rod bolt *1
a square drive
3）Main cap bolt

Engine
Torque 4）Flywheel bolt
Dimensions
scale
(kgf.m) (mm) Weight Scope
Part No. (bolt size) 5）Crank pulley mounting bolt
(kg)
min ‒ max L L a A
790-331-1120 4 ‒ 28 684 600 19.05 20.5 3.5 M14 up to 6）Idle gear shaft mounting bolt
790-331-1110 6 ‒ 42 948 900 19.05 20.5 4.6 M16 up to 7）Crank journal counterweight
mounting bolt
*For angle tightening, it is difficult to uniformly determine scope because of
varying tightening conditions. Applicable bolt sizes are determined according Hydraulic
Final drive cover bolt
to KES 04･123･1 "Tightening Torque of Bolts" as a guide. Excavator
48
Shop level indicated by the lifting attachment
Guide bolt KIT

4
3
2
1
Weight：1.6kg
■ 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.
No. Part No. Q ty Dia. Pitch Long
1 790-201-3110 3 φ 8 1.25 70
2 790-201-3120 3 φ10 1.5 110
3 790-201-3130 3 φ12 1.75 155
4 790-201-3140 3 φ14 2.0 180
5 790-201-3150 1 ー Case
■ Application ■
1）Used as a guide when press fitting the iron bushing of an idler track roller.
2）Used as a guide for hole alignment of covers.
49
Quality assurance, reducing manhour for removal
and installation of bearing lock nut!
Nut wrench KIT

Lock nut final bearing
Weight:10.0kg
■ 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 improved and the quality can be assured.
・By using a torque wrench at the same time, it is possible to measure the preload.
■ Component parts ■ Nut shape ■

and specifications ■
Application Nut
C
ｗ
Knotch
B
■ Specifications and applicable nuts ■

Used for removing and installing the lock nut of bearing.
Dimension Dimension Dimension

Tool *Square Circular nut Number
No. Part No. Q ty A B C
description drive (mm) part No. (mm)
of claws (mm) (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 19.05 01530-03912 49 6 55 7
4 790-102-1821 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 01530-07614 96 8 104 10
13 790-102-1951 Case 1 ーーーーーー
*12.7 mm = 1/2 in, 19.05 mm = 3/4 in. 25.4 mm = 1 in.

50
The lifting equipment shows the level of the repair shop
Sling chain KIT

(Parts No. 790-402-1001)
■ Features ■
・Chains have 10 to 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 carried, 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 designed to be
hooked directly on a crane.
■ Component parts and specifications ■
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 3.2 ton 3-sling lifting
3 790-402-1301 Sling B 1 Max. working load 5.0 ton
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
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
9 790-103-2110 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
51
Contribution to safety and ease of recoil
spring assembling and disassembling works
Recoil spring disassembly/Assembly tool

11 10 9 3 2
4 6 5 8
22
12 7
spacer
14
17
11 16 18 15
It allows you to work on recoil springs

with strong spring safely and quickly.
Compressor（A）
(Parts No. 790-434-1701 , 791-600-2001)
■ Features ■
7
6 5 4 2 ・This tool allows disassembly and assembly works of
8 3
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.
■ Application ■
Used to compress a spring when disassembling and assembling a recoil spring.
Part No. Dimensions Weight
791-685-8006 1,600
（L） 610
（W） 750
（H）mm 467kg
791-685-8502 2,300
（L） 610
（W） 750
（H）mm 500kg
791-600-2001 1,600
（L）xΦ480 mm 212.6kg
790-434-1701 2,300
（L） 410
（W） 410
（H）mm 235kg
★A hydraulic pump and hydraulic cylinder are required for this tool.
52
Round head wrench for removing hydraulic cylinders
Cylinder round head wrench

It allows you to secure the round head part of a

hydraulic cylinder with a hook part corresponding
to the groove shape for safe operation.
Weight
NO. Part No. Part name Q ty
（kg）
7 8,9,10 1 790-102-2380 Wrench 1 3.8
3,4,5 2 790-102-2390 Wrench 1 1.82
6 3 790-102-2320 Screw 3 0.31

4 790-102-2330 Screw 3 0.32
5 790-102-2350 Screw 3 0.31
6 0582-12419 Nut 3 0.06
7 04020-00820 Pin 1 0.008
8 01010-62065 Bolt 2 0.226
2 1
9 01640-22032 Washer 2 0.028
Weight:6.8kg
10 01582-12016 Nut 2 0.035
Option 790-102-2341 Screw 3 0.29
For wrench assembly hydraulic cylinder

(Parts No. 790-102-2304) ■ Application ■
Used for removing and installing the head
7 9 0 - 1 0 2 - 2 3 2 0 7 9 0 - 102-2330 790-102-2350 790-102-2341
of a round head type work equipment cylinder.
Applicable head outer
1) ∼ φ150mm
diameter
2) Head notch width 9.5mm to 15mm
3) Tooth setting angle 120 to 180
4) Torque wrench drive angle 25.4mm 25.4mm
5) Maximum operating torque 890.7 Nm (100 kgm)
■ 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.
53
Indispensable ones! Power source for
hydraulic cylinders and pullers (1)
Manual/Electric hydraulic pumps

(Parts No. 790-101-1102 Manual)
■ Application ■
It is a pump that apply pressure to a cylinder or pullers. It is
connected to the cylinder or pullers with two hoses. Oil is fed
through one hose and returned through the other. The feeding
and returning hoses can be switched with a lever.
■ Specifications ■ 790-101-1102
Specifications Modified pump

Discharge flow/ 4.6 cc/68.6 MPa（700kg/cm2)
Discharge pressure (at 129 cc/735.50 MPa
(at/stroke) {75 kg/cm²} or less)
Valve type(push, pull) 4-way control valve (push, pull)
Handle operating force 40 N (4.1kg)
Tank capacity 5ℓ
Oil used SAE 10W

Weight 280.47 N {28.6 kg}
Overall length 1,075mm
Overall height 305 mm
Overall width 210 mm
Hose length 2.5 m
Common quick coupler for

hydraulic pump & actuators
(Parts No. 790-101-1190) (Parts No. 790-101-1430)
■ Features ■
Manual hydraulic pump
• This is a manual pump for use in the field, and can be used as a power source for cylin-
ders and pullers.
Electric hydraulic pump
• This pump is lightweight and compact, and is fitted with castors, 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.
54
Indispensable ones! Power source for
hydraulic cylinders and pullers (2)
Electric hydraulic pump

Komatsu's standard quick coupler is used for easy

connection to a hydraulic cylinder or pullers.
■ Features ■
・It can be used easily at sites with 100, 115, and 230 VAC voltage.
・Lightweight, small size, and highly portable with casters
・The remote switch allows operation while checking installation of the jig, tool, and hydraulic
cylinder for safety.
Part No. 790-190-1200 790-190-1300 790-190-1400

Maximum working
68.6MPa(700 kg/cm²)
ressure
Pressure Low pressure 4.1MPa(42 kg/cm²)
High pressure 68.6MPa(700 kg/cm²)
Pressure Flow rate ℓ/min

MPa(kg/cm²) 50Hz 60Hz
0.7 (7) 8.9 10.7
Discharge flow rate
6.9 (70) 1.1 1.3
34.3 (350) 0.9 1.1
68.6 (700) 0.8 0.9
Tank capacity 7.6 ℓ

AC single phase AC single phase AC single phase
Motor
100 V,830 W, 50/60Hz 115 V,830 W, 50/60Hz 230 V,830 W, 50/60Hz
AC single phase AC single phase
AC single phase
Power supply 125 V, 20 A 250 V, 15 A
125 V, 30 A
with ground wire with ground wire
Weight 40kg
Size （mm） 305

（W）x 430
（L）x 550
（H）
55
Speed up track link pin removal and
installation operations (Type A)
Tool for disassembling and assembling track-shoe master pin

(Parts No. 791-615-7001 , 791-620-7000)
3 ■ Application ■
4
Use the tool for pulling out and press fitting of the
8
track-shoe master pin.
9
6 7
■ Tool for common use ■
5
790-101-1102 Pump 1 set

2
1 790-105-1100 Cylinder（294kN 30t) 1 piece
■ Part No. and applicable model ■
D20, 21-5, 6, 7, 8, D21-8E0, D30, 31-15, 16, D37A-2,

CD35-1, CD35C-1, PC38UU-1, D31-17, 18, 20, D37P-2A,
Applicable PC40-6, 7, 7, D37-6
model PC45-1, PC58UU-3, 5, PC40, PC80, 90-1, PC80(LC)-3,
45R-8, PC60, 60L, U-1, 2, 3, 5, PC100N-6, PC100,
No. Part No. Part PC75UU-1, 2, 120-1, 2, 3, 6 Weight
name BC100-1, PC60-6, 7, BR100JG-2, PC100D-3, PC100L-6, (kg)
All models
PC70-7, PC50UU-1, 2, PC58SF-1, PC130-6, PC128US-2
PC78US, UU-6
Part No.
for set 791-615-7001 791-620-7000
1 791-615-7110 Head 1 1 1 5.1
2 791-615-7120 Plate 1 1 1 4.9
3 791-615-7130 Rod 2 2 2 1.9
4 01580-12218 Nut 2 2 2 0.1
5 791-615-7140 Pusher 1 1 1 0.8
6 791-615-7150 Adapter 1 1 0.7
7 791-620-7150 Adapter 1 1 1 0.7
8 791-615-7161 Pin pusher 1 1 0.5
791-620-3260 Pin pusher 1 1 0.9
9 791-615-7170 Guide 1 1 0.5
791-620-3270 Guide 1 1 0.8
Operating Instructions B A
56
installation operations (TypeB・C)
Type B
(Parts No. 791-616-1001)
13 14 5 2 11 12 4 3 1 ■ Application ■
Use the tool for pulling out and press fitting of the
track-shoe master pin.
7
9
10
790-101-1102 Pump 1 set

6 8
7 7 8 10 9 9 10 9
790-105-1100 Cylinder（294kN 30t) 1piece
Rib ■ Specifications ■
Maximum capacity 287 kN (29.3 ton)
1) Hydraulic cylinder Maximum pressure 68.6 MPa (700 kg/cm2)

