SEN06502-17

ENGINE 107E -3 SERIES

 00 INDEX AND FOREWORD

107E-3 SERIES 00-1

INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ............................................................................................................................. 00-5
FOREWORD, SAFETY, BASIC INFORMATION ....................................................................................00-11
HOW TO READ THE ENGINE SHOP MANUAL .............................................................................00-11
SAFETY NOTICE FOR OPERATION............................................................................................. 00-13
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-21
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-23
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-24
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-25
PRECAUTIONS FOR DEF............................................................................................................. 00-26
STORE AdBlue/DEF ...................................................................................................................... 00-27
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-28
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-31
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-38
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-40
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-41
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-42
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-46
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-50
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-51
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-56
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-57
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-61
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-64
CONVERSION TABLE ................................................................................................................... 00-71
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-4
SPECIFICATIONS ................................................................................................................................ 01-10
OUTLINE OF EXHAUST GAS REGULATION................................................................................ 01-10
LIST OF APPLICABLE MACHINES: 107E-3.................................................................................. 01-13
SPECIFICATIONS ......................................................................................................................... 01-14
ENGINE GENERAL VIEW ............................................................................................................. 01-29
ENGINE PERFORMANCE CURVE ............................................................................................... 01-85
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-5
UREA SCR SYSTEM.............................................................................................................................10-11
LAYOUT DRAWING OF UREA SCR SYSTEM ...............................................................................10-11
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-19
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-21
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-22
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-23
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-45
ENGINE SYSTEM ................................................................................................................................ 10-57
LAYOUT OF ENGINE COMPONENTS .......................................................................................... 10-57
INTAKE AND EXHAUST SYSTEM PARTS .................................................................................... 10-61
ENGINE MAIN BODY PARTS........................................................................................................ 10-68
TURBOCHARGER SYSTEM ......................................................................................................... 10-84
LUBRICATION SYSTEM...............................................................................................................10-118
FUEL SYSTEM .............................................................................................................................10-130
COOLING SYSTEM......................................................................................................................10-139
ELECTRICAL SYSTEM .......................................................................................................................10-146

00-2 107E-3 SERIES

00 INDEX AND FOREWORD INDEX

COMPONENT PARTS OF ELECTRICAL SYSTEM ......................................................................10-146

SENSOR.......................................................................................................................................10-172
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24,
D51PXI-24)................................................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)...................................... 20-12
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (PC170LC-11) .................................... 20-15
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8) ......................................... 20-18
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)...................................... 20-21
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24,
D61PXI-24)................................................................................................................................. 20-24
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,
D61PXI-24E0) ............................................................................................................................ 20-27
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
GD675-7E0) ............................................................................................................................... 20-30
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC210LC-11, PC210LCI-11)............. 20-33
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11) .... 20-36
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC240LC-11) .................................... 20-39
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)............. 20-42
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8, WA270-8E0)..................... 20-45
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8, WA320-8E0)..................... 20-48
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8) ......................................... 20-51
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ................................................. 20-54
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (D51EX-24,
D51EXI-24, D51PX-24, D51PXI-24) ........................................................................................... 20-54
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (HB215LC-3)......
................................................................................................................................................... 20-56
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (PC170LC-11) ....
................................................................................................................................................... 20-58
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (WA200-8) .........
................................................................................................................................................... 20-60
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (BR380JG-3)......
................................................................................................................................................... 20-62
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24,
D61EXI-24, D61PX-24, D61PXI-24) ........................................................................................... 20-64
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24E0,
D61EXI-24E0, D61PX-24E0, D61PXI-24E0) .............................................................................. 20-66
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (GD655-6,
GD655-7, GD675-6, GD675-7E0)............................................................................................... 20-68
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC210LC-11,
PC210LCI-11)............................................................................................................................. 20-70
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3
(PC228USLC-11, PC238USLC-11)............................................................................................. 20-72
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC240LC-11) ....
................................................................................................................................................... 20-74
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC290LC-11,
PC290LCI-11)............................................................................................................................. 20-76
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA270-8,
WA270-8E0) ............................................................................................................................... 20-78
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA320-8,
WA320-8E0) ............................................................................................................................... 20-80
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA380-8) .........
................................................................................................................................................... 20-82
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2

107E-3 SERIES 00-3

INDEX 00 INDEX AND FOREWORD

ABBREVIATION LIST ............................................................................................................................. 50-3

RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-9
HOW TO READ THIS MANUAL....................................................................................................... 50-9
COATING MATERIALS LIST...........................................................................................................50-11
SPECIAL TOOLS LIST .................................................................................................................. 50-15
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-17
ENGINE SYSTEM ................................................................................................................................ 50-18
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3).......................................... 50-18
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3).......................................... 50-92
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3) ..............................................50-161
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3) ..............................................50-167
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3) ...............................................50-172
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3) ...............................................50-177
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)..................................................50-181
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3)..................................................50-185
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE SYSTEM .................................................................................................................................. 60-9
INTAKE AND EXHAUST SYSTEM PARTS ...................................................................................... 60-9
ENGINE MAIN BODY PARTS.........................................................................................................60-11
LUBRICATION SYSTEM................................................................................................................ 60-31
INDEX..................................................................................................................................................................1

00-4 107E-3 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

107E-3 SERIES 00-5

ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

00-6 107E-3 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

107E-3 SERIES 00-7

ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

00-8 107E-3 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

107E-3 SERIES 00-9

ABBREVIATION LIST 00 INDEX AND FOREWORD

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

00-10 107E-3 SERIES

00 INDEX AND FOREWORD HOW TO READ THE ENGINE SHOP MANUAL

FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUC-
TURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
Symbol
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.

107E-3 SERIES 00-11

HOW TO READ THE ENGINE SHOP MANUAL 00 INDEX AND FOREWORD

Symbol Item Remark

This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.

Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

This symbol indicates the works which require special caution for the ma-
Safety
chine safety when assembling.

Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.

Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

00-12 107E-3 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpo-
ses.

• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.

107E-3 SERIES 00-13

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.

,&

Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).

00-14 107E-3 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.

• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.

107E-3 SERIES 00-15

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.

,&

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.

00-16 107E-3 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.

• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

107E-3 SERIES 00-17

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in “DISASSEMBLY AND
ASSEMBLY”.
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

00-18 107E-3 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

107E-3 SERIES 00-19

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, “Pre-
cautions for disconnection and connection of air conditioner
piping”.

00-20 107E-3 SERIES

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.

107E-3 SERIES 00-21

PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.

00-22 107E-3 SERIES

00 INDEX AND FOREWORD ACTIONS IF FIRE OCCURS

ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

107E-3 SERIES 00-23

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

00-24 107E-3 SERIES

00 INDEX AND FOREWORD ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine complies with either regulation Tier4 Final (North America) or Stage IV (EU) (until 2018), Stage V
(EU) (after 2019).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as “regeneration”.
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Urea SCR system is not installed to some machine models or specifications.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).

107E-3 SERIES 00-25

PRECAUTIONS FOR DEF 00 INDEX AND FOREWORD

PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.

PRECAUTIONS FOR STORING

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unatten-
ded and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical re-
actions.

THE OTHER PRECAUTIONS

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.

00-26 107E-3 SERIES

00 INDEX AND FOREWORD STORE AdBlue/DEF

STORE AdBlue/DEF
• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
Max.25 °C Up to 18 months
Max.30 °C Up to 12 months
Max.35 °C Up to 6 months

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.

107E-3 SERIES 00-27

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.

• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.

Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.

00-28 107E-3 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.

Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.

Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.

107E-3 SERIES 00-29

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.

00-30 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and as-
sembly” of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.

107E-3 SERIES 00-31

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

Introduction of parts for the disconnection of the taper seal type hoses and
tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

00-32 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the disconnection of the split flange type hoses and
tubes

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

Introduction of parts for the removal of O-ring boss type joint

107E-3 SERIES 00-33

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222

14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026

Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

00-34 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.

107E-3 SERIES 00-35

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.

00-36 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY
AND ASSEMBLY”.

107E-3 SERIES 00-37

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical
equipment”.
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.

Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.

00-38 107E-3 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.

Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.

107E-3 SERIES 00-39

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.

00-40 107E-3 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.

107E-3 SERIES 00-41

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).

2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.

3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.

Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).

00-42 107E-3 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

107E-3 SERIES 00-43

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

00-44 107E-3 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

107E-3 SERIES 00-45

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.

3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.

Connecting connectors
1. Check the connector visually.

00-46 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.

• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.

• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.

Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.

107E-3 SERIES 00-47

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.

Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.

00-48 107E-3 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.

107E-3 SERIES 00-49

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
CONNECTOR 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).

Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.

00-50 107E-3 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).

107E-3 SERIES 00-51

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24)

Insert it straight until it clicks.

00-52 107E-3 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PULL

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.

Method for connecting connector with lock to pull

Insert the connector securely until it “clicks”.

107E-3 SERIES 00-53

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PUSH 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series

• 107 series

REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.

Method for connecting connector with lock to push (BOSCH-3)

Insert it straight until it clicks.

00-54 107E-3 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH

Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.

Method for connecting connector with lock to push (AMP-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4)

Insert it straight until it clicks.

107E-3 SERIES 00-55

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH HOUSING TO ROTATE 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.

00-56 107E-3 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in (Table 1).
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on
the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).

Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)

Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)

Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place

107E-3 SERIES 00-57

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D

AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
(mm2)
d (approx.) - 0.9 - 1.1 - 1.4

00-58 107E-3 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D

CAVS Standard - 1.6 - 1.8 - 2.1

REMARK
“f” of nominal No. denotes “flexible”.
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White

REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is “Green” and marking is “White”.

107E-3 SERIES 00-59

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -

00-60 107E-3 SERIES

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called “tolerance”.
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126

• The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/
lower limit of tolerance).”
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0

107E-3 SERIES 00-61

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called “standard value”, which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.

Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called “interference”.
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is “standard interference”.
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called “allowable value” or “allowable dimension”.
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called “allowable clearance”.
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called “allowable interference”.
• The allowable interference shows the repair limit of the part of smaller tolerance.

00-62 107E-3 SERIES

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

• The parts whose interferences are out of the allowable interference must be replaced or repaired.

107E-3 SERIES 00-63

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter Width across flats

Tightening torque (Nm {kgfm} )
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}

*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.

00-64 107E-3 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Thread diameter Width across flats

Tightening torque (Nm {kgfm} )
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.

Type of bolt A B

Nominal size - Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC

5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC

3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC

7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC

1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC

9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC

5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC

3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4

7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC

107E-3 SERIES 00-65

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Type of bolt A B

Nominal size - Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
threads per inch Range Target Range Target
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}

11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}

11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}

11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}

REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.

Type of bolt A B

Nominal size - Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
threads per inch Range Target Range Target
1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF

5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF

3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF

7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF

1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF

9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF

5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF

3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF

7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF

1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}

11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}

11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}

11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}

00-66 107E-3 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread di- Width across Tightening torque (Nm {kgfm} )

Nominal No.
ameter (mm) flats (mm) Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread diam- Width across Tightening torque (Nm {kgfm} )

Nominal No.
eter (mm) flats (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}

107E-3 SERIES 00-67

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diam- Width across Tightening torque (Nm {kgfm} )

Nominal No.
eter (mm) flats (mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Width Tightening torque (Nm {kgfm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter(mm)
hose (mm)
(mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ -16UN 17.5
16
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16

05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -

00-68 107E-3 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside di- Tightening torque (Nm {kgfm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter(mm) (refer-
(mm) threads per inch
pipe (mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN

10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16

12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN

15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2

Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter (mm) Tightening torque (Nm {kgfm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.

107E-3 SERIES 00-69

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diameter (mm) Tightening torque (Nm {kgfm} )

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}

Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16

1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8

1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4

3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8

1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2

3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4

00-70 107E-3 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE

CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898

mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

107E-3 SERIES 00-71

CONVERSION TABLE 00 INDEX AND FOREWORD

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

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

ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

00-72 107E-3 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgfm to lbft
1 kgfm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kgf/cm2 to lb/in2
1 kgf/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

107E-3 SERIES 00-73

CONVERSION TABLE 00 INDEX AND FOREWORD

1 kgf/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6

00-74 107E-3 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

107E-3 SERIES 00-75

 01 SPECIFICATIONS

107E-3 SERIES 01-1

CONTENTS 01 SPECIFICATIONS

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 01-4
SPECIFICATIONS ....................................................................................................................................... 01-10
OUTLINE OF EXHAUST GAS REGULATION....................................................................................... 01-10
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION................................01-11
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION................................. 01-12
LIST OF APPLICABLE MACHINES: 107E-3......................................................................................... 01-13
SPECIFICATIONS ................................................................................................................................ 01-14
SPECIFICATIONS: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24) .................... 01-14
SPECIFICATIONS: SAA4D107E-3 (HB215LC-3)........................................................................... 01-15
SPECIFICATIONS: SAA4D107E-3 (PC170LC-11) ......................................................................... 01-16
SPECIFICATIONS: SAA4D107E-3 (WA200-8)............................................................................... 01-17
SPECIFICATIONS: SAA6D107E-3 (BR380JG-3)........................................................................... 01-18
SPECIFICATIONS: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24) .................... 01-19
SPECIFICATIONS: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0) ... 01-20
SPECIFICATIONS: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0).......................... 01-21
SPECIFICATIONS: SAA6D107E-3 (PC210LC-11,PC210LCI-11) ................................................... 01-22
SPECIFICATIONS: SAA6D107E-3 (PC228USLC-11, PC238USLC-11) ......................................... 01-23
SPECIFICATIONS: SAA6D107E-3 (PC240LC-11) ......................................................................... 01-24
SPECIFICATIONS: SAA6D107E-3 (PC290LC-11, PC290LCI-11) .................................................. 01-25
SPECIFICATIONS: SAA6D107E-3 (WA270-8, WA270-8E0).......................................................... 01-26
SPECIFICATIONS: SAA6D107E-3 (WA320-8, WA320-8E0).......................................................... 01-27
SPECIFICATIONS: SAA6D107E-3 (WA380-8)............................................................................... 01-28
ENGINE GENERAL VIEW .................................................................................................................... 01-29
ENGINE GENERAL VIEW: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24) ........ 01-29
ENGINE GENERAL VIEW: SAA4D107E-3 (HB215LC-3)............................................................... 01-33
ENGINE GENERAL VIEW: SAA4D107E-3 (PC170LC-11)............................................................. 01-37
ENGINE GENERAL VIEW: SAA4D107E-3 (WA200-8) .................................................................. 01-41
ENGINE GENERAL VIEW: SAA6D107E-3 (BR380JG-3)............................................................... 01-45
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24) ........ 01-49
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0).
................................................................................................................................................... 01-53
ENGINE GENERAL VIEW: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0).............. 01-57
ENGINE GENERAL VIEW: SAA6D107E-3 (PC210LC-11,PC210LCI-11)....................................... 01-61
ENGINE GENERAL VIEW: SAA6D107E-3 (PC228USLC-11, PC238USLC-11) ............................. 01-65
ENGINE GENERAL VIEW: SAA6D107E-3 (PC240LC-11, PC290LC-11, PC290LCI-11)................ 01-69
ENGINE GENERAL VIEW: SAA6D107E-3 (WA270-8, WA270-8E0).............................................. 01-73
ENGINE GENERAL VIEW: SAA6D107E-3 (WA320-8, WA320-8E0).............................................. 01-77
ENGINE GENERAL VIEW: SAA6D107E-3 (WA380-8) .................................................................. 01-81
ENGINE PERFORMANCE CURVE ...................................................................................................... 01-85
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24) ....
................................................................................................................................................... 01-85
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (HB215LC-3)................................................. 01-86
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (PC170LC-11) ............................................... 01-87
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (WA200-8) .................................................... 01-88
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (BR380JG-3)................................................. 01-89
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24) ....
................................................................................................................................................... 01-90
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,
D61PXI-24E0) ............................................................................................................................ 01-91
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)..........
................................................................................................................................................... 01-92
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC210LC-11, PC210LCI-11) ........................ 01-93
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11) ............... 01-94
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC240LC-11) ............................................... 01-95
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC290LC-11, PC290LCI-11) ........................ 01-96
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA270-8, WA270-8E0)................................ 01-97

01-2 107E-3 SERIES

01 SPECIFICATIONS CONTENTS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA320-8, WA320-8E0)................................ 01-98

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA380-8) .................................................... 01-99

107E-3 SERIES 01-3

ABBREVIATION LIST 01 SPECIFICATIONS

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

01-4 107E-3 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

107E-3 SERIES 01-5

ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

01-6 107E-3 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

107E-3 SERIES 01-7

ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

01-8 107E-3 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

107E-3 SERIES 01-9

OUTLINE OF EXHAUST GAS REGULATION 01 SPECIFICATIONS

SPECIFICATIONS
OUTLINE OF EXHAUST GAS REGULATION
• Diesel engines discharge the following 3 major materials
that have bad effects on the human body and environment.
NOx (nitrogen oxides): Respiratory disorder, acid rain
HC (Hydrocarbon): Photochemical smog
PM (particulate in air such as soot): Carcinogenic, respira-
tory disorder
• NOx is material which is produced at high temperature
from nitrogen (N2) and oxygen (O2) in the air. It is pro-
duced in the diesel engine because of excessive air (nitro-
gen). To reduce NOx, the combustion temperature in the
cylinder must be reduced to restrict oxidation of nitrogen.
For this purpose, the air from turbocharger (1) has been
cooled by air-cooled aftercooler (2) and recirculated (EGR
system).
• HC is the main component of the fuel. HC contained in the
blowby gas is the main part of the toxic material dis-
charged from the diesel engine, but it has been discharged
into the atmosphere.
• PM is produced by incomplete combustion of fuel, similarly
to HC. It is particles (solid matter) sticking soot, etc. Gener-
ally, if either of NOx and PM is reduced, the other increa-
ses. To reduced PM, common rail (3) is employed, and
electronically controlled high-pressure fuel injection system
is used to spray fuel finely, shorten the injection period, and improve the injection timing.
• Exhaust gas regulations are made and applied in Japan, USA, and EU. The following figure shows the his-
tory of the exhaust gas regulation in USA from Tier 1 to Tier4. (History of exhaust gas regulation by EPA
(*1) of USA (For engine rated horsepower: 130 to 560 kW))
The horizontal axis is NOx + NMHC (*2) and the vertical axis is PM. Discharge levels of both NOx + NMHC
and PM are reduced to almost 1/10 from Tier 3 to Tier 4 Final. This exhaust gas regulation is called “Tier 4
Final Regulation”.
*1: United States Environmental Protection Agency
*2: General term for hydrocarbon (HC) which highly causes
photochemical reaction.