NO rib With rib
Stroke 209 mm
2) Shoe width Maximum 750 mm
3) Master pin diameter Maximum 38 mm

■ Features ■
・Can be used with a ribbed link.
・The master pin can be dismounted and mounted without removing the shoe.
・It stands astride the shoe and positioning is possible even if the link has a rib.
・Can be used even if a shoe with a maximum width of 750mm is mounted.
Type C
Tool for disassembling and assembling dry-type track-shoe master pin
(Parts No. 791-620-3000)
9 22
17 ■ Application ■
12
Use the tool for pulling out and press fitting of the track-shoe
21
2 14
11
master pin and straight pin.
3
4 23 ■ Tool for common use ■
13
15
19
8
16 9
10
790-101-1102 Pump 1 set
24
790-105-1300 Cylinder
（980kN 100t) 1 piece
6 5 1 8
Tool for disassembling and assembling oil lubrication type track-shoe master pin
(Parts No. 791-620-3500)
9 10 ■ Application ■
8
7 Use the tool for pulling out
and press fitting of the oil
6
lubrication type track-shoe
pin and straight pin and for
2
link assembly.
100t cylineder
3 4 1 5 11 12
57
installation operations (TypeD・E)
Type D
(Parts No. 791-675-9500)
3
20 21 22
4
6 5 17
1
14 16 15 2 24
23 25
7 8 9 18 11
13
10
19 12
■ Application ■
Use the tool for disassembly and assembly of the link of the master pin portion.
790-101-1102 Pump 1 set
790-101-4300 Cylinder（147kN 150t) 1 piece
790-101-4200 Cylinder（294kN 30t) 1 piece
Master pin
Type E
(Parts No. 791-832-1200 , 791-832-1500)
Link Pin
58
installation operations
■ Tool No.and applicable model ■
Tool type Tool No. Applicable model
Type A 791-615-7001 D20, 21-5, 6, 7, 8, D21-8E0, CD35-1, CD35C-1, PC38UU-1,

PC40-6, 7, 7, PC45-1, PC58UU-3, 5, PC40, 45R-8,
PC60, 60L, U-1, 2, 3, 5, PC75UU-1, 2, BC100-1, PC60-6, 7, BR100JG-2, PC70-7,
PC50UU-1, 2, PC58SF-1, PC78US, UU-6
791-620-7000 D30, 31-15, 16, D37A-2, D31-17, 18, 20, D37P-2A, D37-6
PC80, 90-1, PC80(LC)-3, PC100N-6, PC100, 120-1, 2, 3, 6
PC100D-3, PC100L-6, PC130-6, PC128US-2
Type B 791-616-1001 PC20-3, 6, PC30-3, 5, 6

791-616-1020 PC38UU-1, PC30-3, 5, 6, PC40-5, 6, PC40R, 45R-8,
PC58SF-1, PC58UU-3, BR100JG-2
791-616-1030 PC60-6, PC60, 70-7, PC75UU-1, 3,
PC78US-5, PC78US, UU-6, BR120T-1
791-616-1060 D20, 21-5, 6
791-616-1040 PC80-3, PC90-1, PC100, 120-3, 5, 6

PC120-6Z, PC128UU-1, 2, D31-17, 18, D37-2, BZ210-1
Type C 791-620-3000 D31-18, 20, 21, D37A-2, P-2A, D37-5, 21, PC100, 120-3, 5
PC100D-3, CD40-1, PF3-1
(For dry type
track ) 791-630-3200 D41A, E, P-6, D39-21
791-630-3000 D40, 45-1, D57-1, CD60-1, BP500-1, BR480RG-1, PC100(L, U)-3

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, PC400(LC)-3, PC400-5, 6-7
791-650-3000 D75-2, 3, D85-21, PC400-1, 7
791-665-3000 D95-1, 2
Type C 791-620-3500 D31-8, 20, D37-5, D37A-2, D37P-2A, D31, 37-21

(For lubricated 791-630-3500 D40, 45-1
type track )
791-645-3500 D60, 65-8, 12, 15, D85ESS-2, 2A, D66S-1, D70LE-12
791-650-3500 D75-5, D95-2, D80, 85-21
Type D 791-675-9500 D135A-2, D150, 155A-1

791-680-9501 PC650-1, 3, 5, PC750, 800-6, D355A-3#9001 and up
796-832-1100 PC100-6, PC1250-7
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
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
Type E 791-832-1200 D575A-2, 2E
791-832-1500 D475A-2, 3
791-832-1600
59
Hydraulic pushing and pulling power, 30 to 200 tons
(using with the former pumps)!
Hydraulic cylinder and puller (For press fitting and pulling out)
(Parts No. refer to specifications) ■ Example of use ■
■ 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.
Parts No. 790- 790- 790- 790- 790- 790-
Item 105-1100 101-1300 101-1600 101-4000 101-4300 101-4500
Maximum 29.3 t / 100 t / 70 t / 50.9 t / 158.8 t / 209.1 t /
capacity Push
700 kg/cm2 700 kg/cm2 700 kg/cm2 700 kg/cm2 700 kg/cm2 700 kg/cm2
/
Maximum 15.1 t / 85 t / 50 t / 132. t / 159.4 t /
Pull ー
operating pressure 700 kg/cm2 700 kg/cm2 700 kg/cm2 700 kg/cm2 700 kg/cm2
Stroke 209 mm 152 mm 152 mm 50 mm 350 mm 200 mm
Weight 19.5 kg 52 kg 31 kg 13.5 kg 148 kg 134 kg
Overall length 372 mm 431 mm 353 mm 128.6 mm 717 mm 589 mm
Cylinder O.D. φ100 φ160 φ128 φ139 φ216 φ245
■ Oil used ■ Hydraulic puller

ｰ10℃ to 40℃ （Type B）
For ordinary-climate IDEMITSU 57T Hydraulic puller
region (or SAE #10 or its equivalent) （Type A）
For cold region ｰ40℃ to 10℃
IDEMITSU AV oil
Oil level 0.2ℓ
D
D
L L
■ Specifications ■
Cylinder outside
Maximum Weight diameter x width
Type Part No. Capacity Stroke
pressure (including oil)
ΦL D
Type A 790-101-2102 30 ton (pushes) 50.8 mm 6.3 kg φ１05㎜ 122.0ｍｍ
790-101-3800 50 ton (pushes) φ１39㎜ 87.4ｍｍ
700 kg/cm2 13.8 mm ―
Type B 790-101-4200 30 ton (pushes) φ１19㎜ 90.8ｍｍ
80 ton (pushes)
790-314-1000 15.0mm 17kg φ１19㎜ 87.4ｍｍ
53 ton (pulls)
60
Repair stand improves working efficiency and safety!
Component repair Stand (Torque converters, PPMs, deferential gears, etc.)

■ Example for mounting of

a torque converter ■
■ Application ■
The following features are provided for ease of
disassembly and assembly of individual units on a
reversal stand for various units such as an engine,
torque converter, transmission and differential gear
by changing the attachment.
■ Features ■
・ Using a motor with a brake and speed reducer, stopping at an arbitrary rotation angle
position and forward and reverse rotation can be achieved safely and simply by operating
a pushbutton switch.
・ The rotating head can be raised or lowered by operating a hydraulic jack and the height of
a unit of a varying shape and size can be changed in accordance with its height to allow
safe and efficient work.
・ A pan is provided on the top face of the rotating head allowing it to be used conveniently
as a rest for placing disassembled parts, tools and the like.
・ A wheel is provided and it can be moved easily on a flat road.
・ It is powered by the general single-phase 100V power supply by simply plugging it to a
plug socket in the plant.
Part No. 790-501-5000 790-501-5200
1）Dimensions (L W H) 1,130 1,410 1,585 1,130 1,410 1,585 (mm)
2）Weight 295 kg 295 kg
3）Rotating shaft permissible 8,826 Nm ( 900 kgm) 8,826 Nm ( 900 kgm)

moment
4）Maximum axial torque 1,079 Nm (110 kgm) 1,079 Nm ( 110 kgm)
5）Drive source AC 100V electric motor AC 120 V electric motor・AC 220V electric motor
※Use single-phase AC 110V or 220V as necessary.

61
Reduce time when disassembling or assembling
the engine! (1)
Engine repair stand

■ Application ■
Can be used for disassembly and assembly of an engine from a small engine to a large
engine by changing the attachment on the reversal stand dedicated for engine use.
■ Features ■
・Unlike the ordinary vertical rotation type, the reversing mechanism is of a horizontal rotation
type (see Operating Instructions ) and the total height is low, causing no unnatural work
attitude and assuring safe and efficient work. An excellent workability is assured especially
in dismounting and mounting the piston as a height difference is not caused in the liner posi-
tion.
・A hydraulic cylinder is used in reverse rotation of the engine featuring no work burden to the
worker and speedy reverse rotation.
・The power unit is provided with an air-driven hydraulic pump and motive power can be
obtained from air supply pipe in the plant.
1）Dimensions (L W H) 1,055 1,200 1,300 （mm）
2）Weight 500 kg
3）Rotating shaft permissible 13,729 Nm（1,400 kgm）

moment
4）Drive source Air (0.29 to 0.69 Mpa（3 to 7 kg/cm2）
Air-driven hydraulic pump 68.6 MPa（700 kgm/cm2）used

Use a motor-operated pump or an air driven pump in the 68.6MPa
(700kg/cm2) series sold on the market for 790-501-300.
62
Reduce time when disassembling or assembling
the engine! (2)
Attachments for the engine repair stand

■ Features ■
・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.
■ Application ■ ■ Example of use ■

Can be used for disassembly and assembly of an
engine from a small engine to a large engine by
changing the attachment on the reversal stand
dedicated for engine use.
1) Service capacity 5,400 kg
2) Rotating shaft permissible 26,478 Nm ( 2,700 kgm)

moment
3) Turning angle 90
4) Revolving speed 0.83 rpm/50 Hz
5) Power source Motor, 2.2 kw, 3 phase
6) Dimensions (L W H) 4,380 1,570 1,320 (mm)
7) Weight 1,700 kg
■ Attachments for the ■ Operating Instructions

engine repair stand ■ (Engine Reverse Operation Method)■
Engine repair stand
1)Engine Installation
（790-501-4000） Mount a suitable attachment onto the engine
2 4 6
9,10 and set the engine in that condition on the stand.
2)Turning over onto its side
9,12
1 3 5 7
8,11
63
Reduce manhours and make sure high tightening
nut torque of rebuilding hydraulic cylinders (1)
Hydraulic cylinder repair stand

(Parts No. 790-502-1003)) ■ Example of use ■
■ Application ■
3
2D
For use in disassembly of various hydraulic cylinders
4 2
1
including dismounting and mounting of a nylon nut.
2A,2B,2C
1A
1D 2A,2B,2C
1C 1B
■ Features ■
○Wrench Ass y
・ Driving Method
45 -feed rotation is achieved by a cranking method by means of hook meshing using a
hydraulic cylinder of 68.6MPa (700kg/cm2) and 294kN (30tons). If the torque is small,
it can be driven directly by an adapter using a 3/4 drive angle.
・ Drive shaft
Can be used by selecting one of the three drive angles in accordance with the required
torque.
・ Hydraulic cylinder
The hydraulic cylinder can be rotated in reverse by removing the hook at tip of it.
○Frame Ass y
・ Can be set to a cylinder piston rod length of 3,060mm maximum and to a cylinder
outside diameter of 364mm maximum.
○Vice Ass y
・ Reaction is held down vertically so that a torque of 39,227Nm (4,000kgm) is reliably
transmitted to the frame.
○Cart Ass y
・ The cart Ass y is rugged and can make fine adjustment vertically to withstand disas-
sembly and assembly of a large cylinder.
・ Use a holder small (790-445-3040) when supporting a cylinder and piston rod 155mm
or less in diameter.
64
Reduce manhours and make sure high tightening
nut torque of rebuilding hydraulic cylinders (2)
Specifications Modified pump
1） Dimensions (L W H) 3,750 900 1,790 （mm）

2） Weight 662 kg
3） Maximum drive torque 39,227 Nm（4,000 kgm）
4） Drive cylinder
Maximum capacity 294 kN（30 ton）
Maximum operating pressure 68.6 MPa（700 kg/cm2）
Maximum stroke 180 mm
■ Applicable cylinder size ■

・ A cylinder with a round head less than 2,880mm in distance between the bottom bin and rod pin.
・ Dismounting and mounting of a nylon nut less than 3,060mm in rod length.
・ Cylinder outside diameter.
364mm or less when a cart and vice are used.
No. Part No. Part name Q ty Remarks

1 790-445-3500 Frame Ass y 1
1A 790-445-3520 ・Frame 1
1B 790-445-2700 ・Frame 1
1C 790-445-2710 ・Frame 1
1D 790-445-2720 ・Oil pan 1
1 Hydraulic cylinder 294 kN（30 ton）
2 790-445-3301 Wrench Ass y 68.6 MPa（700 kg/cm2）
2A 790-502-1220 ・Drive shaft 1 3-1/2
2B 790-502-1230 ・Drive shaft 1 2-1/2
2C 790-502-1240 ・Drive shaft 1 1-1/2
2D 790-445-2841 ・Gauge 1
3 790-502-1702 Vice Ass y 1
4 790-445-3001 Cart Ass y 1
5 790-502-1280 Sim 1 20 140 mm
6 790-502-1290 Sim 1 40 140 mm
7 790-445-2770 Sim 1 70 200 mm
8 790-502-1270 Chain 1 Length 1.5m
■ Tool for common use ■ ■ Option ■
790-101-1102 Pump (Operates the drive cylinder) 790-445-2871 Blanket （1）

790-105-1300 Cylinder（980kN 100t） 790-445-3590 Pin （2）
■ Application ■
Mounted on the wrench Ass y (790-445-3301) when the power wrench is mounted on the
cylinder repair stand.
65
Improved efficiency of engine oil replacement operation
■ Eco-drain valve ■
An example of installation An example of installation
for the PC200-7 (Standard type) for the PC800-6 (Elbow 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.
■ Part number and major dimensions ■

Thread
Type Part No. M P M P
dimension
795-999-1810 M12 1.5
07705-01100 M16 1.5
795-999-1210 M18 1.5
795-999-1110 M18 1.5
Standard 795-999-1410 M20 1.5
type Elbow type
07705-01200 M22 1.5
6738-21-5610 M22 1.5 Standard type
07705-01400 M24 1.5
795-999-1610 M24 2.0 M P
07705-11100 M16 1.5 ※Nut
Elbow 07705-11200 M22 1.5

type
07705-11300 M22 1.5
07705-11400 M24 1.5
07705-21100 M16 1.5
Short type
795-999-1310 M20 1.5
Short 07705-21200 M22 1.5
type 07705-21300 M22 1.5 Large type
※Can set position of
07705-21400 M24 1.5 open / close lever.
795-999-1510 M24 2.0
Large type 21T-01-31940 M36 1.5
66
Brake release pump for emergency escape
Brake release pump

(Parts No. 790-190-1500 , 790-190-1601) ■ Connection of the pump assembly ■
Model Part No.
D31、
D37、D39EX、PX-21/22 790-190-1500
D275AX-5、
D375A-5/5E0 and others 790-190-1601
■ Application ■
・ To tow the machine to other location when the parking brake of the travel motor cannot be
released, do the following.
・ To release the brake, connect the dedicated pump assembly to the towed machine and use oil
pressure of the pump.
■ Emergency escape in case of power line failure ■
0
1/ 9EX
0
15
5E
5E
16
1E
6
0 PX-
-5/
-5/
-5/
5/
5/
X-2 /3
Model
22
5
/1 1EX/
X-1
X-1
/P 1/37
/5 75A-
AX
AX
AX
55
75
75
5E
5E
5E
E0
D4
D3
D6
D6
D8
D1
D2
D2
Part No. Part name
799-190-1500 Pump Ass'y ○

799-190-1601 Pump Ass'y ○ ○ ○ ○ ○ ○ ○
19M-06-32820 Switch Ass'y ○ ○ ○ ○ ○ ○ ○
799-101-5220 Nipple ○ ○ ○
07002-11023 O-ring ○ ○
7824-66-6430 Resistor ○ ○ ○
134-06-72810 Resistor ○
17M-06-41530 Wirering harness ○ ○ ○
17A-06-41410 Wirering harness ○
195-06-71220 Wirering harness ○ ○

144-865-6260 Elbow ○
7824-66-6430 Redundant resistor ○
7827-10-1520 Redundant resistor ○
67
Suitable for streamlining of pressure pick-up work of PM
clinic operation
Quick coupler for oil pressure measurement
CEJN quick coupler CEJN quick coupler CEJN quick coupler

（PS 1/4 female) （PT 1/4 male) （10 1.25 male)
CEJN quick coupler CEJN quick coupler CEJN quick coupler

（14 1.5 male) （10 1.25 male) （12 1.5 male)
CEJN（ PS 1/4) CEJN （elbow PS 1/4 female) CEJN（ Both male)

1 2
Thread（PT 3/8 male) SYM Part name Remarks

(Parts No. 799-101-5280)
1 Nipple CEJN make 10-315-5104
2 Nipple CEJN make 70-358-6154

68
Introduction of the lubrication unit with fuel filter
Oil feeder with filter

(Parts No. 79A-110-1300)
■ Development concept ■
・Komatsu genuine fuel filter that can be obtained anywhere with
guaranteed filtration accuracy is used.
・Compact portable type.
■ Features ■
・For small and medium-sized machines for which drum lubrication
is often used
・Pressure gauge is provided for detecting clogging.
・Gun type lubrication nozzle is used (oil feed and stop can be done
at hand).
・When oil feed is stopped at hand, the relief valve operates to
protect the pump.
・Pump protection strainer with a check valve with lock function is
installed at the inlet port.
・Electric cables and hoses are arranged neatly.
Oil used Light oil

■ Unit Part no. and specifications ■ ■ Clogging test ■
Dust used ISO A2
DC 24V A rough guide Light oil amount 24 liters
Power supply voltage Gauge differential
for clogging
（12V can be supported.） pressure（Kg/ｃｍ2） Oil temperature 38℃
Working power 264W 0.8
0.6
Pump type Base pump 0.4
Discharge flow rate 38 ℓ/min 0.2
0
Weight 21 kg 0 200 400 600 800 1000
Input amount (ｇｒ)
Hose length in 3m out 3m 40
Power cord 4m 30
Combustion filter 600-311-7132 20
Hughes
（15A） 10
Safety device
Relief valve 0
0 200 400 600 800 1000
Flow rate
・It works well for fueling lease machines. （L/min） Input amount (ｇｒ)
・Very effective for flushing in the fuel tank. ※Pressure and flow rate vary depending on the viscosity.
■ Cleanliness improvement effect ■

Filtration efficiency Single pass test
（Komatsu genuine 600-311-7132）
(%) < Dust used : ISO A2 >
100
80
60
Flow rate 1.9ℓ/min
40 Flow rate 3.6ℓ/min
0
0 2 4 6 8 10 12 14 16 18 20
Dust particle size
（μm）
69
Introduction of the vacuum pump Ass y
(negative pressure generator)
Vacuum pump
(negative pressure generator)
(Parts No. 799-410-1100） ■ Specifications ■
No. Item Specifications
1 Appearance : L W H 270 180 160 mm
2 Weight 2.0 kg
3 Input DC12V 0.75A
4 Intake amount 8.0 ℓ/ｍin
5 Negative pressure reached -40 KPa

(setting pressure)
6 Operating temperature range 0℃ to 45℃
7 Protection device Overvoltage protection
■ Features ■
・No man-hour for removing hydraulic oil from the hydraulic oil tank.
・No man-hour for preparing and cleaning a container for temporarily storing hydraulic oil.
・No cleaning of trickling when removing and filling hydraulic oil.
・No intrusion of contaminants during removal, storage, and filling of hydraulic oil.
・No environment contamination associated with trickling during removal and filling of hydraulic
oil.
■ Components and supply unit ■
1
No. Part No. Part name Remarks
3 1 Case Ass y 799-410-1110
2 2 Pump Ass y 799-410-1120
6
3 Filter Ass y 799-410-1130 1 set
5 4 4 Gauge Ass y 799-410-1140
5 Switch Ass y 799-410-1150
6 Code Ass y 799-410-1160
・Air hose length: 1.5 m, electric cord length: 4.0 m
■ Setup procedure ■
1)Power supply connection 2)Connect the gauge Ass y to the tank oilhole.
3)Turn on the switch.