01-10 107E-3 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION

SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION

A: From atmosphere B: To atmosphere

1: Air cleaner 12: Engine oil pan
2: VGT 13: Engine
3: Air-cooled aftercooler 14: Mixing connector
4: Intake air heater 15: AdBlue/DEF mixing tube
5: Intake manifold 16: SCR assembly
6: Exhaust manifold 17: AdBlue/DEF tank
7: EGR valve 18: AdBlue/DEF pump
8: KCCV ventilator 19: AdBlue/DEF injector
9: KDPF(*1), KDOC(*2) 20: Engine controller
10: EGR cooler 21: Various sensors
11: Flywheel housing
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

107E-3 SERIES 01-11

OUTLINE OF EXHAUST GAS REGULATION 01 SPECIFICATIONS

IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION

Improved points of Tier 4 Interim over Tier 3
• Increase of efficiency of EGR cooler (10) (Reduction of NOx)
• Increase of intake air (reduction of PM) in engine low speed range by variable rotation of turbocharger
(VGT)
• Oxygen density control (reduction of NOx and PM) by EGR ratio (*1) control matched to operating condition
which are attained by high-precision EGR valve (EGRV), intake air flow and temperature sensor (MAF), en-
gine controller, and sensing of various portions of EGR circuit
• Fine fuel injection (reduction of PM) by increase of common rail pressure and fuel injection pressure
• Internal recirculation of blowby gas (reduction of HC) by employment of blowby reducing device (KCCV)
• Employment of soot collecting filter (KCSF) (reduction of PM) (*2)
• Oxidation catalyst is employed (to reduction PM and HC) (*3)
• Improvement of combustion chamber (reduction of NOx, reduction of PM, low fuel consumption)
• High altitude is recognized by ambient pressure sensor (PAMB), and fuel injection and VGT are controlled
automatically (reduction of NOx and PM at high altitude).
• Sensing of rotation of VGT (REV) (protection of VGT)
• Clogging of soot collecting filter (KCSF) is detected by differential pressure (dP) in KDPF, and engine con-
troller performs regeneration *4) as necessary (automatic regeneration) or performance of manual regener-
ation is displayed on machine monitor (maintenance of function of KDPF) (*2)
*1: EGR ratio means the ratio of EGR gas contained in the intake gas.
*2: Six cylinder engine is shown.
*3: Four cylinder engine is shown.
*4: Function to purify (burn) soot accumulated in soot collecting figure (KCSF) in KDPF.
Improved points of Tier 4 Final over Tier 4 Interim
• AdBlue/DEF is sprayed over toxic nitrogen oxides (NOx) contained in exhaust gas to decompose the into
harmless nitrogen and water. Urea SCR system (*5) is employed for this purpose.
*5: Function to purify NOx by making ammonia in AdBlue/DEF react with NOx inside catalyst.

01-12 107E-3 SERIES

01 SPECIFICATIONS LIST OF APPLICABLE MACHINES: 107E-3

LIST OF APPLICABLE MACHINES: 107E-3

Engine Applicable machines
D51EX-24
D51EXI-24
Bulldozer
D51PX-24
SAA4D107E-3 D51PXI-24
HB215LC-3
Hydraulic excavator
PC170LC-11
WA200–8 Wheel loader
BR380JG-3 Mobile crusher
D61EX-24
D61EX-24E0
D61EXI-24
D61EXI-24E0
Bulldozer
D61PX-24
D61PX-24E0
D61PXI-24
D61PXI-24E0
GD655-6
GD655-7
Motor grader
GD675-6
SAA6D107E-3 GD675-7E0
PC210LC-11
PC210LCI-11
PC228USLC-11
PC238USLC-11 Hydraulic excavator
PC240LC-11
PC290LC-11
PC290LCI-11
WA270–8
WA270–8E0
WA320–8 Wheel loader
WA320–8E0
WA380–8

107E-3 SERIES 01-13

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS
SPECIFICATIONS: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
Engine model SAA4D107E-3
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}
Firing order - 1-3-4-2
Overall length mm 822
Overall width mm 696

Dimensions Overall height (excluding

mm 1029
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 99.2±5 {133±6.7}/ 2200 {2200}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 584±29.2 {59.6±3}/ 1450 {1450}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2270±30 {2270±30}
(high idle speed)
Min. speed with no load
min-1{rpm} 1075±25 {1075±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 217.6{162}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 467
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 17(15.5)
Amount of coolant ℓ 9.7
Alternator - 24 V, 85 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE200

01-14 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA4D107E-3 (HB215LC-3)

Engine model SAA4D107E-3
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}
Firing order - 1-3-4-2
Overall length mm 770
Overall width mm 848

Dimensions Overall height (excluding

mm 1255
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 110.3±5 {148±6.7}/ 2000{2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 640±32 {65.3±3.3}/ 1500{1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2060±50 {2060±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 700±25 {700±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 207 {154}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 478
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 20(18)
Amount of coolant ℓ 8.2
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE200

107E-3 SERIES 01-15

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA4D107E-3 (PC170LC-11)

Engine model SAA4D107E-3
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}
Firing order - 1-3-4-2
Overall length mm 797
Overall width mm 835

Dimensions Overall height (excluding

mm 1214
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 90.0±4.5 {121±6.1}/ 2100 {2100}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 498.9±24.9 {50.9±2.5}/ 1500 {1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2320±30 {2320±30}
(high idle speed)
Min. speed with no load
min-1{rpm} 1050±25 {1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216{159}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 436
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 20(18)
Amount of coolant ℓ 8.2
Alternator - 24 V, 85 A
Starting motor - 24 V, 4.5 kW
VGT (Turbocharger) - HE200

01-16 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA4D107E-3 (WA200-8)

Engine model SAA4D107E-3
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}
Firing order - 1-3-4-2
Overall length mm 826
Overall width mm 829

Dimensions Overall height (excluding

mm 1074
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 95.2±4.8{128±6.4}/2000{2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 599±30.0{61.1±3.1}/1350{1350}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2250±50{2250±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 825±25{825±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 211{155}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 474
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 17.5(15.5)
Amount of coolant ℓ 9.7
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE200

107E-3 SERIES 01-17

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (BR380JG-3)

Engine model SAA6D107E-3
No. of cylinders-bore x stroke mm 6-107x124
Piston displacement ℓ {cc} 6.69{6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1134
Overall width mm 812

Dimensions Overall height (excluding

mm 1190
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW {HP} /
Rated horsepower (Gross) 158.6±7.9{213±10.6}/2050{2050}
min-1 {rpm}
Nm {kgfm} /
Maximum torque (Gross) 941±47{95.9±4.8}/1500{1500}
min-1 {rpm}

Performance Max. speed with no load

min-1 {rpm} 2180 ± 50{2180 ± 50}
(high idle speed)
Min. speed with no load
min-1 {rpm} 1050±25{1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh {g/HPh} 213{159}
rated point
Dry weight (excluding aftertreatment devices) kg 575
Fuel injection system - High pressure common rail type
Fuel injection system control - Electronic control type
Lubricating oil amount (refill capacity) ℓ 25.4(23.1)
Coolant level ℓ 11.0
Alternator - 24 V, 60 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

01-18 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1451
Overall width mm 806

Dimensions Overall height (excluding

mm 1348
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 127±6.4 {170.3±8.5}/ 2200 {2200}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 767±38.4 {78.2±3.9}/ 1400 {1400}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2280±30 {2280±30}
(high idle speed)
Min. speed with no load
min-1{rpm} 975±25 {975±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216 {161}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 625
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 35.5 (31.6)
Amount of coolant ℓ 11.0
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

107E-3 SERIES 01-19

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,

D61PXI-24E0)
Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1451
Overall width mm 806

Dimensions Overall height (excluding

mm 1348
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 127±6.4 {170.3±8.5}/ 2200 {2200}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 767±38.4 {78.2±3.9}/ 1400 {1400}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2280±30 {2280±30}
(high idle speed)
Min. speed with no load
min-1{rpm} 975±25 {975±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216 {161}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 625
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 35.5 (31.6)
Amount of coolant ℓ 11.0
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

01-20 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1427
Overall width mm 955

Dimensions Overall height (excluding

mm 1456
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 165±8.2 {221±11}/ 2100 {2100}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 941±47.0 {96.0±4.8}/ 1450 {1450}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2200±25 {2200±25}
(high idle speed)
Min. speed with no load
min-1{rpm} 825±25 {825±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216 {161}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 607
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 12.4
Alternator - 24 V, 90 A or 140 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

107E-3 SERIES 01-21

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (PC210LC-11,PC210LCI-11)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1165
Overall width mm 740

Dimensions Overall height (excluding

mm 1211
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 123.2±6.16 {165.2±8.31}/ 2000 {2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 730.8±36.5 {74.5±3.72}/ 1500 {1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2060±50 {2060±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 1050±25 {1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 217.5 {162}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 575
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Amount of lubricating oil (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 11.0
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

01-22 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1165
Overall width mm 801

Dimensions Overall height (excluding

mm 1211
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 123.2±6.16 {165.2±8.31}/ 2000 {2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 730.8±36.5 {74.5±3.72}/ 1500 {1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2060±50 {2060±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 1050±25 {1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 217.5 {162}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 575
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Amount of lubricating oil (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 11.0
Alternator - 24 V, 85 A
Starting motor - 24 V, 4.5 kW or 5.5 kW
VGT (Turbocharger) - HE300

107E-3 SERIES 01-23

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (PC240LC-11)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1137
Overall width mm 664

Dimensions Overall height (excluding

mm 1138
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 141±7.06 {189±9.47}/ 2000 {2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 837.8±41.9 {85.4±4.3}/ 1500{1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2060±50 {2060±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 1050±25 {1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 213 {159}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 575
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 12.4
Alternator - 24 V, 60 A
Starting motor - 24 V, 4.5 kW
VGT (Turbocharger) - HE300

01-24 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (PC290LC-11, PC290LCI-11)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1137
Overall width mm 812

Dimensions Overall height (excluding

mm 1138
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 158.6±7.9 {213±10.6}/ 2050 {2050}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 941±47 {95.9±4.8}/ 1500 {1500}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2180±50 {2180±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 1050±25 {1050±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 213 {159}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 575
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 11.0
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

107E-3 SERIES 01-25

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (WA270-8, WA270-8E0)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1045
Overall width mm 861

Dimensions Overall height (excluding

mm 1183
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 114.5±5.7 {153.5±7.6}/2000{2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 690±35{70.4±3.5}/1300{1300}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2250±50 {2250±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 825±25 {825±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 220 {164}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 615
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25(23.1)
Amount of coolant ℓ 11.7
Alternator - 24 V, 90 A or 140 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

01-26 107E-3 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (WA320-8, WA320-8E0)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1045
Overall width mm 861

Dimensions Overall height (excluding

mm 1194
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 127±6.4 {170.3±8.5}/ 2100 {2100}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 767±38 {78.2±3.9}/ 1400 {1400}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2250±50 {2250±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 825±25 {825±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 220{164}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 620
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25(23.1)
Amount of coolant ℓ 11.7
Alternator - 24 V, 90 A or 140 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

107E-3 SERIES 01-27

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D107E-3 (WA380-8)

Engine model SAA6D107E-3
No. of cylinders - bore x stroke mm 6 - 107 x 124
Piston displacement ℓ{cc} 6.69 {6690}
Firing order - 1-5-3-6-2-4
Overall length mm 1100
Overall width mm 861

Dimensions Overall height (excluding

mm 1164
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 143.4±7.2 {192.3±9.6}/ 2100 {2100}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 941±47 {96±4.8}/ 1450 {1450}
min-1{rpm}

Performance Max. speed with no load

min-1{rpm} 2250±50 {2250±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 850±25 {850±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216 {161}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 607
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 25.4 (23.1)
Amount of coolant ℓ 12.4
Alternator - 24 V, 90 A
Starting motor - 24 V, 5.5 kW
VGT (Turbocharger) - HE300

01-28 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24,
D51PXI-24)
REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 822 mm

107E-3 SERIES 01-29

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-30 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1029 mm
Dimension (C): 334 mm
Dimension (D): 696 mm

107E-3 SERIES 01-31

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-32 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA4D107E-3 (HB215LC-3)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of rear frange
Dimension (A) : 770 mm

107E-3 SERIES 01-33

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of rear frange

01-34 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1255 mm
Dimension (C): 437 mm
Dimension (D): 848 mm

107E-3 SERIES 01-35

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-36 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA4D107E-3 (PC170LC-11)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 797 mm

107E-3 SERIES 01-37

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-38 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1214 mm
Dimension (C): 392 mm
Dimension (D): 835 mm

107E-3 SERIES 01-39

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-40 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA4D107E-3 (WA200-8)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 826 mm

107E-3 SERIES 01-41

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-42 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1074 mm
Dimension (C): 382 mm
Dimension (D): 829 mm

107E-3 SERIES 01-43

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-44 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (BR380JG-3)

REMARK
The shape may vary with the machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1134 mm

107E-3 SERIES 01-45

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-46 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1190 mm
Dimension (C): 407 mm
Dimension (D): 812 mm

107E-3 SERIES 01-47

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-48 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24,

D61PXI-24)
REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1451 mm

107E-3 SERIES 01-49

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-50 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1348 mm
Dimension (C): 377 mm
Dimension (D): 806 mm

107E-3 SERIES 01-51

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-52 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,

D61PX-24E0, D61PXI-24E0)
REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1451 mm

107E-3 SERIES 01-53

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-54 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1348 mm
Dimension (C): 377 mm
Dimension (D): 806 mm

107E-3 SERIES 01-55

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-56 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (GD655-6, GD655-7, GD675-6,

GD675-7E0)
REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1472 mm

107E-3 SERIES 01-57

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-58 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1456 mm
Dimension (C): 409 mm
Dimension (D): 955 mm

107E-3 SERIES 01-59

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-60 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (PC210LC-11,PC210LCI-11)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1165 mm

107E-3 SERIES 01-61

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-62 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1211 mm
Dimension (C): 429 mm
Dimension (D): 740 mm

107E-3 SERIES 01-63

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-64 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1165 mm

107E-3 SERIES 01-65

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-66 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1211 mm
Dimension (C): 429 mm
Dimension (D): 801 mm

107E-3 SERIES 01-67

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-68 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (PC240LC-11, PC290LC-11,

PC290LCI-11)
REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1137 mm

107E-3 SERIES 01-69

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-70 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1211 mm
Dimension (C): 429 mm
Dimension (D): 812 mm

107E-3 SERIES 01-71

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-72 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (WA270-8, WA270-8E0)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1045 mm

107E-3 SERIES 01-73

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-74 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1183 mm
Dimension (C): 429 mm
Dimension (D): 861 mm

107E-3 SERIES 01-75

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-76 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (WA320-8, WA320-8E0)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1045 mm

107E-3 SERIES 01-77

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-78 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1194 mm
Dimension (C): 409 mm
Dimension (D): 861 mm

107E-3 SERIES 01-79

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-80 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D107E-3 (WA380-8)

REMARK
The shape is subject to machine models.
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1100 mm

107E-3 SERIES 01-81

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-82 107E-3 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1164 mm
Dimension (C): 409 mm
Dimension (D): 861 mm

107E-3 SERIES 01-83

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-84 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA4D107E-3 (D51EX-24, D51EXI-24,
D51PX-24, D51PXI-24)
Rated output:99.2±5 kW {133±6.7 HP} /2200 min-1 {2200 rpm} (Gross)
Max. torque: 584±29.2 Nm {59.6±3 kgfm} /1450 min-1 {1450 rpm} (Gross)

800

600

Torque (Nm)
400

200

0
120

100
Flywheel horsepower (kW)

80

60

40

20

Engine speed (min-1)

$(

107E-3 SERIES 01-85

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA4D107E-3 (HB215LC-3)

Rated output:110.3±5 kW {148±6.7 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 640±32 Nm {65.3±3.3 kgfm} /1500 min-1 {1500 rpm} (Gross)

800

600

Torque (Nm)
400

200

0
120

100
Flywheel horsepower (kW)

80

60

40

20

Engine speed (min-1)

$((

01-86 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA4D107E-3 (PC170LC-11)

Rated output:90.0±4.5 kW {121±6.1 HP} /2100 min-1 {2100 rpm} (Gross)
Max. torque: 498.9±24.9 Nm {50.9±2.5 kgfm} /1500 min-1 {1500 rpm} (Gross)

600

Torque (Nm)
400

200

0
100

80
Flywheel horsepower (kW)

60

40

20

Engine speed (min-1)

$(

107E-3 SERIES 01-87

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA4D107E-3 (WA200-8)

Rated output:95.2±4.8 kW {128±6.4 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 599±30.0 Nm {61.1±3.1 kgfm} /1350 min-1 {1350 rpm} (Gross)

800

Torque (Nm)
600

400

200

0
120

100
Flywheel horsepower (kW)

80

60

40

20

Engine speed (min-1)

$((

01-88 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (BR380JG-3)

Rated horsepower: 158.6±7.9 kW {213±10.6 HP} /2050 min-1 {2050 rpm} (Gross)
Maximum torque: 941±47 Nm {95.9±4.8 kgfm} /1500 min-1 {1500 rpm} (Gross)

1000

800

Torque (Nm)
600

400

200

0
180

160

140
Flywheel horsepower (kW)

120

100

80

60

40

20

Engine speed (min-1)

$((

107E-3 SERIES 01-89

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24, D61EXI-24,

D61PX-24, D61PXI-24)
Rated output: 127.4±6.4 kW {170.3±8.5 HP} /2200 min-1 {2200 rpm} (Gross)
Max. torque: 767±38.4 Nm {78.2±3.9 kgfm} /1400 min-1 {1400 rpm} (Gross)

01-90 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,

D61PX-24E0, D61PXI-24E0)
Rated output: 127.4±6.4 kW {170.3±8.5 HP} /2200 min-1 {2200 rpm} (Gross)
Max. torque: 767±38.4 Nm {78.2±3.9 kgfm} /1400 min-1 {1400 rpm} (Gross)

107E-3 SERIES 01-91

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6,

GD675-7E0)
Rated output: 165±8.2 kW {221±11 HP} /2100 min-1 {2100 rpm} (Gross)
Max. torque: 941±47.0 Nm {96.0±4.8 kgfm} /1450 min-1 {1450 rpm} (Gross)

1200

1000

800

Torque (Nm)
600

400

200

0
180

160

140
Flywheel horsepower (kW)

120

100

80

60

40

20

Engine speed (min-1)

*

01-92 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC210LC-11, PC210LCI-11)

Rated output: 123.2±6.16 kW {165.2±8.31 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 730.8±36.5 Nm {74.5±3.72 kgfm} /1500 min-1 {1500 rpm} (Gross)

800

600

Torque (Nm)
400

200

0
140

120
Flywheel horsepower (kW)

100

80

60

40

20

Engine speed (min-1)

$(

107E-3 SERIES 01-93

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC228USLC-11,

PC238USLC-11)
Rated output: 123.2±6.16 kW {165.2±8.31 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 730.8±36.5 Nm {74.5±3.72 kgfm} /1500 min-1 {1500 rpm} (Gross)

800

600

Torque (Nm)
400

200

0
140

120
Flywheel horsepower (kW)

100

80

60

40

20

Engine speed (min-1)

$(

01-94 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC240LC-11)

Rated output:141±7.06 kW {189±9.47 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 837.8±41.9 Nm {85.4±4.3 kgfm} /1500 min-1 {1500 rpm} (Gross)