※Maximum negative pressure
：-40MPa
4)Part removal at repair locations
※Minimum negative pressure after part removal
：-20KPa
Ａ ON/OFF Switch
Ｂ Hughes（５A）
Ａ
ＢＣ Regulator（Negative pressure adjustment：-20 to -40 Pa）
Ｃ
70
Oil lubrication and seal leak check of the oil
lubricated track shoe is performed
Pump for oil lubricated track shoe

(vacuum/hydraulic pump)
(Parts No. 791-601-1000） ■ Example of use - Oil filling work ■
It is used for oil lubrication and seal leak check during a
rebuild of the oil lubricated track shoe.
Used for replenishing oil of the oil lubricated track shoe.
※For details, refer to the Operation Manual.
■ Application ■
Dimensions 750mm（L） 450mm（W）840mm（H）
Weight 35kg
No. Part No. Part name Q ty
1 791-601-1100 Pump unit 1

2 791-601-1301 Nozzle Ass y 1
3 791-601-1600 Seal checker Ass y 1
4 791-601-1900 Cart Ass y 1

5 790-701-3600 Adapter 1
71
Inspection and filling of suspension tool N2 gas and oil
Suspension tool Oil & N2 gas filling

(Parts No.792-610-1000) (Part No.792-610-1101 , 792-610-1200)
N2 Gas filling device

(Parts No.792-610-1200) ■ Example of use ■
Oil filling pump

(Parts No.792-610-1101)
■ Features ■
・ Used for filling N2 gas to accumulators such as the
suspension cylinder, motor scraper, and hydraulic
excavator of a dump truck.
・ The filling line of 792-610-1200 can be divided into
two independent lines. As a result, the left and right
suspension cylinders can be adjusted simultaneously.
■ Application ■
The suspension gas filling diagram for a dump truck is
shown.
72
Required for gas pressure inspection
and filling of accumulators
Gas pressure inspection and filling for accumulators

(Parts No.792-610-1702)
All models using (N2) gas filling accumulators Extender
■ Operating Instructions ■
For some models, (N2) gas is filled to the accu-
mulator. There are two sizes of connectors
(5/8-18 UNF and TV8). When connecting the ■ 792-610-2190 JOINT ■
charging tool to the accumulator with 5/8-18 Used to perform gas pressure inspection
UNF thread, remove the TV8 connector from and filling of an accumulator by using the
the charging tool connector. 792-610-1200 suspension tool.
■ Major component parts ■ ■ Application ■
No. Part No. Part name Used to fill (N2) gas to an accumulator.
1 792-610-1702 Ass y ■ Optional part ■

2 792-610-1931 ・Hose
Part No. Part name Q ty Remarks
3 792-610-1260 ・Joint For U. S. S. R
792-610-1310 Nipple 1
: GOST
4 792-610-2310 ・Extender
For U. S. A
792-610-1320 Nipple 1
5 07000-11009 ・O-ring : CGA No. 351
For U. S. A
792-610-1700 792-610-1330 Nipple 1
Q ty : ASAB-571-1965
（Hydraulic excavator）
For Germany
1) Valve with gauge (150 kg/cm2) 1 792-610-1350 Nipple 1 : DIN 477-1963
: NEN 3268-1966
2) Hose（1.5 m） 1 : SIS-SMS 2235/2238
For U. K
★The 792-610-2190 adapter is required for 792-610-1360 Nipple 1
the accumulator of the hydraulic excavator. : BS 341 part 1-1962
73
Required for heating heat shrink tubes
Heat gun for heating heat shrink tubes

(Part No.79A-106-1000)
■ Features ■
・It was jointly developed by Komatsu, heater manufacturer, and
heat shrink tube manufacturer for heating of heat shrink tubes.
■ Major specifications ■
Hot air temperature 150 to 300℃
Flow rate ３ to 4.4 ℓ/min(Varies depending on voltage)
■ Application examples Gas filling amount Butane gas 16g（80 minutes continuous at Max)*1
for products ■ Battery life 20 to 30H(AA battery X 4 -sold separately-)
Specification ambient 10 to 35℃（For restrictions of gas aerification)*2
temperature
Dimension and weight 260 210mm/325g
Marking ES-1、ES-2(Marking on tube)
*1 A commercially available gas cartridge for gas lighters can be used, but there is a risk
of clogging. One from the manufacturer is recommended.
*2 Gas aerification is insufficient at low temperature. Use of an industrial dryer is
recommended at low temperature (some types allow setting of heating temperature).
■ KES standard for heat shrink tubes ■

In D08046, the 4 sizes in the figure below are specified. The
items corresponding to the nominal codes "01" and "02" are
provided this time.
KES nominal codes 01 02 03
Before shrinkage D 5.72 7.44 10.85
Part heating the heat shrink tube
(reflector) d 1.27 1.65 2.41
Heating with hot air After shrinkage w (Min) 1.20 1.52 1.91
rather than fire
w1 0.56 0.76 1.02
Marking ES-1 ES-2 ES-3
Electric cable allowance (mm2) 1.3 to 15 3.5 to 22 5.0 to 45
Indicated by a value of
dimension code L in 5 mm
Length (mm) units.
20
Example :
(Minimum
"08046-00140" when the L
length)
dimension is 40 mm and
nominal number is 01
Sleeve D08018 ← ←
Adaptable parts D08030 ← ←

Terminals
D08031
Operating temperature range -40℃ to 130℃

＊Take measures so that adhesive does not flow onto
the terminal bearing surface.
Before shrinkage After complete
shrinkage W W1
D ｄ
W
W1
D ：Tube inner diameter before shrinkage

ｄ：Tube inner diameter after shrinkage
W ：Thickness after tube shrinkage
W1：Thickness after adhesion layer contraction
74
Introduction of the hub nut retightening tool
Hub nut retightening tool for HD rear wheel flange type

(Parts No.792-622-1211 , 792-622-1221 , 792-622-1231)
The tires of the dump truck have been changed to the flange type for easy replacement.
As a result, the item "wheel hub nut inspection and retightening" has been added to the
startup inspection items.
The tool required for retightening of the hub nut toward the back of the rear double tire
has been developed, which is introduced below.
The hub nut size is M33 1.5 with bolt width of 46 mm for all models.
(Tightening torque ： 1519 to 1852 Nm)
■ Retightening tool ■
Insert the tool from the gap of the hub of the outer tire and retighten the nut in the back.
Hub nut
Socket Extension
■ Tool part number and Applicable mode ■
Parts name Part No. Applicable mode
792-622-1211
HD465 / 605 / 785-7
(Total length：1,050ｍｍ）
Extension
792-622-1221
HD255-5 / 325 / 405-7
(Total length：555ｍｍ）
Socket 792-622-1231 Common among all models

75
Profitable nut and bolt KIT for field service
Nut and bolt KIT

(Parts No.09941-00000)
■ 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
For tightening electrical
2 ・ Bolt 01010-30820 10
components.
3 ・ Bolt 01010-30825 10 (These are contained in the same box)
4 ・ Bolt 01010-30830 10
5 ・ Bolt 01010-30835 10
6 ・ Bolt 01010-31020 10
For tightening outer fittings.
7 ・ Bolt 01010-31025 10
(There are contained in the same box)
8 ・ Bolt 01010-31030 20
9 ・ Bolt 01010-31035 20
10 ・ Bolt 01010-31220 5
11 ・ Bolt 01010-31225 10 For tightening outer fittings.
12 ・ Bolt 01010-31230 10 (There are contained in the same box)
13 ・ Bolt 01010-31240 5
14 ・ Bolt 01010-31430 2
15 ・ Bolt 01010-31435 2 For tightening outer fittings.
17 ・ Bolt 01010-31640 2
18 ・ Bolt 07372-00830 10
19 ・ Bolt 07372-01030 10 For hydraulic hoses, split flange, etc.
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, spring 01602-01236 30
29 ・ Washer, spring 01602-01030 25
30 ・ Washer, spring 01602-00825 20
31 ・ Washer, flat 01643-31645 5
32 ・ Washer, flat 01643-31445 10
33 ・ Washer, flat 01643-31232 20
34 ・ Washer, flat 01643-31032 20
35 ・ Washer, spring 01602-01422 10
36 ・ Washer, spring 01602-01648 5
37 ・ Case 09941-00090 1
76
Wiring harness connector repair KIT to meet needs of
electronic technology epoch
Connector repair KIT

(Parts No.790-222-2001) ■ Example of use ■
■ Features ■
・ Komatsu products are innovated by electronic technology and lots of electronic devices and
harness 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.
No.
201
200
art
)
2-2
2-2
(kg
yP
Outline
-22
-22
tN
Ass
Part No. Part name

(main uses, structure)
ion
790
790
igh
Opt
We
KIT 1 KIT 2
*1 *2
Three types of crimping tools and a bag to hold
16.67 them (For crimping and stripping covers from
790-222-2100 Repair kit-tool 1 1 ー
{1.7} electric wiring)
Plug type connectors (KES parts), terminals for
Repair 9.81
790-222-2800 1 1 ー DLI connectors, bodies, drawing tools, and
kit-connector {1.0} plastic storage case.
Terminals for CN (KES parts, lock type) connec-
Repair 10.30 tors, bodies, drawing tools, and plastics storage
790-222-3100 1 1 ー
kit-connector {1.05} case.
Round terminals (crimping terminals held by
22.56 screws, 28 types, applicable wire: 0.5 to 15), and
79A-222-2200 Repair 1 1 ー
kit-connector {2.3} plastic storage case.
Terminals for Econoseal (KES parts) connectors,
12.75 bodies,inserting, drawing tools, and plastic
790-222-3000 Repair 1 1 ー
kit-connector {1.3} storage case.
Repair 11.77 Terminals for MIC connectors, bodies, drawing

790-222-2600 1 1 ー
kit-connector {1.2} tools, and plastic storage case.
Crimping connectors with insulation covers (3

Repair 11.08
790-222-3200 1 1 ー types), clamp bands, vinyl tape, and plastic
kit-connector {1.13} storage case.
New X (made by Yazaki), 040 (made by AMP)
Repair 15.20 housings used
790-222-3300 ー 1 ー
kit-connector {1.55} on new models, terminals with cable, metal-
plated MIC terminals, and plastic sotrage case.
21.57 Carrying case for holding above kits 1 ‒ 8 (any 4
790-299-1100 Case (OP) （2）（2） 1
{2.2} kits in one case) (W485 D345 H133 mm)
*1 The new Kit 2 consists of the present Kit 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 Kit 1 or Set 2.
77
Introduction of addition of the repair connector
and connector supply part number (KES part number)
The connector repair kit has been introduced in Service Mate SMP-396 to improve wire
harness repair part number and achieve easier part acquisition. As requested from sales
service information, the repair connector is additionally specified, which is introduced here.
Supply of the KES connector parts has been introduced in Service Mate SMP-521, but it is
also introduced here.
X,SWP-type connector repair KIT M,S-type connector repair KIT

(Parts No.790-222-3500） (Parts No.790-222-3600）
⑱
①∼④
①∼③ ⑰
④∼⑥ ⑤∼⑧
⑦∼⑨ ⑨∼⑫
⑯ ⑬∼⑯
⑰
Rear holder for X,SWP
(Supplied as attached to the connector)
⑩∼⑬
Note : In the photo, the No.14 and 15 blind plugs and Note: In the photo, the No.18 Operation Manual is omitted.
No.18 Operation Manual are omitted.
No. Name Q ty No. Name Q ty

1 X1-pole connector (male, female) 2 each 1 M connector for terminals (female) 50
2 X2-pole connector (male, female) 2 each 2 M connector for terminals (male) 50
3 X3-pole connector (male, female) 2 each 3 M1-pole connector (male, female) 2 each
4 X4-pole connector (male, female) 2 each 4 M2-pole connector (male, female) 2 each
5 SWP6-pole connector (male, female) 2 each 5 M3-pole connector (male, female) 2 each
9 SWP16-pole connector (male, female) 1 each 9 S connector for terminals (female) 50
10 Electric cable with terminals (X, male) 10 10 S connector for terminals (male) 50
11 Electric cable with terminals (X, female) 10 11 S8-pole connector (male, female) 2 each
12 Electric cable with terminals (SWP, male) 10 12 S10-pole connector (male, female) 2 each
13 Electric cable with terminals (SWP, female) 10 13 S12-pole connector (male, female)(White) 1 each
14 Blind plug (for X connector) 10 14 S12-pole connector (male, female)(Blue) 1 each
15 Blind plug (for SWP connector) 10 15 S12-pole connector (male, female)(White) 1 each
16 Terminal pulling tool (3 types) 1 each 16 S12-pole connector (male, female)(Blue) 1 each
17 Housing case 1 17 Terminal pulling tool (2 types) 1
18 Operation Manual 1 18 Housing case 1
19 Operation Manual 1
■ Other ■
1)The case incorporating connectors is supplied in the part number 790-222-2590. Similar products are commercially
available at electronic parts shops .
2)The terminal pulling tool in the repair kit can be purchased alone.
Applicable connector
Pulling tool Repair kit component
X Type SWP Type M Type S Type
part number
799-222-3500 799-222-3600 female male female male female male female male
79A-222-2160 ○ ○ ○ ○ ○ ○ ○
79A-222-2160 ○ ○
79A-222-2170 ○ ○ ○ ○
78
Introduction of the repair kit for connectors
(Deutsch DT, HD30 connectors)
Komatsu has determined to adopt the DT, HD30 connectors of Deutsch instead of the
electric connectors currently used such as the X, SWP connectors.
These connectors have higher reliability with waterproof performance and better electric
characteristics. Harness repair can be done easily such as replacement of connectors
and terminal.
They have been adopted for part of the models, and will be adopted sequentially for the
future models to be introduced to the market. Also, this kit can be used to replace the
current connector with a new connector.
Pin
contact Socket
contact
Plug body
Receptacle body
Receptacle wedge Plug wedge
Socket
Pin contact
contact
Sealing
plug
or or
Socket contact Pin contact
Repair kit for Deutsch connectors（A） Repair kit for Deutsch connectors（B）
(Parts No.790-222-4000） (Parts No.790-222-4100）
The connectors are intended to be repaired at the It is intended for a repair of connectors in the
repair factory. All parts and tools used for DT field. The parts for the frequently-used 2, 3, 4,
connectors are included in the kit. Therefore, only and 6-pole DT connectors are mainly included in
the HD30 connector body has to be purchased for the kit in a compact size. The terminal clamping
all the connectors. tool and terminal pulling tool are included in the
kit as in the repair kit (A), so it is sufficient to be
used for field operation.
■ Case (Option) ■ ■ Specifications ■
Large size Part No. 799-601-7910

Size 410 240 325 mm
Weight 6.0 Kg
Medium size Part No. 799-601-7920
Size 550 325 365 mm
Weight 2.9 Kg
80
Introduction of the connector repair KIT
for Tier Ⅲ engine sensor/solenoid
In the common rail system on the Tier Ⅲ engine, many sensors critical to the system such as the
engine speed sensor and common rail pressure sensor are used. When a connector or terminal
connected to the sensor is damaged, the engine may stop. The repair kit that allows you to repair
important connectors and terminals easily has been specified, which is introduced here.
Connector repair KIT for Tier Ⅲ engine

(Parts No.790-222-5300)
■ Component part number and usage location ■
Number
No. Part No. of poles
Q ty 6D140 6D125 6D170 12V140 6D107 4D107 6D114 4D95
1 790-222-5310 3 1 G sensor
2 790-222-5320 3 1 NE sensor / CAM sensor
3 790-222-5330 3 1 Common rail pressure sensor
4 790-222-5340 3 1 Barometric pressure sensor

Barometric
5 790-222-5350 3 1 Barometric pressure sensor pressure
sensor
6 790-222-5360 3 1 Boost sensor
7 790-222-5370 4 1 Boost/temperature sensor

Boost/
8 790-222-5380 4 1 temperature
sensor
EGR Gas
9 790-222-5390 3 1 pressure sensor
10 790-222-5410 2 1 Lubricating oil switch
11 790-222-5420 3 1 Lubricating oil sensor

Boost/
temperature
■ Features ■ 12 790-222-5430 4 1 sensor
13 790-222-5440 4 1 Injector
This repair kit is provided 14 790-222-5450 2 1 Pump actuator Pump
actuator
with the connector and 15 790-222-5021 3 1 Common rail pressure sensor
terminal integrated so that 16 790-222-5031 2 1 PCV
17 790-222-5061 2 1 Coolant/fuel/lubricating oil temperature sensor

anyone can repair connec-
18 790-222-5071 2 1 Intake air temperature sensor
tors by simple operation. Housing case
19 790-222-5460 − 1
■ Identification method ■
Repair kit Number Housing Bushing Wedge There are similar connectors with slightly different
No. Part No. of poles color color color shapes. A simple identification method is to check the
1 790-222-5310 3 Black Red number of poles of the connector, housing color, rubber
Natural
2 790-222-5320 3 (transparent) Blue bushing color, and wedge (retainer) color in this order.
3 790-222-5330 3 Black Red 1. Number of poles
4 790-222-5340 3 Light gray Blue 2. Connector housing color
5 790-222-5350 3 Black Red White 3. Rubber bushing color
6 790-222-5360 3 Grey Yellow 4. Wedge (retainer) color
7 790-222-5370 4 Grey White
2.Connector housing color
8 790-222-5380 4 Black Red (Black)
9 790-222-5390 3 Dark grey Blue
10 790-222-5410 2 Greenish brown Blue
11 790-222-5420 3 Black Blue 1.Number
of poles
12 790-222-5430 4 Green
13 790-222-5440 4 Grey Vermilion
14 790-222-5450 2 Black Red

15 790-222-5021 3 Black Yellow
16 790-222-5031 2 Grey Red
17 790-222-5061 2 Black Blue
18 790-222-5071 2 Grey Blue 4.Wedge color(White) 3.Rubber bushing color(Red)
■ Repair method and cautions ■

All repair connectors are water-proof. To maintain waterproof performance of the connectors,
terminals and electric cables are swaged and set to the connector housing. Therefore, to repair a
damaged connector housing or damaged/deformed terminal, cut the connector harness in the
middle, and connect the repair connector harness and machine body harness with a sleeve or
soldering.
81
Introduction of the 070 connector repair KIT
The 070 connector repair kit used in controllers and monitor panels is introduced.
Connector repair KIT for 070 connector (controller)

(Parts No.790-222-6000)
Note 1: As a terminal clamping tool, the 79A-222-2030 that has been introduced is used.
Purchase it as required.
Note 2: As a terminal pulling tool, the 79A-222-2170 that has been introduced is used.
Purchase it as required.
Note 3: The terminal supply units are 50 for both the pin contact and socket terminal.
■ Component part number ■
Number
No. Part No. Part name Q'ty / set Maker s Number
of pins
1 790-222-6010 Connector housing (Cap) 10 2 174932-1
6 790-222-6060 Connector housing (Plug) 10 2 174465-1
11 790-222-6110 Contact (Pin) ー 50 175030-1
12 790-222-6120 Contact (Socket) ー 50 175027-1

82
Wiring harness simple repair
Harness repair KIT

(Parts No.799-601-9600)
■ 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 list ■
Weight
No. Part No. Part name Q'ty
(kg)
ー 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

83
Liquid gasket that prevents fluid leakage from
various types of joint surface
Liquid gasket
■ SPECIFICATIONS ■ ■ Application ■
・It is applied on the joint surface of devices to prevent ・Various facilities and machines in shipbuilding, machinery,
leakage from the joint surface when assembled. vehicle, agricultural machine, power, steel, spinning, oil, and
other industries
■ Temperature at usage location ■
・Select the most appropriate one for use.
Liquid gasket TB1110B Type 1110B
(Parts No. 790-129-9080） Major components Acrylic resin
（KES:LG-5） Hue/appearance Cream-color paste
Viscosity (25℃) Pa･s(P) 50 (500）