1000

800

Torque (Nm)
600

400

200

0
160

140

120
Flywheel horsepower (kW)

100

80

60

40

20

Engine speed (min-1)

$(

107E-3 SERIES 01-95

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)

Rated output:158.6±7.9 kW {213±10.6 HP} /2050 min-1 {2050 rpm} (Gross)
Max. torque: 941±47 Nm {95.9±4.8 kgfm} /1500 min-1 {1500 rpm} (Gross)

1000

800

Torque (Nm)
600

400

200

0
180

160

140
Flywheel horsepower (kW)

120

100

80

60

40

20

Engine speed (min-1)

$((

01-96 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA270-8, WA270-8E0)

Rated output: 114.5±5.7 kW {153.5±7.6 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 690±35 Nm {70.4±3.5 kgfm} /1300 min-1 {1300 rpm} (Gross)

107E-3 SERIES 01-97

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA320-8, WA320-8E0)

Rated output: 127.0±6.4 kW {170.3±8.5 HP} /2100 min-1 {2100 rpm} (Gross)
Max. torque: 767±38 Nm {78.2±3.9 kgfm} /1400 min-1 {1400 rpm} (Gross)

01-98 107E-3 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA380-8)

Rated output: 143.4±7.2 kW {192.3±9.6 HP} /2100 min-1 {2100 rpm} (Gross)
Max. torque: 941±47 Nm {96±4.8 kgfm} /1450 min-1 {1450 rpm} (Gross)

107E-3 SERIES 01-99

 10 STRUCTURE AND FUNCTION

107E-3 SERIES 10-1

CONTENTS 10 STRUCTURE AND FUNCTION

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 10-5
UREA SCR SYSTEM....................................................................................................................................10-11
LAYOUT DRAWING OF UREA SCR SYSTEM ......................................................................................10-11
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-19
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-21
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-22
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-23
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM ............................................................................ 10-23
INDUCEMENT STRATEGY ........................................................................................................... 10-26
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-45
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-45
SCR ASSEMBLY ........................................................................................................................... 10-47
AdBlue/DEF TANK ......................................................................................................................... 10-51
AdBlue/DEF PUMP ........................................................................................................................ 10-53
AdBlue/DEF INJECTOR................................................................................................................. 10-54
AdBlue/DEF HOSE ........................................................................................................................ 10-55
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-56
ENGINE SYSTEM ....................................................................................................................................... 10-57
LAYOUT OF ENGINE COMPONENTS ................................................................................................. 10-57
LAYOUT DRAWING OF ENGINE COMPONENTS ........................................................................ 10-57
LAYOUT DRAWING OF ENGINE COMPONENTS ........................................................................ 10-60
INTAKE AND EXHAUST SYSTEM PARTS ........................................................................................... 10-61
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................... 10-61
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................... 10-62
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM................................................................ 10-63
FUNCTION OF INTAKE AND EXHAUST SYSTEM ....................................................................... 10-63
AIR CLEANER ............................................................................................................................... 10-65
INTAKE AIR HEATER .................................................................................................................... 10-67
ENGINE MAIN BODY PARTS............................................................................................................... 10-68
CYLINDER HEAD .......................................................................................................................... 10-68
CYLINDER BLOCK........................................................................................................................ 10-70
MAIN MOVING PARTS .................................................................................................................. 10-72
VIBRATION DAMPER.................................................................................................................... 10-76
TIMING GEAR ............................................................................................................................... 10-77
FRONT COVER............................................................................................................................. 10-78
VALVE SYSTEM ............................................................................................................................ 10-79
FLYWHEEL AND FLYWHEEL HOUSING ...................................................................................... 10-82
TURBOCHARGER SYSTEM ................................................................................................................ 10-84
CIRCUIT DIAGRAM OF VGT SYSTEM ......................................................................................... 10-84
FUNCTION OF VGT SYSTEM....................................................................................................... 10-85
VGT ............................................................................................................................................... 10-87
EGR SYSTEM ............................................................................................................................... 10-93
EGR VALVE ................................................................................................................................... 10-98
EGR COOLER ..............................................................................................................................10-102
KCCV SYSTEM ............................................................................................................................10-105
KCCV VENTILATOR .....................................................................................................................10-109
KDPF ............................................................................................................................................ 10-111
KDOC ...........................................................................................................................................10-115
LUBRICATION SYSTEM......................................................................................................................10-118
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS............................................................10-118
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS............................................................10-120
LUBRICATION SYSTEM CIRCUIT DIAGRAM..............................................................................10-121
LUBRICATION SYSTEM CIRCUIT DIAGRAM..............................................................................10-122
ENGINE OIL PUMP ......................................................................................................................10-123
ENGINE BOOST OIL PUMP.........................................................................................................10-124
ENGINE OIL FILTER ....................................................................................................................10-125

10-2 107E-3 SERIES

10 STRUCTURE AND FUNCTION CONTENTS

ENGINE OIL COOLER .................................................................................................................10-126

ENGINE OIL REGULATOR VALVE ...............................................................................................10-127
SAFETY VALVE OF ENGINE OIL .................................................................................................10-128
ENGINE OIL PAN .........................................................................................................................10-129
FUEL SYSTEM ....................................................................................................................................10-130
LAYOUT DRAWING OF FUEL SYSTEM PARTS ..........................................................................10-130
FUEL SYSTEM CIRCUIT DIAGRAM ............................................................................................10-133
FUNCTION OF FUEL SYSTEM ....................................................................................................10-134
SUPPLY PUMP.............................................................................................................................10-136
FUEL PREFILTER ........................................................................................................................10-137
FUEL MAIN FILTER......................................................................................................................10-138
COOLING SYSTEM.............................................................................................................................10-139
LAYOUT DRAWING OF COOLING SYSTEM PARTS...................................................................10-139
COOLING SYSTEM CIRCUIT DIAGRAM .....................................................................................10-140
COOLING SYSTEM CIRCUIT DIAGRAM .....................................................................................10-141
DRIVE PULLEY ............................................................................................................................10-142
WATER PUMP ..............................................................................................................................10-144
THERMOSTAT..............................................................................................................................10-145
ELECTRICAL SYSTEM ..............................................................................................................................10-146
COMPONENT PARTS OF ELECTRICAL SYSTEM .............................................................................10-146
ALTERNATOR ..............................................................................................................................10-146
STARTING MOTOR ......................................................................................................................10-152
ENGINE WIRING HARNESS........................................................................................................10-154
ENGINE CONTROLLER ...............................................................................................................10-158
SENSOR..............................................................................................................................................10-172
LAYOUT DRAWING OF ENGINE SENSOR .................................................................................10-172
LAYOUT DRAWING OF ENGINE SENSOR .................................................................................10-174
STRUCTURE OF AMBIENT PRESSURE SENSOR .....................................................................10-176
FUNCTION OF AMBIENT PRESSURE SENSOR ........................................................................10-176
STRUCTURE OF ENGINE OIL PRESSURE SWITCH .................................................................10-177
FUNCTION OF ENGINE OIL PRESSURE SWITCH .....................................................................10-177
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR ..................10-178
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR......................10-178
STRUCTURE OF COOLANT TEMPERATURE SENSOR.............................................................10-179
FUNCTION OF COOLANT TEMPERATURE SENSOR ................................................................10-179
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ............................................................10-180
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ...............................................................10-180
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR .............................................................10-181
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................10-181
STRUCTURE OF COMMON RAIL PRESSURE SENSOR ...........................................................10-182
FUNCTION OF COMMON RAIL PRESSURE SENSOR ...............................................................10-182
STRUCTURE OF EGR VALVE LIFT SENSOR .............................................................................10-183
FUNCTION OF EGR VALVE LIFT SENSOR.................................................................................10-183
STRUCTURE OF VGT SPEED SENSOR.....................................................................................10-184
FUNCTION OF VGT SPEED SENSOR ........................................................................................10-184
STRUCTURE OF VGT POSITION SENSOR ................................................................................10-185
FUNCTION OF VGT POSITION SENSOR ...................................................................................10-185
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR .........................................10-186
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR.............................................10-186
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .....10-187
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .........10-187
STRUCTURE OF CRANKCASE PRESSURE SENSOR...............................................................10-188
FUNCTION OF CRANKCASE PRESSURE SENSOR ..................................................................10-188
STRUCTURE OF ENGINE OIL LEVEL SENSOR.........................................................................10-189
FUNCTION OF ENGINE OIL LEVEL SENSOR ............................................................................10-189
STRUCTURE OF AIR CLEANER CLOGGING SENSOR .............................................................10-190
FUNCTION OF AIR CLEANER CLOGGING SENSOR .................................................................10-190
STRUCTURE OF WATER-IN-FUEL SENSOR..............................................................................10-191

107E-3 SERIES 10-3

CONTENTS 10 STRUCTURE AND FUNCTION

FUNCTION OF WATER-IN-FUEL SENSOR .................................................................................10-191

STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR) ........................................10-192
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)............................................10-192
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR.................................................10-193
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR ....................................................10-193
STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR.......................................................10-194
FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR ..........................................................10-194
STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR) ................................10-195
FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)....................................10-195

10-4 107E-3 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

107E-3 SERIES 10-5

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

10-6 107E-3 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

107E-3 SERIES 10-7

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

10-8 107E-3 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

107E-3 SERIES 10-9

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

10-10 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction

LAYOUT DRAWING OF UREA SCR SYSTEM

REMARK
PC220 series model 11 is shown in the figure (six cylinder engine) as an example.

107E-3 SERIES 10-11

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

1: AdBlue/DEF filler port 5: AdBlue/DEF tank pressure hose (low temperature

2: AdBlue/DEF tank coolant outlet hose side)

3: AdBlue/DEF return hose 6: AdBlue/DEF pump

4: AdBlue/DEF tank 7: AdBlue/DEF suction hose

10-12 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

8: AdBlue/DEF tank coolant inlet hose 11: KDPF(*1), KDOC(*2)

9: AdBlue/DEF pressure hose (high-temperature side) 12: AdBlue/DEF mixing tube
10: AdBlue/DEF tank heating valve
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

107E-3 SERIES 10-13

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

13: SCR assembly 15: AdBlue/DEF injector

14: AdBlue/DEF injector coolant hose

10-14 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

16: Ambient temperature sensor 17: Engine room temperature sensor

107E-3 SERIES 10-15

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Detailed drawing of SCR assembly (six cylinder engine)

1: SCR outlet NOx sensor 4: Ammonia sensor

2. SCR outlet temperature sensor 5: SCR temperature sensor
3: Turbocharger outlet NOx sensor

10-16 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

Detailed drawing of SCR assembly (four cylinder engine)

1: SCR temperature sensor 3: SCR outlet temperature sensor

2: SCR outlet NOx sensor

107E-3 SERIES 10-17

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Detailed drawing of AdBlue/DEF tank

1: AdBlue/DEF tank sensor

10-18 107E-3 SERIES

10 STRUCTURE AND FUNCTION UREA SCR SYSTEM DIAGRAM

UREA SCR SYSTEM DIAGRAM

REMARK
Six cylinder engine is shown in the figure.

A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor 19: Downstream SCR catalyst and ammonia oxidation
2: Engine catalyst (integrated type)
3: Engine controller 20: Ammonia sensor
4: KDPF assembly 21: KDPF temperature sensor controller
5: KDOC unit 22: SCR temperature sensor
6: KCSF unit 23: SCR outlet temperature sensor
7: KDPF differential pressure sensor 24: SCR temperature sensor controller

8: KDPF outlet pressure sensor 25: SCR outlet NOx sensor

9: Turbocharger outlet NOx sensor 26: SCR outlet NOx sensor controller

10: Turbocharger outlet NOx sensor controller 27: Smart sensor

11: KDOC inlet temperature sensor 28: Ambient temperature sensor

12: KDOC outlet temperature sensor 29: Engine room temperature sensor (*1)

13: KDPF outlet temperature sensor 30: AdBlue/DEF system

14: KDPF temperature sensor controller 31: AdBlue/DEF tank heating valve

15: AdBlue/DEF mixing tube 32: AdBlue/DEF tank

16: AdBlue/DEF injector 33: AdBlue/DEF tank sensor

17: SCR assembly 34: AdBlue/DEF suction line

18: Upstream SCR catalyst 35: AdBlue/DEF return line

36: AdBlue/DEF pressure line

107E-3 SERIES 10-19

UREA SCR SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

37: AdBlue/DEF pump 39: Machine monitor

38: AdBlue/DEF line heater relay
*1: There are some machine models which are not equipped with it.

10-20 107E-3 SERIES

10 STRUCTURE AND FUNCTION UREA SCR SYSTEM DIAGRAM

UREA SCR SYSTEM DIAGRAM

REMARK
Four cylinder engine is shown in the figure.

6 13
4
2 5 14 15
11 12 19
3 A
8 9 B 16 17
7 20
10 18

21
22

23
28
30 25
A
B
29
32
31 26
33

27
24
A4P12567

A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor 18: SCR temperature sensor controller
2: Engine 19: SCR outlet NOx sensor
3: Engine controller 20: SCR outlet NOx sensor controller
4: KDOC assembly 21: Smart sensor
5: KDOC unit 22: Ambient temperature sensor
6: Turbocharger outlet NOx sensor 23: Engine room temperature sensor (*1)
7: Turbocharger outlet NOx sensor controller 24: AdBlue/DEF system
8: KDOC inlet temperature sensor 25: AdBlue/DEF tank heating valve
9: KDOC outlet temperature sensor 26: AdBlue/DEF tank
10: KDOC temperature sensor controller 27: AdBlue/DEF tank sensor
11: AdBlue/DEF mixing tube 28: AdBlue/DEF suction line
12: AdBlue/DEF injector 29: AdBlue/DEF return line
13: SCR assembly 30: AdBlue/DEF pressure line
14: Upstream SCR catalyst 31: AdBlue/DEF pump
15: Downstream SCR catalyst and ammonia oxidation 32: AdBlue/DEF line heater relay
catalyst (integrated type) 33: Machine monitor
16: SCR temperature sensor
17: SCR outlet temperature sensor
*1: There are some machine models which are not equipped with it.

107E-3 SERIES 10-21

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

REMARK
Four cylinder engine is shown in this item.

5
CO N2

1 NOx H2O
HC CO2
6 7 8

2
4
3

A4P16366

1: Engine 6: KDOC
2: Engine controller 7: SCR catalyst
3: AdBlue/DEF pump 8: Downstream SCR catalyst and ammonia oxidation
4: AdBlue/DEF tank catalyst (integrated type)

5: AdBlue/DEF injector
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

10-22 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

FUNCTION OF UREA SCR SYSTEM

REMARK
Six cylinder engine is shown in this item.

1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

FUNCTION OF AdBlue/DEF SUPPLY SYSTEM

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF pump
4
3A: Flow control valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF supply system consists of AdBlue/DEF tank
3C
(1), AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3),
and AdBlue/DEF injector (6).
3B 3
• The AdBlue/DEF supply system is a part of the Komatsu
Urea SCR system and its function is to provide
AdBlue/DEF into the SCR Catalyst Assembly.
However, the comprising devices, such as the AdBlue/DEF A4P15761

pump, may not start functioning till certain conditions are

fulfilled.

107E-3 SERIES 10-23

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at -11 °C.
Function of AdBlue/DEF injection system
• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through
the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate. (*1)
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate. (*2)
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and
result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF
injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passag-
es.
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
• In the case of the AdBlue/DEF purging of the engine shut- 3C
down, the purging operation continues several minutes af-
ter the engine stops. 3B 3
NOTICE
Do not turn the battery disconnect switch to OFF position
A4P15762
till the System Operating Lamp in the battery box goes out.
The System Operating Lamp will go out when the system
shuts itself down after the purging operation completes.
Function of AdBlue/DEF thawing and preventing from freezing
• This function has the thawing mode and freeze prevention mode.
• One operation mode is “Thaw mode”.

10-24 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

• At engine start-up if the Engine Controller judges AdBlue/DEF is frozen, it automatically commands
heating the AdBlue/DEF injection system.
• The AdBlue/DEF pump and the AdBlue/DEF injector hold their operation till the Engine Controller judg-
es the completion of AdBlue/DEF thawing operation.
• The other operation mode is “Freeze Prevention mode”.
• While the machine is in operation if the Engine Controller judges AdBlue/DEF is likely to freeze, it auto-
matically commands heating the AdBlue/DEF system.
• While the heating is on during machine operation if the Engine Controller judges that cooling by the
ambient exceeds the heating capacity of the system, it automatically starts AdBlue/DEF purging and
shuts down the operation of the AdBlue/DEF pump and the AdBlue/DEF injector. However, the heating
system is kept on as long as the machine is in operation.
• Thawing and freeze prevention mode are controlled by sensor and the sensors vary by devices which AdBl-
ue/DEF system consists of. The following table shows the relationship among the object devices, heating
system and the sensors for each mode.

Relationship among the object devices, heating system and the sensors for each mode
When the engine room temperature sensor is equipped
Object devices for function of
Sensors for Thawing Sensors for Freeze Pre-
AdBlue/DEF thawing and prevent- Heating system
mode vention mode
ing from freezsing
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor

When the engine room temperature sensor is not equipped

Object devices for function of
Sensors for Thawing Sensors for Freeze Pre-
AdBlue/DEF thawing and prevent- Heating system
mode vention mode
ing from freezsing
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
sensor sensor
AdBlue/DEF pressure hose
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor

107E-3 SERIES 10-25

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed.
The warning steps of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

5%
2: Without Red
(Within the CA3498
Escalated treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

2.5%
Mild Induce- CA1673
ment (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)

10-26 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red

CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)

Red

Not remaining CA1673

Final Induce- in the tank CA3547
ment (*6) 5: Engine is Engine speed
5 running at low Continuously AS00ZK is fixed to low
(Inducement (All grada- idle. Red (AdBlue/DEF idle
3) tions lights level low error
off) 5)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.

107E-3 SERIES 10-27

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Yellow

1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))

Red

4: Engine AS00R4 Torque:

Severe In-
ducement power is CA3571 (Inducement 50%
Continu-
4 4 hours under 2 (SCR De-
(Induce- Red ously CB3571 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))

10-28 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

AS00R5
Final In- Engine
ducement 5: Engine is CA3571 (Inducement
Until repair- Continu- speed is
5 running at 3 (SCR De-
(Induce- ing Red ously CB3571 fixed to low
low idle. vice Abnor-
ment 3) idle
mality))

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDOC SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
REMARK
Four cylinder engine is shown in this item.
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDOC. Although the total
steps are the same and 5, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

107E-3 SERIES 10-29

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*4)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2)
ment strategy
el) status (*3)

Red

1: Please
inspect and
Long inter- Torque: over
1 Warning 1 hour maintain CA5391 No indication
Red mittently 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*5) AS00R2
Escalated treatment,
Warning Short inter- CA5391 (Warning 2 Torque: over
2 2 hours engine
power will mittently (SCR Device 25%
(Warning 2)
be derated. (*6) Abnormality))

Red

Red

Red AS00R3
Mild In- 3: Engine
ducement power is Long inter- (Inducement Torque: over
3 3 hours CA5391 1 (SCR De-
(Induce- under dera- mittently 25%
tion. vice Abnor-
ment 1)
mality))
Red

10-30 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*4)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2)
ment strategy
el) status (*3)

Red

4: Engine AS00R4 Torque: over

Severe In- 50%
ducement power is (Inducement
Continu-
4 4 hours under CA5391 2 (SCR De- and
(Induce- ously
heavy de- vice Abnor- RPM: over
ment 2) ration. mality)) 40%
Red

Red

Red AS00R5
Final In- Engine
ducement 5: Engine (Inducement
Until repair- Continu- speed is
5 is running CA5391 3 (SCR De-
(Induce- ing ously fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*4: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*5: Construction equipment with crawler
*6: Construction equipment with wheel

107E-3 SERIES 10-31

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
REMARK
Six cylinder engine is shown in this item.
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 5, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 1 hour maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Escalated treatment,
2 Warning 2 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

10-32 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA4151 (Inducement Torque: over
3 3 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red

Red

4: Engine Red AS00R4 Torque: over

Severe In- 50%
ducement power is CA4151 (Inducement
Continu-
4 4 hours under 2 (SCR De- and
(Induce- ously CB4151
heavy de- vice Abnor- RPM: over
ment 2) ration. mality)) 40%
Red

Red

Red AS00R5
Final In- Engine
ducement 5: Engine CA4151 (Inducement
Until repair- Continu- speed is
5 is running 3 (SCR De-
(Induce- ing ously CB4151 fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))
Red

107E-3 SERIES 10-33

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.

10-34 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)

Red

CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

107E-3 SERIES 10-35

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF

QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Yellow

1: Please
inspect and CA3571
1 Warning 5 hours maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

10-36 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Red

AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA3571 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))

Red

4: Engine AS00R4 Torque:

Severe In-
ducement power is CA3571 (Inducement 50%
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing Red ously CB3571 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDOC SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
REMARK
Four cylinder engine is shown in this item.
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDOC. Although the total
steps are the same and 4, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

107E-3 SERIES 10-37

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*4)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2)
ment strategy
el) status (*3)

Red

1: Please
inspect and
Long inter- Torque: over
1 Warning 5 hours maintain CA5391 No indication
Red mittently 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*5) AS00R2
Continuous treatment,
Warning Short inter- CA5391 (Warning 2 Torque: over
2 10 hours engine
power will mittently (SCR Device 25%
(Warning 2)
be derated. (*6) Abnormality))

Red

Red

Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- (Inducement Torque: over
3 20 hours CA5391 1 (SCR De-
(Induce- under dera- mittently 25%
tion. vice Abnor-
ment 1)
mality))
Red

10-38 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*4)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2)
ment strategy
el) status (*3)

Red

4: Engine Red AS00R4 Torque: over

Severe In- 50%
ducement power is (Inducement
Until repair- Continu-
4 under CA5391 2 (SCR De- and
(Induce- ing ously
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*4: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*5: Construction equipment with crawler
*6: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
REMARK
Six cylinder engine is shown in this item.
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 4, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning ”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

107E-3 SERIES 10-39

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 5 hours maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Continuous treatment,
2 Warning 10 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

Red

Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA4151 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red

10-40 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

4: Engine Red AS00R4 Torque: over

Severe In- 50%
ducement power is CA4151 (Inducement
Until repair- Continu-
4 under 2 (SCR De- and
(Induce- ing ously CB4151
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. It has 4 levels to-
tally which is the same as that, but it has different display on the machine monitor, and engine power dera-
tion (torque lowering ratio is 25% or more) and alarm starts from “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

107E-3 SERIES 10-41

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA2271
Long inter- Torque: over
1 Warning 5 hours maintain No indication
Red mittently CB2271 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Continuous treatment,
2 Warning 10 hours engine Short inter- CA2271 (Warning 2 Torque: over
power will mittently CB2271 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

Red

Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA2271 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB2271 25%
tion. vice Abnor-
ment 1)
mality))
Red

10-42 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

4: Engine Red AS00R4 Torque:

Severe In-
ducement power is CA2271 (Inducement 50%
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing ously CB2271 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.

107E-3 SERIES 10-43

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.

10-44 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

COMPONENT PARTS OF UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction

AdBlue/DEF MIXING TUBE

STRUCTURE OF AdBlue/DEF MIXING TUBE
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: Clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector

107E-3 SERIES 10-45

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF AdBlue/DEF MIXING TUBE

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

A: Exhaust gas inlet (from KDOC) B: Exhaust gas outlet (to SCR)
1: AdBlue/DEF mixing tube (connector) 4: Gasket for AdBlue/DEF injector
2: Clamp 5: AdBlue/DEF injector
3: AdBlue/DEF mixing tube (tube)

FUNCTION OF AdBlue/DEF MIXING TUBE

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.

10-46 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

SCR ASSEMBLY
SCR
Abbreviation for Selective Catalytic Reduction

STRUCTURE OF SCR ASSEMBLY

REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

107E-3 SERIES 10-47

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

A: From AdBlue/DEF mixing tube B: To exhaust pipe

1: SCR body 10: Sensor table
2: SCR temperature sensor 11: Sensor table band
3: SCR outlet NOx sensor 12: Catalyzer hold mat
4: SCR outlet temperature sensor 13: Water dam
5: Temperature sensor controller 14: Downstream SCR catalyst and ammonia oxidation
6: Ammonia sensor catalyst (integrated type)

7: Hanger plate 15: Upstream SCR catalyst

8: water baffle 16: Rectifier tube

9: Water drain port

• SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water
dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation cata-
lyst (14) while exhausting gas.
• Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 14, 15)cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and
SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as
they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (15, a part of 14) uses the ceramic honeycomb.
• The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also protects the outer periphery of SCR assembly against a
heat transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (14).
• Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.

10-48 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

STRUCTURE OF SCR ASSEMBLY

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

A: From AdBlue/DEF mixing tube B: To exhaust pipe

1: Hanger plate 6: SCR body
2: SCR temperature sensor 7: Water drain port
3: SCR outlet NOx sensor 8: SCR temperature sensor controller
4: water baffle 9: SCR outlet temperature sensor controller
5: SCR outlet temperature sensor

107E-3 SERIES 10-49

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

10: Rectifier tube 13: Water dam

11: Upstream SCR catalyst 14: Catalyzer hold mat
12: Downstream SCR catalyst and ammonia oxidation
catalyst (integrated type)
• SCR assembly consists of rectifier tube (10) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (11), downstream SCR catalyst, ammonia oxidation catalyst (integrated type)
(12), and water dam (13) which prevents rain water from entering into downstream SCR catalyst and am-
monia oxidation catalyst (integrated type) (12) while exhausting gas.
• Ammonia oxidation catalyst (a part of 12) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 12) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 12, 11) cannot completely consume it.
• SCR assembly has SCR temperature sensor (2), SCR outlet temperature sensor (5), and SCR outlet NOx
sensor (3) (1 piece each). These sensors monitor the function of SCR catalyst. These sensors are used for
various troubleshooting.
• Rectifying tube (10) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (a part of 12, 11) uses the ceramic honeycomb.
• The catalyzer holding mat (9) is made of a specific fiber and protects the ceramic catalyst against vibrations
by the engine and the machine body. It also protects the outer periphery of SCR assembly against a heat
transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (integrated type) (12).
• Water baffle (4) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.

10-50 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK

A: Coolant outlet D: To AdBlue/DEF pump

B: Coolant inlet E: To breather
C: From AdBlue/DEF pump
1: AdBlue/DEF tank 5: Drain plug
2: AdBlue/DEF filler cap 6: AdBlue/DEF tank sensor
3: Sensor flange assembly 7: AdBlue/DEF tank filter
4: Sight gauge

107E-3 SERIES 10-51

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
The shape is subject to machine models.

1: Connector 4: Level sensing part

2: Cover 5: Concentration Sensing part
3: Temperature sensing part

FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.

10-52 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF PUMP
STRUCTURE OF AdBlue/DEF PUMP
A: Suction from AdBlue/DEF tank
B: Return to AdBlue/DEF tank
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF return connector (*1)
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)
*1: There are some machine models which are not equipped
with check valve.

• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It sucks AdBlue/DEF from AdBlue/DEF tank, pressurizes it
to 900 kPa {9.18 kgf/cm2} , and sends it to AdBlue/DEF in- 2 3 4
jector.
• To prevent wrong connection of connectors, the return
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P

A4P15769

107E-3 SERIES 10-53

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector

FUNCTION OF AdBlue/DEF INJECTOR

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.

OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.

10-54 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE

1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one
touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.

FUNCTION OF AdBlue/DEF HOSE

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent AdBlue/DEF from freezing again while machine is operated.

107E-3 SERIES 10-55

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE

A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring

FUNCTION OF AdBlue/DEF TANK HEATING VALVE

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is
de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid (1).

OPERATION OF AdBlue/DEF TANK HEATING VALVE

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.

10-56 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT OF ENGINE COMPONENTS

ENGINE SYSTEM
LAYOUT OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

107E-3 SERIES 10-57

LAYOUT OF ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION

General view

1: Starting motor 6: KCCV ventilator

2: EGR cooler 7: Alternator
3: Engine oil filter 8: Vibration damper
4: SCR assembly 9: Auto-tensioner
5: KDPF 10: Air cleaner

10-58 107E-3 SERIES

10 STRUCTURE AND FUNCTION LAYOUT OF ENGINE COMPONENTS

11: VGT 14: Engine controller

12: Supply pump 15: Engine oil pan
13: Engine boost oil pump 16: Engine oil cooler

107E-3 SERIES 10-59

LAYOUT OF ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF ENGINE COMPONENTS

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.
General view

1: Starting motor 8: Auto-tensioner

2: EGR cooler 9: Air cleaner
3: Engine oil filter 10: VGT
4: SCR assembly 11: Supply pump
5: KDOC 12: Engine controller
6: KCCV ventilator 13: Engine oil pan
7: Alternator 14: Engine oil cooler

10-60 107E-3 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

INTAKE AND EXHAUST SYSTEM PARTS

LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

A: To KDPF E: From air cleaner

B: From EGR valve F: To aftercooler
C: From aftercooler G: From exhaust manifold
D: To intake manifold
1: VGT 4: Exhaust manifold
2: EGR valve 5: EGR cooler
3: Intake connector

107E-3 SERIES 10-61

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

A: To KDOC E: From air cleaner

B: From EGR valve F: To aftercooler
C: From aftercooler G: From exhaust manifold
D: To intake manifold
1: VGT 4: Exhaust manifold
2: EGR valve 5: EGR cooler
3: Intake connector

10-62 107E-3 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM

A: From atmosphere B: To atmosphere

1: Air cleaner 9: KDPF(*1), KDOC(*2)
2: VGT 10: EGR cooler
3: Air-cooled aftercooler 11: Flywheel housing
4: Intake air heater 12: Engine oil pan
5: Intake manifold 13: Engine
6: Exhaust manifold 14: Mixing connector
7: EGR valve 15: AdBlue/DEF mixing tube
8: KCCV ventilator 16: SCR assembly
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

FUNCTION OF INTAKE AND EXHAUST SYSTEM

• This engine is equipped with VGT (Variable Geometry Turbocharger), EGR system (EGR valve, EGR cool-
er) which recirculates a part of exhaust gas to the combustion chamber to reduce generation of NOx, KDPF
(KOMATSU Diesel Particulate Filter) which is an exhaust gas purifying device, KDOC (KOMATSU Diesel
Oxdation Catalyst)(*2), and urea SCR (*2) and KCCV (KOMATSU Closed Crankcase Ventilation) which re-
circulates the blowby gas.
• Since clean air is required to maintain the engine performance, the engine is damaged and its performance
is degraded, if it takes dirt or dust into it.
• Air is sucked into the engine through air cleaner (1), VGT (2), and air-cooled aftercooler (3).
Also, since VGT is equipped with the variable mechanism which is not installed to conventional turbocharg-
er, foreign material can damage VGT largely. Accordingly, cleaner or replace the air cleaner element ac-
cording to the procedure in Operation and Maintenance Manual, and take extreme care that foreign materi-
al does not enter.

107E-3 SERIES 10-63

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

• The intake air is sucked into the compressor side of VGT (2) through air cleaner (1). The air turbocharged
by VGT (2) is cooled by air-cooled aftercooler (3). Then, the air flows through mixing connector (14) and
intake manifold (5) into the cylinders and is used for combustion.
• The exhaust gas flows through exhaust manifold (6) to the turbine of VGT (2) and drives the turbine wheel
with its energy.
• To attain both clean exhaust gas and low fuel consumption, EGR system outputs signals from the engine
controller so that EGR valve (7) opens properly according to the engine load.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows through exhaust manifold (6) and
EGR piping to EGR cooler.
• The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air in
mixing connector (14), and then flows in intake manifold (5).
• KDPF (9) is installed to conform with the exhaust gas regulations and composed of KDOC (oxidation cata-
lyst) and KCSF (soot collecting filter) (*1).
• KDOC (9) is installed for the engine to be conformed with the exhaust gas regulations, and it is composed
of KDOC (oxidation catalyst). (*2)
• KCSF (soot collecting filter) collects particulate soot contained in the exhaust gas of the engine to clean the
exhaust gas.
• KDOC (Oxidation Catalyst) (9) cleans the exhaust gas by oxidization of SOF component (unburnt fuel and
constituent of lubrication oil) of PM (particulate matter) contained in the exhaust gas from the engine. (*2)
• AdBlue/DEF mixing tube (15) mixes AdBlue/DEF injected by AdBlue/DEF injector with the exhaust gas to
hydrolyze the exhaust gas into ammonia at high temperature.
• SCR assembly (16) makes the ammonia decomposed in AdBlue/DEF mixing tube (15) react chemically
with toxic nitrogen oxides (NOx) contained in the exhaust gas in the catalyst, and decomposes them into
harmless nitrogen and water.
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

10-64 107E-3 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

AIR CLEANER
STRUCTURE OF AIR CLEANER
REMARK
The shape is subject to machine models.
General view and sectional view

1: Vacuator valve 6: Rectifying wire net(*1), Rectifying guide(*2)

2: Inlet 7: Outer element
3: Air cleaner clogging sensor or dust indicator mount- 8: Guide bane
ing portion 9: Inner element
4: Outlet 10: Wire mesh
5: Mass air flow and temperature sensor mounting
portion
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

SPECIFICATIONS OF AIR CLEANER

Type: Cyclopac type
Filtering area (outer cylinder) (*1): 7.6 m2
Filtering area (inner cylinder): 1.4 m2
*1: Varies with the specification

OPERATION OF AIR CLEANER

1. Since inlet (2) is placed in the tangential direction, the intake air swirls along the body and generates a cen-
trifugal force.

107E-3 SERIES 10-65

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

2. The dust in the intake air is separated by the centrifugal separation effect.
3. Outer element (7) removes dust 99.9 % or more, and only clean air passes through outer element (7) and
rectifying wire net (6) (*1), rectifying guide (6) (*2) and is sucked into engine through the outlet (4).
4. Rectifying wire net (6) (*1) and the rectifying guide (6) (*2) rectify the air flow to the mass air flow and tem-
perature sensor (5) which has large effects on control of the engine.
5. The dust removed during the air intake process is automatically discharged out through vacuator valve (1)
when the engine stops.
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

10-66 107E-3 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

INTAKE AIR HEATER

STRUCTURE OF INTAKE AIR HEATER
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view

1: Intake air heater 4: Housing

2: Intake connector 5: Internal wiring diagram
3: Heater coil

SPECIFICATIONS OF INTAKE AIR HEATER

Type of heater: Ribbon heater
Rated voltage : 22 V (DC)
Load current : 100 A

107E-3 SERIES 10-67

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

ENGINE MAIN BODY PARTS

CYLINDER HEAD
STRUCTURE OF CYLINDER HEAD
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view and sectional view

1: Cylinder head 4: Cylinder head mounting bolt

2: Cylinder head cover 5: Injector assembly
3: Oil filler cap

10-68 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

SPECIFICATIONS OF CYLINDER HEAD

Cylinder head
Direct fuel injection type
Integrated type
4-valve
Valve seat
Press-fitted valve seat inserts on both intake and exhaust sides
Injector assembly
Installation: Dry type (without sleeve)

107E-3 SERIES 10-69

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

CYLINDER BLOCK
STRUCTURE OF CYLINDER BLOCK
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view and sectional view

a: Center of crankshaft b: Rear face of cylinder block

1: Main bearing cap 3: Cam bushing
2: Main bearing cap bolt 4: Cylinder block

SPECIFICATIONS OF CYLINDER BLOCK

Cylinder block
Crankshaft part: 7 bearings (*1), 5 bearings (*2)

10-70 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

Camshaft part: 7 bearings (*1), 5 bearings (*2)

Linerless
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

107E-3 SERIES 10-71

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

MAIN MOVING PARTS

STRUCTURE OF MAIN MOVING PARTS
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
Sectional view

1: Crankshaft 7: Thrust bearing

2: Front crankshaft gear (number teeth: 36) 8: Rear crankshaft gear (number teeth: 36)
3: Connecting rod 9: Main bearing
4: Cylinder block 10: Top ring
5: Piston 11: Second ring
6: Piston pin 12: Oil ring

10-72 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

13: Connecting rod bushing 16: Main bearing cap bolt

14: Connecting rod cap 17: Main bearing cap
15: Connecting rod cap bolt 18: Connecting rod bearing
Structure of crankshaft and main bearing
• Crankshaft is balance type forged steel, and has journal on
7 places. (*1)
• Crankshaft is balance type forged steel, and has journal on
5 places. (*2)
• Bearing shells on the lower part of main bearings (7
pieces) are all the same. (*1)
• Bearing shells on the lower part of main bearings (5
pieces) are all the same. (*2)
• Bearing shells on the upper part are all the same except
for 6th journal.
• 6th journal from the front has upper bearing shell with
flange. This flange determines the end thrust of the crankshaft. (*1)
• 4th journal from the front has upper bearing shell with flange. This flange determines the end thrust of the
crankshaft. (*1)
• There are 2 holes on the upper bearing.
• The larger hole is for oil coming from main oil line.
• The smaller hole is to be aligned to camshaft journal, and
works as orifice of oil flowing to camshaft journal.
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

Structure of piston and connecting rod

• Piston has 3 ring grooves on casted aluminum body with
oil passage for cooling the piston.
• Piston ring consists of three rings. The top ring is trapezoi-
dal, and held with Ni-resist cast iron insertion.

107E-3 SERIES 10-73

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

• Free flow type hollow piston pin is used for connecting pis-
ton and connecting rod.
• Pin and journal are lubricated by oil to be injected when
the piston is cooled.

• The bearing surface of connecting part of connecting rod

and piston is large because it is cut with angle.
• Bronze bushing is press-fitted into pin hole of the connect-
ing rod.