Quality
Specific gravity (25℃) 1.11
Nonvolatile component（%） 85 or more
■ Features ■ Property
State after drying Hardening
Presence of rubber elasticity
・ It hardens when it enters a gap of metals
Padding characteristic Nothing
and air is shut off.
・ It has proper thixotropy and lubricity so it Removability Normal
is suitable for sealing of threaded portion. Adhesiveness Fluidity
・ Breakdown torque：4N･m(40kgf･cm) Operating temperature range (℃) -50 to 150

・ Escape torque：2N･m(20kgf･cm) Diluted solution
Capacity 100g
Liquid gasket TB1211 Liquid gasket TB1215

(Parts No.790-129-9090） (Parts No.790-129-9160）（KES:LG-6）
■ Features ■
■ Features ■
・ Universal Liquid gasket
・ It has low viscosity, high fluidity, and great workability. ・ It has high engine oil resistance.
・ It can be used with a fixing gasket, and for temporary ・ It has high gear oil resistance.
fixing of an O-ring. ・ It corrodes copper/copper alloys so it cannot
・ It corrodes copper/copper alloys so it cannot be used be used for copper/copper alloys in the sealed
for copper/copper alloys in the sealed state. state.
Liquid gasket TB1207C Type 1211 1215 1207C

(Parts No.790-129-9170) Major components Silicon Silicon Silicon
（KES:LG-7）
Hue/appearance White paste Gray paste Red-brown paste
Viscosity (25℃) Pa･s(P) 70 (700） 20 (200） 70 (700）

Phenomenon
Specific gravity (25℃) 1.01 1.55 1.50
Surface drying time

(min) 90 60 5
■ Features ■
Reaction type Deoximation Deoximation Deacetone
・ Because of high viscosity and great
padding characteristics, it is effec- Hardness (JISA) 20 45 60
tive for a joint surface with a large Tensile strength MPa
2 1.0 (10） 1.5 (15） 4.0 (40）
clearance. Property after (kg/cm )
hardening
・ It has high engine resistance and Elongation 230 320 170
LLC resistance. Tensile shearing

1.0 (10） 0.8 (8） 2.0 (20）
adhesive strength (kg/cm2)
・ It achieves good pressure resis-
Slump fluidity Fluidity Fluidity Non-fluidity
tance immediately after application
and installation due to great drying Removability Good Good Good
performance.
Operating temperature range (℃) -60 to 200 (250) -60 to 200 (250) -60 to 200 (250)
・ It does not corrode copper/copper
alloys. Capacity 100g 17kg 250g 333ml 20kg 250g 333ml 20kg
84
It prevents looseness and leakage from thread portion
Anaerobic adhesive Locktight 648 (Parts No.79A-129-9110)

■ Specifications ■ Thread 120 to 180 kg/cm2
Shearing strength
Fit 200 to 250 kg/cm2
Viscosity 500 CP / 25℃
Clearance limit 0.15 ｍｍ
Hardening time Active surface 1 to 3ｈ
(Fixed position) Inert surface 3 to 6ｈ
Hardening method Sealed temperature
Actual-use temperature range -55℃ to +175℃
Liquid color Green
Capacity 50cc
■ Features ■
・ Adhesive that prevents looseness or leakage due to vibration.
・ It is of the one-compound type and easy to apply.
・ It prevents looseness and leakage when air is shut off the gap between metals.
・ Typical applications include fixing of gears and sprockets on a gear box and fixing of a rotor installed on an
electric motor shaft.
・ Standard for press fitting and gap fitting part assembly.
・ It fills "inner space" between components. It becomes a precision assembled part after hardening.
・ The fit adhesive is suitable for use at 150℃ or lower. It fills the maximum gap of 0.15 mm.
・ Fixing time is 5 minutes.
Anaerobic adhesive TB1386 (Parts No.790-129-9040)（KES:LT-4）

Viscosity Breakdown Hardening speed Usable
Product
Appearance torque Time until Time until Lubricity temperature range
name ｍPa･s(cP) N.m(kg･cm) actual-use strength strongest strength ℃
1386D Russet 1800 (1800) (160) ∼1 hour ∼12 hours ○ -40 to 150
■ Features ■
・ Unlike normal sealants and adhesives, it does not harden as long as it is in contact with air.
When it enters a small gap between metals and air is shut off, it hardens at room temperature
with little localized necking.
・ After hardening, it has great properties such as vibration resistance, heat resistance, and
chemical resistance. It bonds thread and engaging parts of machines and devices chemically
to strongly prevent looseness and leakage.
・ Because it is of the one-compound no-solvent type, it has great workability and anyone can
use it easily.
Anaerobic adhesive Fixing of threaded portion TB1374 (Parts No.790-129-9180)

■ Features ■
・ Anaerobic strong sealing agent.
・ Unlike normal sealants and adhesives, it does not harden as long as it is in contact with air.
When it enters a small gap between metals and air is shut off, it hardens at room temperature
with little localized necking.
・ After hardening, it has great properties such as vibration resistance, heat resistance, and
chemical resistance. It bonds thread and engaging parts of machines and devices chemically
to strongly prevent looseness and leakage.
・ Because it is of the one-compound no-solvent type, it has great workability and anyone can
TB1374
use it easily.
・ It is applied in a gap between metal parts such as thread and shaft. It hardens when air is
shut off. It prevents looseness and leakage by chemical bonding.
■ Application ■ ■ Specifications ■
・When a gap is large
Liquid
・To bond inert surfaces such as a plated surface, gold, silver, Capacity Anaerobic High strength Viscosity
color type
and alumite. Unremovable
Red 50g ○ 750mPa･s
・For fixing of high-tensile bolts. fixed type
・When axial force is applied.
■ Characteristic table for anaerobic sealing agent for thread ■
Return torque(kgf/cm)
10φ JIS Class2 Hardening speed Major features
Viscosity CPS Mild steel bottle nut used (20 to 25℃) and applications
Type Tone 20%
(25℃) Breakdown Time until Time until
Escape torque Fixing of high-tensile bolts
torque actual-use strength strongest strength
with good lubricity
TB1374 Red 750 100 to 150 150 to 200 1 hour to 12 hours 24 hours
85
Adhesive and seal suitable for repair work
Instant adhesive TB1741 Instant adhesive TB391D

(Parts No. 790-129-9050) (KES:LT-1B) (Parts No. 790-129-9150)
■ Features ■ ■ Features ■
・ Three Bond 1700 series instant ・ It can be sprayed on a stuck
adhesive includes various grades for solid gasket that cannot be
different purposes and applications. removed easily and fluid sealant
A desired product can be selected to remove it quickly and easily.
・
from a wide range of grades. Environment friendly product
without chlorine solvent.
Type 1741
Appearance Colorlessness
Instant adhesive
Viscosity (mPa･s) 2
(Parts No. 790-129-9130)
NBR 5
Z time (Second)
Steel plate 5 ■ Features ■
Steel plate ・Good adhesiveness for metals,
plating, rubber, and plastic.
○
Aluminum
Stainless
Adhesiveness for Brass

various materials Copper
○
Polycarbonate
6-Nylon ■ Specifications ■
PPS ○ Capacity
○ ○ ○
Acrylic resin : 2g (5 piece set )

NBR ○ Hardening type
EPDM : Fast hardening
Wood (Maximum strength after 30 minutes)
Peel strength ○ Tensile adhesive strength
Impact resistance
Performance ：300kg/cm2 or more
Viscosity
(For the same type of adherend
Head cycle resistance
material of hard PVC, iron, and copper)
Capacity (g) 2,20,50
Instant adhesive TB1735For impact resistance

■ Features ■
(Parts No. 790-129-9140)
・ Great peel strength, impact resis-
tance, humidity resistance, and
■ Specifications ■ adhesiveness at low temperature.
○ Capacity：50g ・ It has high adhesive workability for
○ Adhesion time：Adhesion time: 5 sec to 3 min materials with a large area and
○ Adhesive strength : Iron and iron：184kg/cm2 great adhesiveness for various
○ Iron and rubber : Up to material failure of rubber rubber materials.
Instant adhesive TB1521 (Parts No. 790-129-9030) (KES:LT-1A)

■ Features ■
・ It can bond a wide variety of materials from soft materials such as rubber and leather to
hard materials such as metals.
・ It has high initial bonding strength. Elasticity is not lost after adhesion.
Heat resistant seal material MH705 (Parts No. 790-129-9120)
■ Specifications ■ ■ Features ■
○ Part name Q：FIRE GUM • Applied to parts that become hot such as a
○ Capacity：75g muffler.
○ Suze：100 30 200 • Seal with high heat resistance.
○ Number of pieces contained : 20 Heat resistant temperature 1,000℃.
86
The seal kit is suitable for field service
Seal KIT
(Parts No. 09940-10002)
■ Features ■
・ This is a kit consisting of the sealants and O-rings frequently used
for field service of Komatsu products. ｗ
・ Individual items have their own part numbers, so it is also possible ｄ

to purchase individual items.
■ Specifications ( Component parts ) ■
No. Type Part No. Q ty Capacity
1 Sealant kit 09940-10002
2 ・ Liquid gasket 09940-00013 4 SS60C 100ｇ 4
3 ・ Screw lock 09940-00031 2 50 G 50g 2 （KES : LT - 2）
4 ・ Lubricant 09940-00041 1 NO1 200 g 1 （KES : LM - P）

・ Rust preventive
5 09940-00052 1 200 g 1
penetrant
KES standard O-ring
6 ・ O-ring kit 09940-00061 1 Operating
Lubricating
d w Hardness Materials temperature
liquid
range
7 ・・ O-ring 07002-12434 10 pcs. 20.7 3.4

90HS
8 ・・ O-ring 07002-13634 10 pcs. 32.7 3.4
9 ・・ O-ring 07000-13075 10 pcs. 74.6 3.5
10 ・・ O-ring 07000-13060 10 pcs. 59.6 3.5 88