SPECIFICATIONS OF MAIN MOVING PARTS

Crankshaft
Closed die forging
Journal: Induction hardening
Piston
Toroidal combustion chamber for direct fuel injection
Aluminum piston (shaker)
Connecting rod
Closed die forging
Cap bolt: Screwed-in type (torque plus angle method tightening)

PISTON RING
STRUCTURE OF PISTON RING
Sectional view
1: Top ring
2: Second ring
3: Oil ring

10-74 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

Structure
Top ring (1) is a keystone, inner cut, barrel face, hard chromium plated ring.
Second ring (2) is taper type.
Oil ring (3) is an M-shaped steal ring equipped with a coil expander and hard chromium plated.

107E-3 SERIES 10-75

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

VIBRATION DAMPER
This item applies to six cylinder engine only.

STRUCTURE OF VIBRATION DAMPER

REMARK
The shape is subject to machine models.
General view

1: Vibration damper 3: Vibration damper mounting bolt

2: Dowel pin 4: Crankshaft pulley

FUNCTION OF VIBRATION DAMPER

Vibration damper (1) absorbs torsional vibration acting on the crankshaft and prevents breakage of the crank-
shaft and abnormal wear of the shaft and gears.

10-76 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

TIMING GEAR
STRUCTURE OF TIMING GEAR
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
Structural view

a: Matching mark b: Chamfered teeth

1: Supply pump gear (number of teeth: 27) 4: Engine boost oil pump gear (number of teeth: 36)
2: Camshaft gear (number of teeth: 72) (*1)

3: Timing (crankshaft) gear (number teeth: 36)

*1: Applies to six cylinder engine only.

FUNCTION OF TIMING GEAR

Timing of opening and closing of intake and exhaust valve and moving up and down of piston is adjusted by
installing timing (crankshaft) gear (3) and camshaft gear (2) as the engaging position is aligned to the match
mark (a) and chamfered teeth (b).

107E-3 SERIES 10-77

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

FRONT COVER
STRUCTURE OF FRONT COVER
REMARK
The shape is subject to machine models.
General view and sectional view

1: Front seal 4: Mounting hole for Bkup (camshaft) speed sensor

2: Front gear housing 5: Mounting hole for NE (crankshaft) speed sensor
3: Mounting hole for engine oil pressure switch

10-78 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

VALVE SYSTEM
STRUCTURE OF VALVE SYSTEM
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.

107E-3 SERIES 10-79

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

General view and sectional view

1: Exhaust valve 3: Valve seal

2: Intake valve 4: Valve spring

10-80 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

5: Valve cotter 10: Lock nut

6: Camshaft gear 11: Rocker arm
7: Camshaft 12: Push rod
8: Thrust plate 13: Tappet
9: Adjustment screw
Structure of camshaft, tappet, push rod
• Camshaft is gear-driven by crankshaft.
• Camshaft bushing is used for journals of both ends to re-
ceive the side load from accessory drive.
• Cast iron bore of cylinder block is used for other journals.

• Camshaft has camshaft lobe to activate the (air) intake

and exhaust valve.
• Camshaft lobe contacts to tappet that moves push rod up
and down.

• Tappet is mushroom shaped.

• The part contacting to the camshaft lobe is convex portion,
and the tappet rotates as it lifts up the push rod.

• The end of the sphere on the lower part of the push rod
enters into the ball socket of the tappet.
• The upper part of the push rod is socket where the end of
the sphere of adjustment screw of rocker arm fits in.

107E-3 SERIES 10-81

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

FLYWHEEL AND FLYWHEEL HOUSING

STRUCTURE OF FLYWHEEL AND FLYWHEEL HOUSING
REMARK
The shape is subject to machine models.
General view and sectional view

1: Flywheel housing 3: Starting motor

2: Flywheel 4: Ring gear

10-82 107E-3 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

5: Rear seal

SPECIFICATIONS OF FLYWHEEL AND FLYWHEEL HOUSING

Rear seal
For dry type: Single lip with dust seal
For wet type: Double lip

107E-3 SERIES 10-83

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

TURBOCHARGER SYSTEM
CIRCUIT DIAGRAM OF VGT SYSTEM
REMARK
Six cylinder engine is shown in the figure.

C: Blower impeller T: Turbine impeller

1: Air cleaner 6: Hydraulic actuator
2: Mass air flow and temperature sensor 7: Engine controller
3: VGT 8: EPC valve (for VGT)
4: VGT speed sensor 9: KDPF, AdBlue/DEF mixing tube, SCR assembly
5: VGT position sensor 10: EGR system (EGR cooler, EGR valve)

10-84 107E-3 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

REMARK
Four cylinder engine is shown in the figure.

C: Blower impeller T: Turbine impeller

1: Air cleaner 5: VGT electrical actuator
2: Mass air flow and temperature sensor 6: Engine controller
3: VGT 7: KDOC, AdBlue/DEF mixing tube, SCR assembly
4: VGT speed sensor 8: EGR system (EGR cooler, EGR valve)

FUNCTION OF VGT SYSTEM

VGT control system
• Engine controller (7) processes the data of VGT position sensor (5), intake air flow and temperature sensor
(2), VGT speed sensor, etc. and sends the result to hydraulic actuator (6) via oil pressure controlled by EPC
valve to move the piston. (*1)
• Engine controller (6) processes the information from the position sensor (5) which is built in the VGT electri-
cal actuator, mass air flow and temperature sensor (2), and VGT speed sensor (4), and operates the link
through the VGT electrical actuator (5). (*2)
• High altitude is recognized by the ambient pressure sensor, and the fuel injection and VGT are controlled
automatically to secure better response at high altitude.
• The rotation of VGT is controlled to protect VGT from over-speed.
Lubrication
• The lubricating oil cooled by the engine oil cooler is supplied through the feed pipe to VGT.
• The oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• The return oil flows through the return pipe connected to under the bearing housing and falls into the engine
oil pan.

107E-3 SERIES 10-85

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

Cooling
• The coolant from the cylinder block flows into the center housing to cool VGT.
• The return coolant flows from the center housing to the radiator. (*1)
• The return coolant flows from the center housing to the water pump inlet. (*2)
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.

10-86 107E-3 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

VGT
VGT
Abbreviation for Variable Geometry Turbocharger

STRUCTURE OF VGT
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.
General view, sectional view

A: Intake air inlet B: Intake air outlet

107E-3 SERIES 10-87

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

C: Exhaust inlet D: Exhaust outlet

1: Blower housing 7: Nozzle ring
2: VGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12: Piston

STRUCTURE OF VGT
REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.
General view, sectional view

A: Intake air inlet C: Exhaust inlet

B: Intake air outlet D: Exhaust outlet
1: Actuator (EDU) 4: Center housing
2: VGT speed sensor 5: Turbine housing
3: Blower housing 6: Link arm

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

FUNCTION OF VGT

C: Blower impeller T: Turbine impeller

1: Air cleaner 5: SCR assembly
2: VGT 6: EGR cooler
3: KDPF (*1), KDOC (*2) 7: EGR valve
4: AdBlue/DEF mixing tube
*1: Six cylinder engine is shown.
*2: Four cylinder engine is shown.
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on
turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Ko-
matsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
REMARK
It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.

OPERATION OF VGT
REMARK
Six cylinder engine is shown in this item.

107E-3 SERIES 10-89

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston in the actuator up and down with the hydraulic pressure controlled by
EPC valve installed to the front cover, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
VGT speed sensor (2) detects the rotation of the turbocharger.
When nozzle ring is “closed”
1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

When nozzle ring is “open”

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases exhaust gas inlet
passage (P) is widened (L2) so that the exhaust gas acts
on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are made in
one unit, and it slides only and does not rotate.
• Hydraulic actuator (3) is equipped with VGT position sen-
sor. VGT position sensor is calibrated together with the vari-
able mechanism of VGT and the result is written in the
memory in VGT position sensor. Accordingly, if any of hy-
draulic actuator (3), VGT position sensor, and VGT unit
fails, whole VGT must be replaced.
Operation of hydraulic actuator
The shape is subject to machine models.
1. Hydraulic actuator (1) is controlled by EPC valve (3) instal-
led to EGR valve (2) and driven hydraulically.
2. The hydraulic pressure supplied by boost oil pump (4) is
used for this purpose.
3. The position of hydraulic actuator (1) is fed back to engine
controller by the signals from VGT position sensor.

OPERATION OF VGT
REMARK
Four cylinder engine is shown in this item.

107E-3 SERIES 10-91

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

A: Moving shroud is open. B: Moving shroud is close.

1: Turbine rotor 3: Moving shroud
2: Fixed vane
• (L1) and (L2) shows the flow rate range of exhaust gas.
• Turbo pressure is controlled by the exhaust gas whose passage is controlled by the moving shroud (3) be-
ing moved.
• The position of the moving shroud (3) is determined by the actuator which is driven by the command from
the engine controller.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation

LAYOUT DRAWING OF EGR SYSTEM

REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

1: VGT 4: Intake connector

2: EGR valve 5: Exhaust manifold
3: Intake pipe 6: EGR cooler

LAYOUT DRAWING OF EGR SYSTEM

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

107E-3 SERIES 10-93

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

1: VGT 4: Intake manifold

2: EGR valve 5: Exhaust manifold
3: Intake connector 6: EGR cooler

FUNCTION OF EGR SYSTEM

REMARK
Six cylinder engine is shown in this item.
• EGR valve (hydraulically driven type) (2) controls the gas flowing from the exhaust section to the intake
section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
• EGR cooler (6) cools down the exhaust gas.
Engine coolant is used for cooling.
• It controls EGR circuit on the basis of the information from the sensors installed to various parts so that
clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR
ratio means the ratio of EGR gas contained in the intake gas.)
• It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure
from occurring.

FUNCTION OF EGR SYSTEM

REMARK
Four cylinder engine is shown in this item.
• EGR valve (electric motor driven type) (2) controls the gas flowing from the exhaust section to the intake
section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
• EGR cooler (6) cools down the exhaust gas.
Engine coolant is used for cooling.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

• Air intake manifold (4) returns the air from the air-cooled aftercooler and the exhaust gas from EGR valve
(2) to the intake section.
• It controls EGR circuit on the basis of the information from the sensors installed to various parts so that
clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR
ratio means the ratio of EGR gas contained in the intake gas.)
• It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure
from occurring.

CIRCUIT DIAGRAM OF EGR SYSTEM

REMARK
Six cylinder engine is shown in the figure.

C: Blower impeller T: Turbine impeller

1: Air Cleaner 9: EGR valve lift sensor
2: KDPF, AdBlue/DEF mixing tube, SCR assembly 10: EPC valve (for VGT)
3: Ambient pressure sensor 11: Exhaust manifold
4: Aftercooler 12: Engine boost oil pump
5: EGR cooler 13: Intake manifold
6: EGR valve 14: Charge (boost) pressure and temperature sensor
7: Hydraulic actuator (power piston) 15: Engine controller
8: EPC valve (for EGR valve) 16: Mass air flow and temperature sensor

CIRCUIT DIAGRAM OF EGR SYSTEM

REMARK
Four cylinder engine is shown in the figure.

107E-3 SERIES 10-95

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

C: Blower impeller T: Turbine impeller

1: Air Cleaner 8: Aftercooler
2: Mass air flow and temperature sensor 9: Exhaust manifold
3: Electrical actuator (VGT) 10: Intake manifold
4: EGR cooler 11: Charge (boost) pressure and temperature sensor
5: EGR valve 12: Engine controller
6: Electrical actuator (EGR valve) 13: KDOC, AdBlue/DEF mixing tube, SCR assembly
7: Ambient pressure sensor 14: Exhaust manifold pressure sensor

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

OPERATION OF EGR SYSTEM

REMARK
Six cylinder engine is shown in this item.
1. The engine controller outputs signals in order to open EGR valve (7) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12) into
EGR cooler (6) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in the
intake connector, and then flows in intake manifold (14).

OPERATION OF EGR SYSTEM

REMARK
Four cylinder engine is shown in this item.
1. The engine controller outputs signals in order to open EGR valve (5) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (5) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (9) into EGR
cooler (4) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (4) flows through EGR valve (5) and mixes with the intake air in the
intake connector, and then flows in intake manifold (10).

107E-3 SERIES 10-97

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

EGR VALVE
EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR VALVE

REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.
Sectional view

A: EGR gas inlet (from EGR cooler) D: Servo drive oil outlet
B: EGR gas outlet (to intake manifold) E: VGT control hydraulic outlet
C: Servo drive oil inlet F: VGT drive pressure outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool 8: EPC valve (for VGT)
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

• There are 2 EPC valves, one for the EGR valve and the other for VGT.

STRUCTURE OF EGR VALVE

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.
General view and sectional view

A: EGR gas inlet (from EGR cooler) B: EGR gas outlet (to intake manifold)
1: DC motor assembly (brushless motor with built-in 6: Valve seat
position sensor) 7: Valve
2: DC motor shaft 8: Seal
3: Rod 9: Spring
4: Filter
5: Housing
Structure
• This is a small-size EGR valve driven with a DC motor.
• The DC motor has a built-in position sensor and it can sense the valve position.
• The operating effort is small since this cancels EGR gas with structure of 2 valves.

107E-3 SERIES 10-99

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF EGR VALVE

REMARK
Six cylinder engine is shown in this item.
1. The oil from the engine boost oil pump flows in port (C) of
EGR valve. The control pressure from EPC valve solenoid
enters port (E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and valve (1) is closed by the reaction for spring
(2). Accordingly, the exhaust gas from EGR cooler does
not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve en-
ters port (E) first. The position of spool (4) is determined by
the balance of the control pressure and spring (5).
4. Since the notch of power piston (3) opens, the oil from the
engine boost oil pump flows through port (C) and pushes
power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller
controls the control pressure with EPC valve solenoid.
8. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
9. EGR valve lift sensor senses the displacement of spool (4).

OPERATION OF EGR VALVE

REMARK
Four cylinder engine is shown in this item.

A: EGR gas inlet (from EGR cooler)

B: EGR gas outlet (to intake manifold)
1. DC motor shaft (2) of the DC motor converts rotary motion into linear motion. When the motor rotates, valve
(7) opens or closes.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

2. Valve is open: DC motor rotates and pushes out DC motor shaft (2), and it pushes rod (3) to open valve (7).
When valve (7) opens, EGR gas flows into the intake manifold.
3. Valve is close: DC motor rotates in reverse and pulls in DC motor shaft (2). Spring (9) pushes back rod (3)
to close valve (7).

107E-3 SERIES 10-101

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

EGR COOLER
EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR COOLER

REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view and sectional view

A: EGR gas inlet D: EGR gas outlet (to EGR valve)

B: Air vent E: Coolant inlet
C: Coolant outlet
1: Flat tube
Detailed drawing of flat tube
1: Flat tube
2: Inner fin

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

STRUCTURE OF EGR COOLER

REMARK
• Four cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view and sectional view

A: EGR gas inlet D: EGR gas outlet (to EGR valve)

B: Air vent E: Coolant inlet
C: Coolant outlet
1: Flat tube
Detailed drawing of flat tube
1: Flat tube
2: Inner fin

OPERATION OF EGR COOLER

• EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).
• Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).

107E-3 SERIES 10-103

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

• Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(D).

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

LAYOUT DRAWING OF KCCV SYSTEM

REMARK
The shape is subject to machine models.
General view

A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to
VGT)
1: KCCV ventilator 5: Check valve
2: VGT 6: Crankcase pressure sensor
3: blowby gas pipe 7: CDR valve
4: Flywheel housing

107E-3 SERIES 10-105

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF KCCV SYSTEM

• In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is restric-
ted by emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove
the engine oil to prevent the following possible problems if it is recirculated to VGT (2) as it is.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
• Abnormal combustion in engine
• Malfunction of each sensor caused by sticking engine oil

FORMING OF CONDENSED WATER AND EMULSION IN KCCV SYSTEM

A: Inside of KCCV piping C: Back of head cover

B: inside of breather D: Dipstick
1: Air Cleaner 5: Breather
2: VGT 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Engine

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

Outline of forming of condensed water and emulsion in KCCV system

• If low-load operation is continued while the ambient tem-
perature is low, moisture in the blowby gas does not evap-
orate but condenses, and is returned to engine oil pan (7)
through KCCV ventilator (6).
The flow of this phenomenon is as follows;
1. Moisture in blowby gas condenses in KCCV piping
(A).
2. The condensed water flows into engine oil pan (7)
through the drain circuit.
3. The water evaporates in engine oil pan (7).
4. When the water vapor condenses again inside the en-
gine where the temperature is relatively low, it is
mixed with oil and clouded sediment is produced.
This sediment is called mayonnaise sludge (*1).
5. If the temperature of various parts does not increase
because of light-load operation, mayonnaise sludge
(*1) is accumulated.
• Mayonnaise sludge (*1) is produced inside breather (B),
on back of head cover (C), dipstick (D), etc. where the
temperature is low and condensation occurs easily.
• Mayonnaise sludge (*1) is eliminated when loaded opera-
tion is continued and the engine oil temperature increases.
• Mixing of water condensed from the blowby gas into the oil
is not problem. However, if the engine coolant is mixed in,
the cause of coolant leakage must be removed.
*1: Emulsion made from oil and water which looks like mayon-
naise

107E-3 SERIES 10-107

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF KCCV SYSTEM

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby
gas which is sucked in KCCV ventilator and recirculated.

A: Blowby gas C: Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: Turbocharger 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase) 8: VGT
1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV
ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (8).
2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

STRUCTURE OF KCCV VENTILATOR

REMARK
The shape is subject to machine models.
General view and sectional view

A: Blowby gas inlet (from flywheel housing) C: Oil drain port (to engine oil pan)
B: Blowby gas outlet (to VGT intake side)
1: Case 4: Relief valve
2: CDR valve 5: Impactor
3: Crankcase pressure sensor 6: Filter
Structure
• Filter is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• Crankcase pressure sensor is installed to blowby gas inlet piping if it is top load type, and installed to upper
part of KCCV ventilator body if it is bottom load type.

FUNCTION OF KCCV VENTILATOR

• If the blowby gas is returned to the intake side of VGT and crank case pressure becomes negative, the dust
may be sucked in through crank seal.
Blowby pressure in crankcase is controlled by CDR valve (2) and crankcase pressure sensor.
• Crankcase pressure may increases and oil leakage may occur if filter (6) of KCCV ventilator is clogged.
Thus, crankcase pressure sensor detects the clogging of filter (6).

107E-3 SERIES 10-109

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

• Keep KCCV ventilator warm with warmed-up engine coolant, to prevent the blowby gas passage from being
clogged.
• Relief valve (4) is inside case (1), and it operates to bypass the blowby gas and protect both KCCV ventila-
tor and the engine when filter (6) is blocked.

OPERATION OF KCCV VENTILATOR

1. When the blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6),
large particles in the oil mist are separated.
2. Small particles in the oil mist are separated by filter (6).
3. The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to
the engine oil pan.
4. The crankcase pressure sensor senses the crankcase pressure (blowby gas pressure).
If the engine controller judges through detected value of crankcase pressure sensor that the filter is clog-
ged, it displays failure code CA555, and if the pressure increases further, it displays failure code CA556.
5. Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.
6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively
negative.

CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator

OPERATION OF CDR VALVE

1. Spring (2) normally pushes up diaphragm (1), and the
blowby gas flows from crankcase side (A) into turbocharg-
er side (air intake side) (B).
2. As the intake air at turbochaeger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

KDPF
This item applies to six cylinder engine only.
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter

STRUCTURE OF KDPF
REMARK
The shape is subject to machine models.
General view

A: From VGT B: To AdBlue/DEF mixing connector

1: Inlet unit 8: Temperature sensor controller
2: Hanger bracket 9: KDOC outlet temperature sensor
3: Outlet unit 10: KDOC inlet temperature sensor
4: Sensor bracket band 11: KDPF differential pressure sensor port
5: KCSF unit 12: KDPF differential pressure sensor
6: Sensor bracket 13: KDPF differential pressure sensor port
7: KDPF outlet temperature sensor
Structure
• KDPF has a function to introduce the exhaust gas, and it consists of inlet unit (1) to store the oxidation cata-
lyst (KDOC), KCSF unit (5) to store the soot collecting filter with catalyst, and outlet unit (3) to discharge the
exhaust gas.
• Inlet unit (1) stores KDOC consisting of ceramic honeycomb with the oxidation catalyst.

107E-3 SERIES 10-111

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

• The ceramic honeycomb contributes to properly perform two following processes, which are to oxidize NO
(nitrogen monoxide) contained in the exhaust gas into NO2 (nitrogen dioxide), and to burn the fuel injected
during automatic regeneration and manual stationary regeneration. (Automatic regeneration means the
method to purify (oxidize) the soot accumulated on soot collecting filter (KCSF) in KDPF.)
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body This mat also thermally insulates the periph-
ery of KDPF from the ceramics which becomes high temperature during operation.
• KCSF unit (5) consists of ceramic honeycomb with the oxidation catalyst as well as KDOC does.
This ceramic honeycomb collects soot.
The inside of KCSF unit (5) consists of many cells partitioned by ceramic walls. The cells blocked on the
inlet side and those blocked on the outlet side are arranged alternately.
• KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC out-
let temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assem-
bly of KDPF differential pressure sensor and KDPF outlet pressure sensor).
The system monitors the combinations of temperatures measured by 3 temperature sensors to see if KCSF
unit (5) and KDOC function normally , and to troubleshoot various components.
The differential pressure sensor detects the pressure difference between before and after the KCSF unit (5)
to monitor the accumulation of soot in KCSF unit (5), and to troubleshoot various components.

FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen mon-
oxide) contained in the exhaust gas into NO 2 (nitrogen di-
oxide), and regenerates (*1) KCSF.
• KCSF (2) captures soot.
• Accumulated soot in KCSF (2) in operation range where
the temperature of exhaust gas is relatively high state is
naturally oxidized and burnt away by the effect of KDOC
(oxidation catalyst) (1). (This is called “passive regenera-
tion”)
REMARK
“Passive regeneration” cannot be performed if the light
load operation and low temperature state of the exhaust
gas continue. Accumulated soot is gradually increased.
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn (oxydize) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the
injector, and exhaust gas volume is controlled by VGT.

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).
REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside
KCSF (2).
REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”.
*1: Soot purification (oxidation) treatment

TYPES OF REGENERATION FUNCTIONS

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Passive regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).

107E-3 SERIES 10-113

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a fail-
ure in KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire,
check that there is no combustible around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
REMARK
• If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more fre-
quent.
• Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is
automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnor-
mal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual sta-
tionary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically
and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the ex-
haust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell
different from usual. This is not abnormal phenomenon.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when
operation is continued at relatively low temperature for long hours.This is a function that the engine control-
ler increases the engine exhaust temperature automatically and performs dry operation of KCSF when the
set condition is satisfied. When the automatic dry operation is insufficient for the treatment, manual station-
ary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet KDOC Out (KDOC out- KDPF Out (KDPF outlet
temperature sensor) let temperature sensor) temperature sensor)
While regeneration is not performed
100 to 250 °C
(idling state)
While regeneration is performed (ther-
100 to 250 °C 400 to 550 °C
mal mode)

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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

KDOC
This item applies to four cylinder engine only.
KDOC
Abbreviation for Komatsu Diesel Oxidation Catalyst

STRUCTURE OF KDOC
REMARK
The shape may vary depending on the machine models.
General view

A: From VGT B: To AdBlue/DEF mixing pipe

1: KDOC 6: Exhaust gas inlet pipe
2: Turbocharger outlet NOx sensor controller 7: KDOC outlet temperature sensor
3: KDOC temperature sensor controller 8: Turbocharger outlet NOx sensor
4: Sensor bracket 9: KDOC inlet temperature sensor
5: Exhaust gas outlet pipe 10: Sensor bracket band
Structure
• KDOC consists of the inlet pipe (6) which leads the exhaust gas from the engine, the KDOC (1) which
stores the oxidation catalyst, and the outlet pipe (5) which discharges the exhaust gas. All of these parts
are welded as a unit.
• KDOC (1) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body.
• KDOC inlet temperature sensor (9) and KDOC outlet temperature sensor (7) are installed to the KDOC.
The two temperature sensors that KDOC oxidation catalyst is functioning normally, and uses those temper-
atures for troubleshooting of various components.
• Turbocharger outlet NOx sensor (8) is installed to the KDOC.
This sensor monitors the NOx contained in the exhaust gas from the engine, and is used for the control of
AdBlue/DEF injection which works as a reduction agent.

107E-3 SERIES 10-115

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

SCR outlet NOx sensor and Turbocharger outlet NOx sensor (8) monitor the function of SCR system, and is
used for various troubleshooting.

FUNCTION OF KDOC
• KDOC is installed in order to conform to the severe regulations of exhaust gas. KDOC has a function of
oxidization of SOF (soluble organic fraction in particles of exhaust gas) , HC (unburnt combustible content),
and CO (carbon monoxide) to clean the exhaust gas.
• Function of oxidation catalyst
(1) Oxidizes SOF (soluble organic fraction in particles of exhaust gas)
(2) Oxidizes HC (unburnt combustible content)
(3) Oxidizes CO (carbon monoxide)

TYPES OF REGENERATION FUNCTIONS

The regeneration function is a function for the urea SCR system to be maintained normally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• The automatic regeneration is a function that starts the regeneration automatically upon receiving a re-
quest from the urea SCR system in order to maintain the urea SCR system normally by the fuel dosing
(*2) when the engine controller enters the exhaust temperature rise control (*1) .
The automatic regeneration is also performed by the command from the engine controller at a set time
after the previous regeneration.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: This is a fuel injection performed to accelerate the regeneration by increasing the exhaust tempera-
ture.
• Manual stationary regeneration
• The exhaust temperature may not reach a certain level depending on the operating condition of the
machine even if the automatic regeneration is performed upon receiving a request from the urea SCR
system when the exhaust temperature does not reach a certain level or when the operator disables re-
generation. In such case, a request for the manual stationary regeneration request is displayed on the
machine monitor. This unction is a function that is performed by the operator with the operation on the
monitor screen.
There is also another regeneration function that is performed by a technician with operation on the ma-
chine monitor screen when replacing the engine controller or troubleshooting. (“Active Regeneration for
Service”)

10-116 107E-3 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

NOTICE
• For the procedure to start and stop the regeneration of the aftertreatment devices, see Operation and
Maintenance Manual for each machine.
• Use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, the aftertreatment
devices may cause a failure.
• Use the engine oil conforming to Komatsu genuine KDPF. If any oil other than the specified one is
used, the KDOC performance is deteriorated which leads to the deterioration of the exhaust gas puri-
fying function, and fuel consumption, and the aftertreatment devices may cause a failure.
• Do not modify the aftertreatment devices and exhaust pipe. If modification is performed, the after-
treatment devices cannot operate normally and may cause a failure.
• Do not give the aftertreatment devices strong impact by standing on it, dropping off it, or hitting it, or
such. Otherwise the impact may damage the built-in ceramic parts of the aftertreatment devices.
• The white smoke may be discharged through the exhaust pipe outlet for a short time during the “au-
tomatic regeneration” and the “manual stationary regeneration”, especially at low temperature, but
this is not a failure. Be sure to perform regeneration in a well-ventilated area, since carbon monoxide
may be generated.
• The temperature of the gas exhausted from the exhaust pipe may become 650 °C or higher during
“automatic regeneration” and “manual stationary regeneration”. Check that there is no combustibles
around the exhaust pipe in order to prevent the fire. Thoroughly ensure the safety around the ma-
chine by checking that there is no persons at the place where the gas is exhausted to.
REMARK
• The engine controller may start “automatic regeneration”. This is a treatment to maintain the function of the
urea SCR system normal, and is not a failure. The automatic regeneration or manual stationary regeneration
to maintain the normal function of the urea SCR system runs approximately for one hour.
• VGT is actuated automatically and the engine sounds differently during “automatic regeneration” and “man-
ual stationary regeneration”. Also, as the flow rate of the exhaust gas in the aftertreatment devices changes,
the exhaust sound changes, but this is not a failure.
• The exhaust pipe may smell different from usual during the “automatic regeneration” and the “manual sta-
tionary regeneration”, but this is not a failure.
• “KDOC dry operation” function is provided to prevent excessive accumulation of unburnt fuel in KDOC when
operation is continued at relatively low temperature for long hours.
• This is a function that the engine controller increases the engine exhaust temperature automatically and per-
forms dry operation of KDOC when the set condition is satisfied. When the automatic dry operation is insuffi-
cient for the treatment, a manual stationary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet tempera- KDOC_Out (KDOC outlet tem-
ture sensor) perature sensor)
While regeneration is not performed (idling state) 100 to 250 °C
While regeneration is performed (thermal mode:
100 to 250 °C 400 to 550 °C
1000 rpm)

107E-3 SERIES 10-117

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

LUBRICATION SYSTEM
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.

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10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

1: VGT 4: Engine boost oil pump

2: EGR valve 5: Engine oil pan
3: Engine oil filter

107E-3 SERIES 10-119

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

1: Engine oil filter 4: Engine oil pan

2: VGT 5: Engine oil cooler
3: Engine oil pump

10-120 107E-3 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

LUBRICATION SYSTEM CIRCUIT DIAGRAM

REMARK
Six cylinder engine is shown in this item.

1: Strainer 11: Engine boost oil pump

2: Engine oil pump 12: Regulator valve
3: Regulator 13: EPC valve (for VGT)
4: Bypass valve 14: VGT
5: Engine oil cooler 15: EPC valve (for EGR valve)
6: Engine oil filter 16: EGR valve
7: Engine oil filter safety valve 17: Piston cooling gallery
8: VGT lubrication 18: Piston cooling
9: Main gallery lubrication 19: Engine oil pan
10: Lubrication of each bearing

107E-3 SERIES 10-121

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

LUBRICATION SYSTEM CIRCUIT DIAGRAM

REMARK
Four cylinder engine is shown in this item.

1: Strainer 7: VGT lubrication

2: Engine oil pump 8: Main gallery lubrication
3: Regulator valve 9: Lubrication of each bearing
4: Engine oil cooler 10: Piston cooling gallery
5: Engine oil filter 11: Piston cooling
6: Engine oil safety valve 12: Engine oil pan

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10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL PUMP

STRUCTURE OF ENGINE OIL PUMP
REMARK
The shape is subject to machine models.
General view and sectional view

1: Bushing 6: Idler gear

2: Drive shaft 7: Drive gear
3: Back plate 8: Inner rotor (drive rotor)
4: Housing 9: Outer rotor (planetary rotor)
5: Idler shaft

SPECIFICATIONS OF ENGINE OIL PUMP

Type: Trochoid pump
Speed: Engine speed x 1.5

FUNCTION OF ENGINE OIL PUMP

• The engine oil pump pressure-feeds engine oil to lubricate the inside of the engine.
• This is installed in the circuit between the engine oil pan and regulator valve and driven with the power from
the front crankshaft gear.

107E-3 SERIES 10-123

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE BOOST OIL PUMP

This item applies to six cylinder engine only.

STRUCTURE OF ENGINE BOOST OIL PUMP

REMARK
The shape is subject to machine models.
General view and sectional view

a: Center of drive shaft c: Suction opening

b: Discharge opening d: Outside perimeter of camshaft gear
1: Regulator valve

SPECIFICATIONS OF ENGINE BOOST OIL PUMP

Engine boost oil pump
Type: Gear pump
Speed: Engine speed x 1.0
Regulator valve
Cracking pressure: 1.43±0.1 MPa {14.6±1 kgf/cm2}

FUNCTION OF ENGINE BOOST OIL PUMP

• The engine boost oil pump pressure-feeds engine oil to drive EGR valve and VGT.
• This pump is installed in the circuit from the main gallery to EGR valve and VGT circuit, and driven with the
power from the main idler gear.
• This pump supplies hydraulic pressure to the 4 circuits of EGR valve drive, EGR valve control, VGT drive,
and VGT control.

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10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL FILTER

STRUCTURE OF ENGINE OIL FILTER
REMARK
The shape is subject to machine models.
General view

A: Oil outlet B: Oil inlet

1: Filter cartridge 3: Filter head
2: Plug

FUNCTION OF ENGINE OIL FILTER

• When the engine oil lubricate the inside of the engine, impurities such as carbon, sludge, metal powder, etc.
are mixed in it.
This filter is installed to remove those impurities.
• It is equipped with an engine oil filter safety valve which bypasses the engine oil to each part of the engine
when the filter is clogged.
• It is remote-mounted on some machine models for the ease of replacement of the filter cartridge.

107E-3 SERIES 10-125

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE OIL COOLER

STRUCTURE OF ENGINE OIL COOLER
REMARK
The shape is subject to machine models.
General view and sectional view

1: Engine oil cooler core assembly 4: Engine oil pump

2: Regulator valve 5: Engine oil pump gear
3: Safety valve 6: Crankshaft gear

SPECIFICATIONS OF ENGINE OIL COOLER

Number of elements: 7

FUNCTION OF ENGINE OIL COOLER

This is installed to cool down the engine oil circulating inside the engine, and located in between regulator valve
and oil filter.

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10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL REGULATOR VALVE

STRUCTURE OF ENGINE OIL REGULATOR VALVE
REMARK
The shape is subject to machine models.
General view and sectional view

1: Regulator valve

SPECIFICATIONS OF ENGINE OIL REGULATOR VALVE

Cracking pressure: 499 kPa {4.58 kgf/cm2}

FUNCTION OF ENGINE OIL REGULATOR VALVE

Regulator valve (1) adjusts (reduces) the oil pressure from the engine oil pump.

107E-3 SERIES 10-127

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

SAFETY VALVE OF ENGINE OIL

STRUCTURE OF SAFETY VALVE OF ENGINE OIL
REMARK
The shape is subject to machine models.
General view

1: Safety valve

SPECIFICATIONS OF SAFETY VALVE OF ENGINE OIL

Cracking pressure: 344 kPa {3.51 kgf/cm2}

FUNCTION OF SAFETY VALVE OF ENGINE OIL

• Safety valve of engine oil filter is installed to adjust the engine oil pressure circulating inside the engine.
• It is installed between engine oil cooler and engine oil filter.
• Lubrication of engine oil flows to engine oil filter normally if it is within cracking pressure which has engine
oil filter differential pressure setting. When it exceeds cracking pressure because of engine oil filter clog-
ging, it goes to main gallery without passing engine oil filter so that lubrication of engine oil is supplied with-
out being blocked.

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10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL PAN

STRUCTURE OF ENGINE OIL PAN
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.

1: Engine oil suction pipe 4: Engine oil pan

2: Engine oil level sensor 5: Engine oil drain valve
3: Engine oil level gauge

107E-3 SERIES 10-129

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL SYSTEM
LAYOUT DRAWING OF FUEL SYSTEM PARTS
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.

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10 STRUCTURE AND FUNCTION FUEL SYSTEM

A: From fuel prefilter B: To fuel tank via fuel cooler

1: Fuel main filter 4: Check valve
2: Injector 5: Supply pump
3: Inlet connector 6: Common rail

107E-3 SERIES 10-131

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

7: High-pressure pipe 9: Feed pump

8: Pressure limiter valve

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10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL SYSTEM CIRCUIT DIAGRAM

REMARK
Six cylinder engine is shown in this figure partially. Basic operation of the four cylinder engine is the same.

1: Fuel main filter 7: Fuel cooler

2: Supply pump 8. Fuel tank
3: Injector 9: Water separator
4: Common rail 10: Fuel prefilter
5: Check valve 11: Priming pump
6: Pressure limiter valve 12: Feed pump

107E-3 SERIES 10-133

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF FUEL SYSTEM

• The fuel injection system is high-pressure common rail type and is controlled electronically.
The high-pressure common rail type consists of 4 main components of feed pump (low-pressure fuel pump)
(12), supply pump (high-pressure fuel pump) (2), common rail (4), and injector (3).
• The fuel system uses injector (3) driven by the solenoid.
• Engine controller (EC) controls fuel supply to each injector (3) and injection timing by driving the solenoid in
injector (3).
• The engine controller controls the injection rate and injection timing of fuel more accurately by controlling
the solenoid electronically.
EC: Engine controller
PS: Common rail pressure sensor
2: Supply pump
3: Injector
4: Common rail

• Supply pump (2) sends high-pressure fuel to common rail

(4). The high-pressure fuel is stored in common rail (4).
• Engine controller (EC) controls fuel supply to each injector
(3) and injection timing by driving the solenoid in injector
(3).
• The fuel flows to feed pump (12) through the fuel prefilter
equipped with the water separator.
• The fuel is discharged from feed pump (12), filtrated by
fuel main filter (1), and sent to supply pump (2).
• The fuel flowing into supply pump (2) is pressurized high
by 3 radial pimping chambers.
• Common rail (4) stores high-pressure fuel and works as a
fuel manifold to distribute the fuel to the supply lines for
each injector (3).
• Common rail (4) has common rail pressure sensor (PS).
Engine controller (EC) monitors the pressure supplied from
supply pump (2) to common rail (4).
• The pressure sensed by common rail pressure sensor
(PS) is used by engine controller (EC) to adjust the fuel
output pressure of supply pump (2).
• In common rail (4), pressure limiter valve (6) (common rail
pressure relief valve) is also installed.
• Pressure limiter valve (6) is a safety valve which releases the pressure in common rail (4) when it exceeds
the set value.
• The fuel released by pressure limiter (6) is returned to the fuel tank through the fuel return circuit connected
to common rail (4).
• The high-pressure fuel flows in the side of injector (3). When the solenoid is energized, the internal needle
rises and the fuel is injected.

10-134 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

Function of injector and inlet connector

NOTICE
Clearance in the injector nozzle is so small that entrance
of dust causes sticking of injector nozzle.
Clean all around the fuel connecting part before perform-
ing service for fuel system, and cover all the openings of
fuel connecting part.