NBR -30℃
Mineral oil
11 ・・ O-ring 07000-13048 10 pcs. 47.7 3.5 -1B to
0.5HS 100℃
water
12 ・・ O-ring 07000-13038 10 pcs. 37.7 3.5
13 ・・ O-ring 07000-13032 10 pcs. 31.7 3.5
14 ・・ O-ring 07000-13028 10 pcs. 27.7 3.5
15 ・
・ O-ring 07000-13025 10 pcs. 24.7 3.5
16 ・
・ O-ring 07000-13022 10 pcs. 21.7 3.5
17 ・ Seal tape 790-301-1430 1 NICHIAS
18 ・ Case 09940-00081 1
87
Required for repair of aluminum radiators
As repair methods "that can be done by yourself in the operation site" by using the existing
repair skills and skills that can be learned easily, the following 2 methods are introduced.
■ Features ■
Item Feature Main candidates for repair
・ Repair using aluminum brazing material ・Aluminum oil cooler with high operating
Brazing ・ Can provide equivalent strength as the pressure, etc.
repair aluminum base metal.
・ Repair using two-compound epoxy resin ・Brass and aluminum radiator, resin cover,
・ Can be handled easily because the mixing etc.
Repair ratio of two compounds is determined ・Can be applied for emergency repair in the
using resin automatically (using a dedicated tool). operating site.
・ Can increase strength by using fiber net.
・ Easy surface finish by coating
■ Using material for implements ■

○Brazing ＆ Flux No. Part name Part No. Remarks
1
1 Flux 790-760-1100 1 set : 6 cases
2
Brazing filler wire diameter : ø1.6
2 790-760-1200
material 1 set : 5 kg
3 Epoxy resin kit 790-760-1300
Epoxy resin
4 790-760-1310
cartridge
A set of 10 paces is
necessary when being
5 Mixing nozzle 790-760-1330
supplied as a single
○Epoxy resin kit spare part.
3 6 Fiber net 790-760-1320
Although it is included
in the kit, it will not be
7 Brush ー supplied as a single
spare part.
It will not be supplied

8 Dispensing gun ー as a single spare part.
8 An article on the
9 Propane burner ー
market
An article on the
10 Cartridge ー
market
4
6
5
7
9
10
3 ※ These parts come with
procedure manual
Part number index
■ Part number index_1
Part No. Part Name Page
02789-00210 Seal hose joint nut (cap) 32

07002-11023 Brake release pump O-ring 66
07281-00259 Blowby pressure measurement hose 23
07281-00289 Blowby pressure measurement hose 23
07376-70210 Seal hose joint blind plug 32
07705-01100 Eco-drain valve standard type 65
07705-11100 Eco-drain valve elbow type 65
07705-21100 Eco-drain valve short type 65
078281-00359 Blowby measurement tool clamp 17
07976-70210 Seal hose joint pressure pick-up adapter and plug 32
09940-10002 Seal KIT 86
09941-00000 Nut & bolt KIT 75
134-06-72810 Brake release pump resistor 66
144-865-6260 Brake release pump elbow 66
17A-06-41410 Brake release pump wirering harness 66
17M-06-41530 Brake release pump wirering harness 66
195-06-71220 Brake release pump wirering harness 66
19M-06-32820 Brake release pump switch Ass'y 66
21T-01-31940 Eco-drain valve large type 65
6738-21-5610 Eco-drain valve standard type 65
7824-66-6430 Brake release pump resistor 66
7824-66-6430 Brake release pump redundant resistor 66
7827-10-1520 Brake release pump redundant resistor 66
7872-10-2103 TierⅡ dynamo test engine controller 41
7872-10-5205 TierⅡ dynamo test Engine controller 41
790-101-1102 Manual/Electric hydraulic pumps 53
790-101-1102 Tool for disassembling and assembling track-shoe master pin pump 55
790-101-1190 Common quick coupler for hydraulic pump & actuators 53
790-101-1300 Hydraulic cylinder and puller (For press fitting and pulling out) 59
790-101-1430 Common quick coupler for hydraulic pump & actuators 53
790-101-4200 Tool for disassembling and assembling track-shoe master pin cylinder(294kN 30t) 57
790-102-1000 Power wrench 45
790-102-1100 Power wrench 45
790-102-1200 Power wrench 45
790-102-1801 Nat wrench KIT 49
790-102-1820 Nat wrench 49
790-102-1821 Nat wrench 49
790-102-1831 Nat wrench 49
790-102-1841 Nat wrench 49
790-102-1861 Nat wrench 49
790-102-1871 Nat wrench 49
790-102-1881 Nat wrench 49
790-102-1891 Nat wrench 49
790-102-1911 Nat wrench 49
790-102-1921 Nat wrench 49
790-102-1931 Nat wrench 49
790-102-1941 Nat wrench 49
790-102-1951 Case 49
790-102-2304 Cylinder round head wrench 52
790-102-2304 For wrench assembly hydraulic cylinder 52
790-102-3500 Power wrench 45
790-129-9030 Instant adhesive TB1521 85
790-129-9040 Anaerobic adhesive TB1386 84
790-129-9050 Instant adhesive TB1741 85
790-129-9080 Liquid gasket TB1110B 83
790-129-9090 Liquid gasket TB1211 83
790-129-9120 Heat resistant seal material MH705 85
790-129-9130 Instant adhesive 85
790-129-9140 Instant adhesive TB1735 for impact resistance 85
790-129-9150 Instant adhesive TB391D 85
790-129-9160 Liquid gasket TB1215 83
790-129-9170 Liquid gasket TB1207C 83
790-129-9180 Anaerobic adhesive fixing of threaded portion TB1374 84
790-190-1200 Electric hydraulic pump 54
790-190-1500 Brake release pump 66
790-190-1601 Brake release pump 66
790-201-3100 Guide bolt KIT 48
■ Part
■ Part
number
number
index_3
index_3

790-222-2001 Connctor repair KIT 76
790-222-2100 Repair KIT-tool 76
790-222-3500 X,SWP-type connector repair KIT 77
790-222-3600 M,S-type connector repair KIT 77
790-222-4000 Repair KIT for Deutsch connectors(A) 78
790-222-4100 Repair KIT for Deutsch connectors(B) 78
790-222-5000 Connector repair KIT for Common rail engine & HPI engine 79
790-222-5300 Connector repair KIT for Tier Ⅲ engine 80
790-222-6000 Connector repair KIT for 070 connector (controller) 81
790-222-6010 Connector housing (Cap) 81
790-222-6020 Connector housing(Cap) 81
790-222-6060 Connector housing(Plug) 81
790-222-6110 070 connector contact (Pin) 81
790-222-6120 070 connector contact (Socket) 81
790-261-1130 CEJN quick coupler 67
790-261-1204 Digital type oil pressure measurement KIT 26
790-299-1100 Connctor repair KIT Case (OP) 76
790-303-1003 Oil leak tester (measurement and diagnosis of oil leak in the hydraulic circuit)） 29
790-331-1110 Wrench (angle tightening wrench) 47
790-331-1120 Wrench (angle tightening wrench) 47
790-402-1001 Sling chain KIT 50
790-434-1502 Tool for disassembling and assembling track-shoe master pin type D 58
790-434-1701 Compressor(A) 51
790-445-2770 Nut torque of rebuilding hydraulic cylinders sim 64
790-445-3001 Nut torque of rebuilding hydraulic cylinders cart Ass y 64
790-445-3301 Nut torque of rebuilding hydraulic cylinders wrench Ass y 64
790-445-3500 Nut torque of rebuilding hydraulic cylinders frame Ass y 64
790-501-2001 Engine repair stand 61
790-501-4000 Engine repair stand 62
790-501-5000 Component repair stand (Torque converters, PPMs, deferential gears, etc.) 60
790-501-5200 Component repair stand (Torque converters, PPMs, deferential gears, etc.) 48
790-502-1003 Hydraulic cylider repair stand 48
790-502-1270 Nut torque of rebuilding hydraulic cylinders chain 48
790-502-1702 Nut torque of rebuilding hydraulic cylinders vice Ass y 76
790-701-3600 Pump for oil lubricated track shoe adapter 76
790-760-1100 Flux 76
790-760-1200 Brazing filler material 76
790-760-1300 Epoxy resin KIT 76
791-600-2001 Compressor（A） 76
791-601-1000 Pump for oil lubricated track shoe (vacuum/hydraulic pump) 76
791-601-1100 Pump for oil lubricated track shoe pump unit 76
791-601-1301 Pump for oil lubricated track shoe nozzle Ass y 77
791-601-1600 Pump for oil lubricated track shoe seal checker Ass y 77
791-601-1900 Pump for oil lubricated track shoe cart Ass y 78
791-615-7001 Tool for disassembling and assembling track-shoe master pin type A 78
791-616-1001 Tool for disassembling and assembling track-shoe master pin type B 80
791-620-3000 Tool for disassembling and assembling track-shoe master pin type C 81
791-620-3500 Tool for disassembling and assembling oil lubrication type track-shoe master pin type C 81
791-685-8006 Recoil spring disassembly/assembly tool 51
791-685-8502 Recoil spring disassembly/assembly tool 51
791-832-1200 Tool for disassembling and assembling track-shoe master pin type E 57
792-610-1000 Suspension tool 71
792-610-1101 Oil & N2 gas filling 71
792-610-1200 Oil & N2 gas filling 71
792-610-1702 Gas pressure inspection and filling for accumulators 72
792-610-2190 Accumulator joint 72
792-622-1211 Hub nut retightening tool for HD rear wheel 74
795-101-1580 Engine compressive pressure measurement gauge adapter Ass y 22
795-201-9020 Handy smoke checker filter paper 35
795-201-9310 Handy smoke checker pump 35
795-201-9320 Handy smoke checker nozzle Ass y 35
795-201-9330 Handy smoke checker nipple 35
795-201-9340 Handy smoke checker smoke scale 35
795-201-9350 Handy smoke checker case 35
795-500-2000 Battery coolant tester 31
795-500-2010 Battery coolant tester lighting plate 31
795-500-2020 Battery coolant tester pin 31
795-502-1205 Engine compressive pressure measurement gauge KIT 22
795-502-1240 Engine compressive pressure measurement gauge adapter 22
795-502-1250 Engine compressive pressure measurement gauge KIT 22
795-502-1283 Engine compressive pressure measurement gauge case 22
795-502-1560 Engine compressive pressure measurement gauge packing 22