1: Inlet connector
7: Common rail
11: High-pressure pipe
17: Injector
18: Retaining nut
• The high-pressure fuel is supplied by high-pressure pipe
(11) and inlet connector (1) from common rail (7) to injector
(17).
• Inlet connector (1) is pressed against the body of injector
(17) by tightening retaining nut (18) of inlet connector (1),
and high-pressure pipe (11) is connected to inlet connector
(1) by tightening the sleeve nut.
• Connection of inlet connector (1) and high-pressure pipe
(11) is very important. If retaining nut (18) is tightened in-
sufficiently, the contact faces are not sealed and the high-
pressure fuel leaks.
• If retaining nut (18) is tightened too strong, inlet connector
(1) and injector (17) are deformed, and the high-pressure
fuel also leaks.
• You cannot check it visually since this leakage occurs in-
side. As a result, a failure code may be displayed, the out-
put may decrease, and the engine may have starting trou-
ble.
• An edge filter is installed in inlet connector (1) to break
small foreign material mixed in the fuel. The edge filter
breaks particles with high pulsation pressure so that they
can pass through the fuel passage in injector (17).
• All of injectors (17) return the fuel to the common return
circuit in the cylinder head.
• Excessive fuel returns from the return circuit to the fuel
tank through the spill tube installed to the rear of the cylin-
der head.
• A check valve is installed to the rear of the cylinder head to
which the spill tube is installed.
• The cylinder head and spill tube are connected by a quick disconnect fitting or an eye joint.

107E-3 SERIES 10-135

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

SUPPLY PUMP
STRUCTURE OF SUPPLY PUMP
General view

A: Fuel inlet (from fuel prefilter) D: Fuel outlet (to common rail)
B: Fuel outlet (to fuel main filter) E: Drain (to fuel tank)
C: Fuel outlet (from fuel main filter)
1: Feed pump 3: IMV (*) solenoid connector
2: Supply pump
* IMV: Abbreviation for Inlet Metering Valve

SPECIFICATIONS OF SUPPLY PUMP

Type: Rotary type pressurized sending method with plunger
Lubrication method: Fuel lubrication

FUNCTION OF SUPPLY PUMP

• The supply pump consists of the feed pump (low-pressure pump) and supply pump (high-pressure pump)
and is driven with the power from the camshaft.
• The feed pump (low-pressure pump) supplies the fuel to the fuel main filter.
• The supply pump (high-pressure pump) pressure-feeds the fuel to the common rail.

10-136 107E-3 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL PREFILTER
STRUCTURE OF FUEL PREFILTER
REMARK
The shape is subject to machine models.
General view and sectional view

A: Fuel outlet B: Fuel inlet

1: Connector 5: Hand primer (priming pump)
2: Clear bowl 6: O-ring
3: Filter cartridge 7: Drain valve
4: Water-in-fuel sensor

FUNCTION OF FUEL PREFILTER

• The fuel flows from the fuel tank through the fuel prefilter to the supply pump.
• The fuel prefilter is a fuel filter having a water separator, which separates water accumulated in the filter.
• A water-in-fuel sensor is installed to sense the quantity of the separated water.

107E-3 SERIES 10-137

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL MAIN FILTER

STRUCTURE OF FUEL MAIN FILTER
REMARK
The shape is subject to machine models.
General view and sectional view

1: Pressure pickup plug 3: Filter cartridge

2: Filter head

FUNCTION OF FUEL MAIN FILTER

• The fuel flows from the feed pump (low-pressure pump) to the supply pump (high-pressure pump) through
the fuel main filter.
• The fuel main filter removes impurities mixed in the fuel.
• It is remote-mounted on some machine models for ease of replacement of the cartridge.

10-138 107E-3 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.

A: From radiator B: To radiator

1: EGR cooler 3: Water pump
2: VGT 4: Engine oil cooler

107E-3 SERIES 10-139

COOLING SYSTEM 10 STRUCTURE AND FUNCTION

COOLING SYSTEM CIRCUIT DIAGRAM

REMARK
Six cylinder engine is shown in this item.

a: Flow when thermostat is open c: The flow when the magnetic valve is open
b: Flow when thermostat is closed
1: Radiator 8: Engine oil cooler
2: Thermostat 9: Water pump
3: Cylinder head 10: AdBlue/DEF tank
4: VGT 11: Solenoid valve
5: EGR cooler 12: AdBlue/DEF injector
6: Cylinder block 13: EGR valve
7: KCCV ventilator

10-140 107E-3 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

COOLING SYSTEM CIRCUIT DIAGRAM

REMARK
Four cylinder engine is shown in this item.

a: Flow when thermostat is open d: The flow of the coolant varies with the machine
b: Flow when thermostat is closed models.

c: The flow when the magnetic valve is open

1: Radiator 8: Engine oil cooler
2: Thermostat 9: Water pump
3: Cylinder head 10: AdBlue/DEF tank
4: VGT 11: Solenoid valve
5: EGR cooler 12: AdBlue/DEF injector
6: Cylinder block 13: EGR vavle
7: KCCV ventilator

107E-3 SERIES 10-141

COOLING SYSTEM 10 STRUCTURE AND FUNCTION

DRIVE PULLEY
STRUCTURE OF DRIVE PULLEY (BULLDOZER)
REMARK
The shape is subject to machine models.

A: From radiator B: To radiator

1: V-belt 5: Air conditioner compressor
2: Auto-tensioner 6: Idler pulley
3: Alternator 7: Water pump
4: Idler pulley 8: Crankshaft pulley
REMARK
Auto-tensioner (2) automatically adjusts the tension of V-belt (1) at a constant level.

10-142 107E-3 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

STRUCTURE OF DRIVE PULLEY (HYDRAULIC EXCAVATOR, WHEEL LOADER,

MOTOR GRADER)
REMARK
The shape is subject to machine models.

A: From radiator B: To radiator

1: V-belt 4: Idler pulley
2: Auto-tensioner 5: Water pump
3: Alternator 6: Crankshaft pulley
REMARK
Auto-tensioner (2) automatically adjusts the tension of V-belt (1) at a constant level.

107E-3 SERIES 10-143

COOLING SYSTEM 10 STRUCTURE AND FUNCTION

WATER PUMP
STRUCTURE OF WATER PUMP
REMARK
The shape is subject to machine models.
General view

A: Coolant inlet B: Coolant outlet (to each part of engine)

1: Impeller 4: Pulley
2: Water seal 5: Drive shaft
3: Pump body

SPECIFICATIONS OF WATER PUMP

Type: Centrifugal type, poly V-belt drive

FUNCTION OF WATER PUMP

• Water pump circulate the coolant round the engine to prevent overheating of engine.
• Fan belt conveys the engine speed to pulley to drive the impeller.

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10 STRUCTURE AND FUNCTION COOLING SYSTEM

THERMOSTAT
STRUCTURE OF THERMOSTAT
REMARK
The shape is subject to machine models.
General view

A: To radiator
1: Thermostat

SPECIFICATIONS OF THERMOSTAT
Thermostat opening temperature: 79.4±83.3 °C
Full open temperature: 95 °C
Valve lift: Min. 9.1 mm

107E-3 SERIES 10-145

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM
COMPONENT PARTS OF ELECTRICAL SYSTEM
ALTERNATOR
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 85A)
REMARK
The shape may vary depending on the machine models.
General view and circuit diagram

1: Alternator (body) 6: Internal wiring diagram

2: Alternator pulley 6A: Field coil
3: Terminal R 6B: Initial excitation resistance
4: Terminal B 6C: Regulator
5: Terminal E

10-146 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

85A)
Type: Manufactured by NIKKO DENKI, open type
Specifications: 24 V, 85 A
Number of pulley grooves: 8
Pulley outside diameter: 85 mm
Weight: 11 kg

107E-3 SERIES 10-147

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 90A)

REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Alternator (body) 6: Internal wiring diagram

2: Alternator pulley 6A: Field coil
3: Terminal R 6B: Initial excitation resistance
4: Terminal B 6C: Regulator
5: Terminal E

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SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

90A)
Type: Manufactured by NIKKO DENKI, open type
Specifications: 24 V, 90 A
Number of thread of pulley: Poly V8 threads
Pulley outside diameter: 80 mm
Weight: 19 kg

107E-3 SERIES 10-149

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Alternator (body) 6A: Initial excitation resistance

2: Alternator pulley 6B: Regulator
3: Terminal R 6C: Field coil
4: Terminal B 6D: Condenser
5: Terminal E 6E: stator
6: Internal wiring diagram 6F: Rectifying diode

10-150 107E-3 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
Type: Open type manufactured by NIKKO DENKI (brushless)
Specifications: 24 V, 140 A
Number of pulley grooves: 8
Pulley outside diameter: 85 mm
Weight: 16.5 kg

107E-3 SERIES 10-151

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

STARTING MOTOR
STRUCTURE OF STARTER WITH BUILT-IN SAFETY RELAY (4.5kW)
REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Pinion 7: Terminal B
2: Magnetic switch 8: Internal wiring diagram
3: Starting motor assembly 8A: Relay
4: Prohibition of “start by short-circuiting” warning plate 8B: Starting switch
5: “Start by short-circuiting” prevention cover 8C: Battery
6: Terminal C 8D: Starting motor

SPECIFICATION OF STARTER BUILT IN SAFETY RELAY (4.5kW)

Type: DENSO, drip proof, oil proof
Specifications: 24 V, 4.5 kW
Number of teeth of pinion: 11
Weight: 8.5 kg

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STRUCTURE OF STARTER WITH BUILT-IN SAFETY RELAY (5.5kW)

REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Pinion 8: Internal wiring diagram

2: Magnetic switch 8A: Relay
3: Starting motor assembly 8B: Starting switch
4: Prohibition of “start by short-circuiting” warning plate 8C: Battery
5: “Start by short-circuiting” prevention cover 8D: 30 (Terminal B)
6: 50 (Terminal C) 8E: 50 (Terminal C)
7: 30 (Terminal B)

SPECIFICATION OF STARTER BUILT IN SAFETY RELAY (5.5kW)

Type: DENSO, drip proof, oil proof
Specifications: 24 V, 5.5 kW
Number of teeth of pinion: 10
Weight: 10.5 kg

107E-3 SERIES 10-153

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE WIRING HARNESS

STRUCTURE OF ENGINE WIRING HARNESS
REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.
General view

No. Connector Connector label

1 NE (crankshaft) speed sensor CRANK SENSOR

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No. Connector Connector label

2 Bkup (cam) speed sensor CAM SENSOR
3 Engine oil pressure switch OIL PRESSURE SWITCH
4 Ambient pressure sensor AMBIENT AIR PRESSURE
5 Coolant temperature sensor COOLANT TEMP
6 Connector box INTER - CONNECT
7 Common rail pressure sensor: FUEL RAIL PRESS
8 Charge (Boost) pressure and temperature sensor BOOST PRESS. & IMT
9 Supply pump INLET METERING VALVE
10 Terminator port TERMINATOR PORT
11 Engine controller connector J1 ECM J1
12 Body harness connector OEM CONNECTION
13 Tool port TOOL PORT
14 Injector wiring harness #5 and #6 INJECTOR CYL 5 & 6
15 Injector wiring harness #3 and #4 INJECTOR CYL 3 & 4
16 Injector wiring harness #1 and #2 INJECTOR CYL 1 & 2

STRUCTURE OF ENGINE WIRING HARNESS

REMARK
• Four cylinder engine is shown in this item.
• The shape is subject to machine models.

107E-3 SERIES 10-155

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

General view

No. Connector Connector label

1 Coolant temperature sensor COOLANT TEMP
2 Injector wiring harness #1 and #2 INJECTOR CYL 1 & 2
3 VGT seppd sensor TURBO SPEED SENSOR
4 VGT actuator VGT ACTUATOR
5 Terminating resistor RESISTOR CAN B
EXHAUST GAS TEMPER-
6 EGR gas orifice temprerature sensor
ATURE
7 Exhaust manifold pressure sensor EXHAUST PRESSURE
8 Injector wiring harness #3 and #4 INJECTOR CYL 3 & 4
9 Common rail pressure sensor FUEL RAIL PRESS
10 Ambient pressure sensor AMB AIR PRESSURE
11 Charge (Boost) pressure and temperature sensor TMAP
12 Supply pump IMV

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No. Connector Connector label

13 EGR valve actuator EGR VALVE
14 Engine controller connector J1 ECM J1
15 Body harness connector OEM CONNECTION
16 Terminating resistor RESISTOR CAN B
17 NE (crankshaft) speed sensor EPS MAIN (CRANK)
18 Bkup (cam) speed sensor EPS BACKUP (CAM)
19 Engine oil pressure switch OIL PRESSURE SWITCH

107E-3 SERIES 10-157

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view

FUNCTION OF ENGINE CONTROLLER

• The employed engine controller is jointly developed by Komatsu and Cummins.
• The engine controller calculates the input signals from sensors installed to various portions, and outputs
them to control the engine properly.
• The engine controller commonly possesses the information of other controllers mounted on the machine
through the network (CAN) and controls the engine and machine properly.
• Since the engine controller is mounted on the engine, its field serviceability is improved.
• It is mounted through rubber vibration isolators to reduce the vibration transmitted to it.

ENGINE CONTROLLER SYSTEM DIAGRAM

REMARK
Six cylinder engine is shown in the figure.

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107E-3 SERIES 10-159

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
Four cylinder engine is shown in the figure.

INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

REMARK
Six cylinder engine is shown in this item.
Delphi96Pin “ECM J1”
Pin No. Signal name Input/output signal
Ground/Shield/
1 Injector #1 (-)
Return

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Pin No. Signal name Input/output signal

Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Sensor power supply relay Output
Ground/Shield/
10 IMV (-)
Return
11 IMV (+) Output
12 (*1) -
13 EGR valve solenoid (+) Output
14 (*1) -
15 (*1) -
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 Injector #1 (+) Output
26 Injector #2 (+) Output
27 Injector #3 (+) Output
28 (*1) -
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -

107E-3 SERIES 10-161

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/output signal

38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 Common rail pressure sensor Input
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
48 (*1) -
49 Injector #4 (+) Output
50 Injector #5 (+) Output
51 Injector #6 (+) Output
52 Engine oil pressure switch Input
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Mass air flow and temperature sensor Input
62 Charge temperature sensor Input
63 Crank case pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input
68 (*1) -
69 CAN_C (+) Communication
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -

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Pin No. Signal name Input/output signal

Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5V power supply Power supply
79 Sensor 5V power supply Power supply
80 Sensor 12V power supply Power supply
81 Sensor 5V power supply Power supply
82 Sensor 5V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 CAN_C (-) Communication
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

Delphi96Pin “CE02/ECM J2”
Pin No. Signal name Input/output signal
1 Power supply (+24 V, continuous) Power supply
Ground/Shield/
2 VGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input/ Output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply

107E-3 SERIES 10-163

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/output signal

9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (sensor controller) Communication
22 Datalink4 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (+24 V, continuous) Power supply
26 Power supply (+24 V, continuous) Power supply
27 Power supply (+24 V, continuous) Power supply
28 Power supply (+24 V, continuous) Power supply
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater Diag1 Input
39 AdBlue/DEF line heater Diag2 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1): Machine equipped with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal

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Pin No. Signal name Input/output signal

(*1): Machine equipped with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (Sensor controller) Communication
46 Datalink4 (-) (KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
58 (*1) -
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
62 (*1) -
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay (+) Output

107E-3 SERIES 10-165

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/output signal

76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 VGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

REMARK
Four cylinder engine is shown in this item.
Delphi96Pin“ECM J1”
Pin No. Signal name Input and output signals
1 Injector #1 (-) Ground/Shield/Return
2 (*1) -
3 Injector #4 (-) Ground/Shield/Return
4 24 VPower supply (VGT controller) Power supply
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Sensor power supply relay Output
10 IMV(-) Ground/Shield/Return
11 IMV(+) Output

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Pin No. Signal name Input and output signals

12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 Turbo speed sensor Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 EGR position (W) Input
23 EGR motor (U) Output
24 EGR motor (V) Output
25 Injector #1 (+) Output
26 (*1) -
27 Injector #4 (+) Output
28 GND Ground/Shield/Return
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 GND Ground/Shield/Return
35 (*1) -
36 Exhaust manifold pressure sensor Input
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 EGR position (V) Input
47 EGR position (U) Input
48 EGR motor (W) Output
49 (*1) -
50 Injector #3 (+) Output

107E-3 SERIES 10-167

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output signals

51 Injector #2 (+) Output
52 Engine oil pressure switch Input
53 (*1) -
54 GND Ground/Shield/Return
55 GND Ground/Shield/Return
56 GND Ground/Shield/Return
57 GND Ground/Shield/Return
58 GND Ground/Shield/Return
59 Common rail pressure sensor Input
60 (*1) -
61 Mass air flow and temperature sensor Input
62 Charge temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 EGR gas temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 Datalink2 (+) (VGT controller) Communication
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
73 (*1) -
74 Injector #3 (-) Ground/Shield/Return
75 Injector #2 (-) Ground/Shield/Return
76 (*1) -
77 (*1) -
78 Sensor 5 V power supply Power supply
79 Sensor 5 V power supply Power supply
80 Sensor 12 V power supply Power supply
81 Sensor 5 V power supply Power supply
82 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -

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Pin No. Signal name Input and output signals

90 (*1) -
91 (*1) -
92 (*1) -
93 Datalink2 (-) (VGT controller) Communication
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
Delphi96Pin “EC02/ECM J2”
Pin No. Signal name Input and output signals
1 Power supply (+24 V continuous) Power supply
2 (*1) -
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input and output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply
9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (sensor controller) Communication
22 Datalink1 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (+24 V continuous) Power supply
26 Power supply (+24 V continuous) Power supply
27 Power supply (+24 V continuous) Power supply
28 Power supply (+24 V continuous) Power supply

107E-3 SERIES 10-169

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output signals

29 (*1) -
30 (*1) -
31 (*1) -
32 GND Ground/Shield/Return
33 GND Ground/Shield/Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater 2 Input
39 AdBlue/DEF line heater 1 Input
40 (*1) -
41 (*1) -
42 (*1) -
(*1): Machine with fuel control dial
43 Input
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine with fuel control dial
44 Input
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (sensor controller) Communication
46 Datalink1 (-) (KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
49 Power GND Ground/Shield/Return
50 Power GND Ground/Shield/Return
51 Power GND Ground/Shield/Return
52 Power GND Ground/Shield/Return
53 AdBlue/DEF injector (-) Ground/Shield/Return
54 GND Ground/Shield/Return
55 (*1) -
56 Ambient temperature sensor Input
57 GND Ground/Shield/Return
58 (*1) -
59 (*1) -
60 (*1) -
61 GND Ground/Shield/Return
62 GND Ground/Shield/Return
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input

10-170 107E-3 SERIES

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Pin No. Signal name Input and output signals

66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
73 Power GND Ground/Shield/Return
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 (*1) -
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

107E-3 SERIES 10-171

SENSOR 10 STRUCTURE AND FUNCTION

SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
REMARK
PC220 series model 11 is shown in the figure (six cylinder engine) as an example.
General view 1

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1: Turbocharger outlet NOx sensor 10: Air cleaner clogging sensor

2: Ammonia sensor 11: Mass air flow and temperature sensor
3: Common rail pressure sensor 12: Engine oil level sensor
4: Crankcase pressure sensor 13: SCR temperature sensor
5: Charge (boost) pressure and temperature sensor 14: KDOC inlet temperature sensor
6: Ambient pressure sensor 15: KDOC outlet temperature sensor
7: Bkup speed sensor 16: KDPF differential pressure and outlet pressure
8: NE speed sensor engine sensor

9. Engine oil pressure switch 17: KDPF outlet temperature sensor

General view 2

18. SCR outlet NOx sensor 21: VGT position sensor

19: SCR outlet temperature sensor 22: VGT speed sensor
20: EGR valve lift sensor

107E-3 SERIES 10-173

SENSOR 10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF ENGINE SENSOR

REMARK
PC170 series model 11 is shown in the figure (four cylinder engine) as an example.
General view 1

1: Mass air flow and temperature sensor 10: NE (crank) speed sensor
2: VGT speed sensor 11: Bkup (cam) speed sensor
3: VGT actuator 12: Engine oil pressure switch
4: Exhaust manifold pressure sensor 13: Coolant temperature sensor
5: EGR orifice temprerature sensor 14: KDOC inlet temperature sensor
6: Common rail pressure sensor 15: KDOC outlet temperature sensor
7: Ambient pressure sensor 16: Turbocharger outlet NOx sensor
8: Charge (boost) pressure and temperature sensor 17: Air cleaner clogging sensor
9: EGR valve actuator 18: Engine oil level sensor

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General view 2

19: SCR temperature sensor 21. SCR outlet NOx sensor

20: SCR outlet temperature sensor

107E-3 SERIES 10-175

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF AMBIENT PRESSURE SENSOR

Ambient pressure sensor is attached to the air intake cover part on the top of engine.
General view

1: Connector (FRAMATOME-3P) 2: Sensor

FUNCTION OF AMBIENT PRESSURE SENSOR

It detects ambient pressure and output a variable voltage.
Output characteristics
The relation between pressure and output voltage is shown in
the following graph.