795-790-1610 Blowby pressure measurement clamp 23
795-790-1900 Blowby pressure measurement (Tool main body) 23
795-799-5460 TierⅡ HPI engine cable 14
795-799-5512 Heat gun (Universal contact free thermometer) 13
795-799-5520 TierⅡ HPI engine socket 14
795-799-5550 TierⅡ HPI engine adaptor 14
795-799-5560 Oil pressure gauge for negative pressure measurement 14
795-799-5610 TierⅢ engine dynamo test controller 42
795-799-5650 TierⅢ engine dynamo test harness 42
795-799-5660 TierⅢ engine dynamo test wire 42
795-799-5720 TierⅢ engine dynamo test 9 pin cable 42
795-799-5732 TierⅢ engine dynamo test Inline5 42
795-799-5742 TierⅢ engine dynamo test cable 42
795-999-1310 Eco-drain valve short type 65
795-999-1510 Eco-drain valve short type 65
795T-280-1030 Disassembly/assembly for hybrid bracket 44
795T-280-1040 Disassembly/assembly for hybrid bracket 44
795T-401-1210 Disassembly/assembly for hybrid engine stand 44
795T-401-1220 Disassembly/assembly for hybrid engine stand plate 44
796-410-1000 Disassembly/assembly for hybrid centering tool guide 44
796-410-1040 Disassembly/assembly for hybrid centering tool bar 44
796-410-1050 Disassembly/assembly for hybrid centering tool plate 44
796-426-1800 Capacitor discharging device for hybrid 43
799-101-1502 Digital thermometer 20
799-101-5002 Analog type (Bourdon tube) oil pressure measurement nipple 25
799-101-5160 Engine boost pressure measurement KIT 24
799-101-5220 Brake release pump nipple 66
799-101-6700 Heat sensitive paper 34

799-201-1104 PM KIT B 5
799-201-1411 Blowby pressure measurement adapter 23
799-201-1421 Blowby pressure measurement plug 23
799-201-1430 Blowby pressure measurement gauge 23
799-201-1470 Blowby pressure measurement hose 23
799-201-1480 Blowby pressure measurement joint 23
799-201-1501 Blowby measurement tool 17
799-201-1506 Blowby pressure measurement standard KIT 23
799-201-1511 Specification of blowby measurement tool(main body) 23
799-201-1530 Blowby pressure measurement nut 23
799-201-1571 Blowby pressure measurement tube 23
799-201-1640 Blowby pressure measurement clamp 23
799-201-1904 PM KIT C 5
799-201-2202 Engine boost pressure measurement KIT 24
799-201-3101 Blowby pressure measurement KITⅡ 23
799-201-9002 Handy smoke checker 35
799-202-9002 Radiator cap tester 21
799-205-1002 Tachometer KIT 19
799-205-1101 Laser type tachometer 19
799-205-1601 Vibration detection type tachometer 19
799-301-1500 Oil leak tester (measurement and diagnosis of oil leak in the hydraulic circuit) 28
799-401-2301 PM KIT A 5
799-401-2311 Engine boost pressure measurement KIT gauge 24
799-401-2330 CEJN（ PS 1/4) 67
799-401-2330 CEJN （elbow PS 1/4 female) 67
799-401-2440 CEJN（ both male) 67
799-401-2610 Engine boost pressure measurement KIT Hose 24
799-402-6000 Test bench for PPM & T/M 37
799-410-1100 Vacuum pump(negative pressure generator) 69
799-552-3710 Pump EPC valve connection cable1 37
799-601-2500 Mechatro-harness checker(T-junction adaptor) 7
799-601-4100 T-junction adapter for Tier Ⅲ engines 15

799-601-4200 T-junction adapter for Tier Ⅲ engines 15
799-601-4510 Tools required for injector trimming 18
799-601-4600 T-junction adapter for Tier Ⅳ interim engine 17
799-601-7500 070 connector (controller system) T-junction adapters 11
799-601-7910 Repair KIT for Deutsch connectors large size 78
799-601-7920 Repair KIT for Deutsch connectors medium size 78
799-601-9000 T-junction adaptor KIT for Deutsch connectors 9
799-601-9100 KIT applicable to connectors for HD30 9
799-601-9200 KIT applicable to DT connectors 9
799-601-9300 T-junction adapter for the NGI controller 11
799-601-9410 T-junction adapter and socket for common rail type engines (125&140) 12
799-601-9440 Socket for boost sensor 12
799-601-9500 Introducing Deutsch connectors! Do-it-yourself KIT 10
799-601-9600 Harness repair KIT 82
799-601-9710 T-junction adapter for medium size wheel loader HST controller 11
799-601-9890 Multi T-junction adapter 16
799-603-3200 Cable diagnosis device 36
799-605-3000 XEP checker 40
799-605-5011 Throttle box 39
799-605-5040 Power harness 39
799-607-4001 TierⅡ engine dynamo test KIT 41
799-607-4010 TierⅡ engine dynamo test KIT throttle box 41
799-607-4020 TierⅡ engine dynamo test KIT wire harness 41
799-607-4030 TierⅡ engine dynamo test KIT power harness 41
799-607-4050 TierⅡ engine dynamo test KIT wire harness 41
799-607-6100 Electronic transmission bench test tool 38
799-607-6110 Electronic transmission bench test switch box 38
799-607-6120 Electronic transmission bench test harness 38

799-607-6150 Electronic transmission bench test adapter 38
799-609-2000 FOWA checker KIT 33
799-609-2100 TBN checker A ssy 33
799-609-2200 TAN checker A ssy 33
799-609-2300 Viscosity checker assembly 33
799-609-2400 Water checker assembly 33
799-609-2500 Hardness checker 33
799-609-2600 Litmus paper 33
799-610-1211 Pump tester 37
799T-201-3210 Blowby measurement tool plug 17
799T-201-3220 Blowby measurement tool cap 17
79A-106-1000 Heat gun for heating heat shrink tubes 73
79A-110-1300 Oil feeder with filter 68
79A-129-9110 Anaerobic adhesive locktight 648 84
79A-212-4201 Soket wrench KIT (for 12 point bolts) 46
79A-222-2200 Connctor repair KIT 76
79A-851-1000 Contaminant checker (measurement of contaminants in the fuel or hydraulic oil) 30
79A-851-1200 Contaminant checker (measurement of contaminants in the fuel or hydraulic oil) 30
CK40-25 Undercarriage wear measurement KIT 27
P40-25 Undercarriage wear measurement case 27
PDG-12 Undercarriage wear measurement depth gauge（large） 27
PDG-34 Undercarriage wear measurement depth gauge(small) 27
POC10-1 Undercarriage wear measurement outside calipers (small) 27
POC15-1 Undercarriage wear measurement outside calipers (medium) 27
POC30-1 Undercarriage wear measurement outside calipers (large) 27
PS50-1 Undercarriage wear measurement wire brush 27
PSR100-1 Undercarriage wear measurement metal measure 27
PSR300-1 Undercarriage wear measurement metal measure 27
PST300-1 Undercarriage wear measurement tape measure 27
PV200-1 Undercarriage wear measurement vernier calipers 27
PWB-1 Undercarriage wear measurement wire brush 27
Measuring & Diagnostic
Assemble & Disassemble
Maintenance ＆ Others
Bond & Seal
Ver.1.0
2011.11 .01 FWD
Technical Development Team,

Global Training Planning Group, Service Department,
Product Support Division, Komatsu

Komatsu Specialtools

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Measuring & Diagnostic

Assemble & Disassemble

Bond & Seal

This booklet introduces items of tools and equipment that we have

1. The top column explains the characteristics of the item.

2. The central column explains the functions of each tool or equipment,

3. A photograph of each tool or equipment (showing the appearance)

Thus, this booklet contains explanations on the features and beneﬁts of

■ Measuring & Diagnostic Page

PM KIT A & B & C 5

■ Maintenance ＆ Others Page

■ Bond & Seal Page

■ Major measurement item ■

Blowby pressure kPa ○ ○

Engine Lubricating oil pressure MPa ○ ○

Torque converter inlet/outlet oil pressure MPa ○ ○

Transmission relief oil pressure MPa ○ ○

Mechatro-Harness Checker (T-junction adaptor)

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

799-601-2500 445 335 95 3.9

799-601-7100 500 400 110 4.0

799-601-7400 500 400 110 4.6

799-601-6000 500 400 170 7.0

■ Applicable model/Component parts ■

16 7170 （Blue) （Blue)

REL 5 799-601-7360 （White)

T-junction adaptor KIT for Deutsch connectors

KIT applicable to connectors for HD30

KIT applicable to DT connectors

T-junction adaptors for DTM2,

■ KIT part number ■

Controller-related T-junction adapters

070 connector (controller system) T-junction adapters

■ Part numbers of the component parts ■

T-junction adapter for the NGI controller

Part No. Q ty Remarks T-junction adapter for 40-pole

799-601-9360 1 24-pole T-junction adapter for 24-pole The box of 799-601-9320

T-junction adapter for medium size wheel loader HST controller

Trouble diagnosis tool for common rail type engines

Socket for boost sensor

NE sensor PCV solenoid

The lead rod of

TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (1)

Heat gun (universal contact free thermometer)

1 795-799-5512 ー Heat gun Used for trouble diagnosis of the injectors

2 795-799-5550 3376859 Adaptor Used for fuel pump pressure measurement

4 795-799-5520 ー Socket(S) Used for trouble diagnosis of the rotation sensor

Used for trouble diagnosis of the water temperature sensor,

6 795-799-5540 ー Socket(A) Used for trouble diagnosis of the temperature sensor

Used for trouble diagnosis of the barometric pressure sensor,

Used for trouble diagnosis of the timing pressure sensor,

TierⅡ HPI engine (6D170E-3) trouble diagnosis tool (2)

Adaptor Oil pressure gauge for negative

Used for inlet pressure

Diagnosis of the electronic control system

The HPI has various sensors. Simple sockets

２）Cable ■ Operating Instructions ■

Used similarly as the T-junction adapter to measure output voltage of the

T-junction adapter for trouble diagnosis of Tier Ⅲ engines