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STRUCTURE OF ENGINE OIL PRESSURE SWITCH

Engine oil pressure switch is installed to the side of the cylinder block.
Type of contact: Normally closed contact
General view

1: Connector (DT-2P) 3: O-ring

2: Sensor

FUNCTION OF ENGINE OIL PRESSURE SWITCH

This switch senses the engine oil pressure and turns “ON” when the pressure decreases below the specified
pressure.

107E-3 SERIES 10-177

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

This is installed to the intake manifold of the engine.
General view

1: Connector (SUMITOMO-4P) 3: O-ring

2: Sensor

FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

This detects engine air intake pressure and temperature, and outputs a variable voltage signal for pressure and
a resistance change signal for temperature.
REMARK
“Charge pressure and temperature” means the pressure and temperature of the intake air in a turbocharged en-
gine turbocharger, and it is also called “Boost pressure and temperature” or “Intake pressure and temperature”.

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STRUCTURE OF COOLANT TEMPERATURE SENSOR

Coolant temperature sensor is attached to the cylinder head of engine.
General view

1: Connector (DELPHI-2P/PACKRD-2P) 3: O-ring

2: Sensor

FUNCTION OF COOLANT TEMPERATURE SENSOR

It converts the temperature variation into the resistance variation and outputs the corresponding signals.

107E-3 SERIES 10-179

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR

This is installed to the front cover of the engine.
General view

1: O-ring 3: Connector (FRAMATOME-3P)

2: Sensor

FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR

It outputs pulse voltage by the rotation of the gear.

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STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR

General view

1: O-ring 3: Connector (FRAMATOME-3P)

2: Sensor

FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR

It outputs pulse voltage generated by rotation of the gear.

107E-3 SERIES 10-181

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF COMMON RAIL PRESSURE SENSOR

This is installed to the common rail of the engine.
General view

1: Connector (BOSCH-3P) 2: Sensor

FUNCTION OF COMMON RAIL PRESSURE SENSOR

It detects fuel pressure and outputs a variable voltage.

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STRUCTURE OF EGR VALVE LIFT SENSOR

This is installed to EGR valve of the engine.
REMARK
This item applies to six cylinder engine only.
General view

1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector (DEUTSCH-3P)

FUNCTION OF EGR VALVE LIFT SENSOR

It detects EGR valve opening position and outputs a corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is shown in the
following graph.

107E-3 SERIES 10-183

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF VGT SPEED SENSOR

This is installed to VGT of the engine.
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view

1: Sensor 3: Connector (AMP-3P)

2: O-ring
This is installed to VGT of the engine.
REMARK
• Four cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view

1: Sensor 3: Connector (AMP-3P)

2: O-ring

FUNCTION OF VGT SPEED SENSOR

It outputs pulse voltage by the rotation of VGT turbine.

10-184 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF VGT POSITION SENSOR

VGT position sensor is attached to VGT of engine.
REMARK
• Six cylinder engine is shown in the figure.
• The shape is subject to machine models.
General view

1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector (DEUTSCH-3P)

FUNCTION OF VGT POSITION SENSOR

It detects the position of nozzle ring which is built in VGT and outputs a corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is shown in fol-
lowing graph.

107E-3 SERIES 10-185

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR

“Mass air flow” is sometimes described as “MAF (Mass Air Flow)”.
Mass air flow and temperature sensor is attached to the outlet side of air cleaner.
General view

1: Connector (SUMITOMO-4P) 3: Sensor

2: O-ring

FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR

It converts the variations of mass air flow and temperature into the pulse voltage and the resistance variation
and outputs the corresponding signals.

10-186 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
KDPF differential pressure and outlet pressure sensor is attached to KDPF.
REMARK
This item applies to six cylinder engine only.
General view

1: High-pressure port 3: Connector (FRAMATOME)

2: Low-pressure port 4: Sensor

FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
• It detects KDPF inlet pressure and outlet pressure and outputs a corresponding variable voltage.
• Differential pressure indicates the difference between KDPF inlet pressure detected at high-pressure port
(1) and KDPF outlet pressure detected at low-pressure port (2).
• KDPF outlet pressure detected at low-presser port (2) is outputted as an outlet pressure.

107E-3 SERIES 10-187

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF CRANKCASE PRESSURE SENSOR

Crankcase pressure sensor is attached to the inlet port side of KCCV head part.
General view

1: Connector (FRAMATOME-3P) 3: O-ring

2: Sensor

FUNCTION OF CRANKCASE PRESSURE SENSOR

It detects crankcase pressure (blowby gas pressure) and outputs a corresponding variable voltage.

10-188 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF ENGINE OIL LEVEL SENSOR

Engine oil level sensor is attached to the side of engine oil pan.
General view

1: Connector (DT-2P) 3: Float

2: Bracket 4: Switch

FUNCTION OF ENGINE OIL LEVEL SENSOR

As the oil goes blow specified level, float drops and turns “OFF” the switch.

107E-3 SERIES 10-189

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF AIR CLEANER CLOGGING SENSOR

Air cleaner clogging sensor is attached to the air cleaner outlet side.
General view

1: Adapter 3: Indicator
2: Hood 4: Connector (DT-2P)

FUNCTION OF AIR CLEANER CLOGGING SENSOR

The switch turns “ON” when the air cleaner is clogged and pressure goes below the specified pressure (nega-
tive pressure).

10-190 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF WATER-IN-FUEL SENSOR

General view
This is installed to the clear bowl of the fuel prefilter.

1: Connector 3: Sensor
2: Tube 4: O-ring

FUNCTION OF WATER-IN-FUEL SENSOR

When this sensor detects water in the fuel, it outputs a signal.

107E-3 SERIES 10-191

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)

REMARK
This item applies to four cylinder engine only.
General view

1: EGR valve motor (with built-in position sensor) 3: Body

2: Connector (SUMITOMO-8P)

FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)

• EGR valve is small-sized EGR valve which is driven by DC motor.
• EGR valve motor has a built-in position sensor, which detects the valve opening position.

10-192 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR

This is installed to the pressure pickup tube attached to the exhaust manifold of the engine.
REMARK
This item applies to four cylinder engine only.
General view

1: O ring 3: Connector(FRAMATOME-3P)
2: Sensor

FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR

It detects the exhaust pressure and outputs a variable voltage.

107E-3 SERIES 10-193

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR

This is installed to the air piping between EGR cooler and EGR valve of the engine.
REMARK
This item applies to four cylinder engine only.
General view

1: Connector (FRAMATOME-2P) 3: Washer

2: Sensor

FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR

It converts the temperature variation into the resistance variation and outputs the corresponding signals.

10-194 107E-3 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)

REMARK
This item applies to four cylinder engine only.
General view

1: Actuator (position sensor) 3: Turbine housing

2: Connector (HISCHMANN-4P)

FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)

• Link is operated by the rotation of DC cooler in order to control the open/close of the passage.
• Actuator has a built-in position sensor, which detects the valve opening position.

107E-3 SERIES 10-195

 20 STANDARD VALUE TABLE

107E-3 SERIES 20-1

CONTENTS 20 STANDARD VALUE TABLE

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
............................................................................................................................................................ 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)............................................. 20-12
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (PC170LC-11) ........................................... 20-15
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8) ................................................ 20-18
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)............................................. 20-21
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
.......................................................................................................................................................... 20-24
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,
D61PXI-24E0) ................................................................................................................................... 20-27
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)......
.......................................................................................................................................................... 20-30
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC210LC-11, PC210LCI-11).................... 20-33
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11) ........... 20-36
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC240LC-11) ........................................... 20-39
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC290LC-11, PC290LCI-11).................... 20-42
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8, WA270-8E0)............................ 20-45
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8, WA320-8E0)............................ 20-48
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8) ................................................ 20-51
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ........................................................ 20-54
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (D51EX-24,
D51EXI-24, D51PX-24, D51PXI-24) .................................................................................................. 20-54
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (HB215LC-3)... 20-56
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (PC170LC-11) . 20-58
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (WA200-8) ...... 20-60
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (BR380JG-3)... 20-62
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24,
D61EXI-24, D61PX-24, D61PXI-24) .................................................................................................. 20-64
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24E0,
D61EXI-24E0, D61PX-24E0, D61PXI-24E0) ..................................................................................... 20-66
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (GD655-6, GD655-7,
GD675-6, GD675-7E0) ...................................................................................................................... 20-68
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC210LC-11,
PC210LCI-11).................................................................................................................................... 20-70
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC228USLC-11,
PC238USLC-11)................................................................................................................................ 20-72
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC240LC-11) . 20-74
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC290LC-11,
PC290LCI-11).................................................................................................................................... 20-76
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA270-8,
WA270-8E0) ...................................................................................................................................... 20-78
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA320-8,
WA320-8E0) ...................................................................................................................................... 20-80
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA380-8) ...... 20-82

20-2 107E-3 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

107E-3 SERIES 20-3

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

20-4 107E-3 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

107E-3 SERIES 20-5

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

20-6 107E-3 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

107E-3 SERIES 20-7

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

20-8 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24,
20 STANDARD VALUE TABLE D51EXI-24, D51PX-24, D51PXI-24)

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24,
D51EXI-24, D51PX-24, D51PXI-24)
Performance
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2270±30 2270±30
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1075±25 1075±25
(Low idle)

Air intake and exhaust system

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 140 Min. 133
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1050} {Min. 850}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
• Engine coolant tempera-
ture: 60 to 100 ℃ SCR outlet (ex-
Exhaust gas Bosch in-
• At rated horsepower haust pipe out- Max. 0.5 Max. 2.0
color dex
• After it is kept for 5 sec- let)
onds at normal condition

Valve clear- Intake valve 0.25±0.05 0.152 to 0.381

mm
ance Exhaust valve 0.51±0.05 0.381 to 0.762

Main body
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

107E-3 SERIES 20-9

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24,
D51EXI-24, D51PX-24, D51PXI-24) 20 STANDARD VALUE TABLE

Fuel system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of kPa -40.7 to 0 -40.7 to 0
At Max. speed with no load
negative pres-
(High idle) {mmHg} {-305 to 0} {-305 to 0}
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

Lubrication system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

20-10 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24,
20 STANDARD VALUE TABLE D51EXI-24, D51PX-24, D51PXI-24)

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-11

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)

Performance
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2060±50 2060±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 700±25 700±25
(Low idle)

Air intake and exhaust system

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.72 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 379} {Max. 760}
kPa Min. 136.7 Min. 110
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1025} {Min. 825}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 620 Max. 670
bine outlet)
• Engine coolant tempera-
ture: 60 to 100 ℃ SCR outlet (ex-
Exhaust gas Bosch in-
• At rated horsepower haust pipe out- Max. 0.5 Max. 2.0
color dex
• After it is kept for 5 sec- let)
onds at normal condition

Valve clear- Intake valve 0.25±0.05 0.152 to 0.381

mm
ance Exhaust valve 0.51±0.05 0.381 to 0.762

Main body
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

20-12 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)

Fuel system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of kPa -40.7 to 0 -40.7 to 0
At Max. speed with no load
negative pres-
(High idle) {mmHg} {-305 to 0} {-305 to 0}
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 575 Max. 575
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

Lubrication system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

107E-3 SERIES 20-13

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3) 20 STANDARD VALUE TABLE

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-14 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3
20 STANDARD VALUE TABLE (PC170LC-11)

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (PC170LC-11)

Performance
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2320±30 2320±30
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 140 Min. 133
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1050} {Min. 850}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 550 Max. 600
bine outlet)
• Engine coolant tempera-
ture: 60 to 100 ℃ SCR outlet (ex-
Exhaust gas Bosch in-
• At rated horsepower haust pipe out- Max. 0.5 Max. 2.0
color dex
• After it is kept for 5 sec- let)
onds at normal condition

Valve clear- Intake valve 0.25±0.05 0.152 to 0.381

mm
ance Exhaust valve 0.51±0.05 0.381 to 0.762

Main body
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

107E-3 SERIES 20-15

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3
(PC170LC-11) 20 STANDARD VALUE TABLE

Fuel system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of kPa -40.7 to 0 -40.7 to 0
At Max. speed with no load
negative pres-
(High idle) {mmHg} {-305 to 0} {-305 to 0}
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

Lubrication system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

20-16 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3
20 STANDARD VALUE TABLE (PC170LC-11)

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-17

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8)

Performance
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2250±50 2250±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 825±25 825±25
(Low idle)

Air intake and exhaust system

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 153 Min. 127
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1150} {Min. 950}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
• Engine coolant tempera-
ture: 60 to 100 ℃ SCR outlet (ex-
Exhaust gas Bosch in-
• At rated horsepower haust pipe out- Max. 0.5 Max. 2.0
color dex
• After it is kept for 5 sec- let)
onds at normal condition

Valve clear- Intake valve 0.25±0.05 0.152 to 0.381

mm
ance Exhaust valve 0.51±0.05 0.381 to 0.762

Main body
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

20-18 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8)

Fuel system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of kPa -40.7 to 0 -40.7 to 0
At Max. speed with no load
negative pres-
(High idle) {mmHg} {-305 to 0} {-305 to 0}
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

Lubrication system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

107E-3 SERIES 20-19

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8) 20 STANDARD VALUE TABLE

Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA4D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-20 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)

Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
At Max. speed
with no load 2180±50 2180±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760 }
kPa Min. 120 Min. 93
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 900} {Min. 700}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure
VGT control MPa 0.3 to1.0 0.3 to 1.0
hydraulic At Min. speed with no load (Low idle)
{kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • When disconnecting KCCV {mmH2O} {Max. 100 } {Max. 200 }

107E-3 SERIES 20-21

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3) 20 STANDARD VALUE TABLE

FUEL SYSTEM
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low pressure
circuit {kgf/cm2} 207 to 500 207 to 500
When cranking
{2.11 to 5.1} {2.11 to 5.1}
Differential At Max. speed with no load (High idle)
pressure be- kPa Max. 81 Max. 81
tween inlet and
outlet of the When cranking {kgf/cm2} {Max. 0.83 } {Max. 0.83 }
main filter

Pressure of re- At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
turn circuit When cranking {kgf/cm2} {Max. 0.19 } {Max. 0.19 }
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Discharged • When cranking
volume of sup- mℓ Min. 70 Min. 70
ply pump • Measurement time: 30 seconds

• At Min. speed with no load (Low idle)

Return amount • Measurement time: 30 seconds
from supply mℓ Max. 575 Max. 575
pump • When cranking (150 rpmMin.)
• Measurement time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 150 Max. 150
Return amount • Measurement time: 30 seconds
mℓ
from injector • When cranking (150 rpmMin.)
Max. 45 Max. 45
• Measurement time: 30 seconds
• At Min. speed with no load (Low idle)
Leakage mℓ Max. 8 Max. 8
amount from • Measurement time: 30 seconds
pressure limit- • When cranking (150 rpmMin.)
er valve - Max. 5 drops Max. 5 drops
• Measurement time: 30 seconds

LUBRICATION SYSTEM
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

20-22 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Cooling system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
Fan speed At rated horsepower rpm 2258 2258

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Tension of al- ment ment
Deflection when finger pressure is 98 N {10 kg} mm
ternator belt
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-23

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24,
D61EXI-24, D61PX-24, D61PXI-24) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24,

D61EXI-24, D61PX-24, D61PXI-24)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2280±30 2280±30
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 975±25 975±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 1113 Min. 87
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 850} {Min. 650}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.7
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve
driving oil MPa Min. 1.2 Min. 1.2
pressure, VGT At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

20-24 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24,
20 STANDARD VALUE TABLE D61EXI-24, D61PX-24, D61PXI-24)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 575 Max. 575
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

107E-3 SERIES 20-25

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24,
D61EXI-24, D61PX-24, D61PXI-24) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-26 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24E0,

D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2280±30 2280±30
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 975±25 975±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 1113 Min. 87
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 850} {Min. 650}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.7
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve
driving oil MPa Min. 1.2 Min. 1.2
pressure, VGT At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

107E-3 SERIES 20-27

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0) 20 STANDARD VALUE TABLE

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 575 Max. 575
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

20-28 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-29

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6,
GD655-7, GD675-6, GD675-7E0) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6,

GD655-7, GD675-6, GD675-7E0)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2200±25 2200±25
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 825±25 825±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 120 Min. 100
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 900} {Min. 750}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

20-30 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6,
20 STANDARD VALUE TABLE GD655-7, GD675-6, GD675-7E0)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

107E-3 SERIES 20-31

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6,
GD655-7, GD675-6, GD675-7E0) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-32 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC210LC-11, PC210LCI-11)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC210LC-11,

PC210LCI-11)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2060±50 2060±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 93 Min. 67
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 700} {Min. 500}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.7
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

107E-3 SERIES 20-33

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC210LC-11, PC210LCI-11) 20 STANDARD VALUE TABLE

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
negative pres- At Max. speed with no load (High idle) mmHg Max. -305 Max. -305
sure circuit
Discharged • At cranking
volume of sup- mℓ Min. 70 Min. 70
ply pump • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 575 Max. 575
supply pump • At cranking (Min. 150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 150 Max. 150
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min. 150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min. 150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

20-34 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC210LC-11, PC210LCI-11)

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (Oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-35

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC228USLC-11, PC238USLC-11) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC228USLC-11,

PC238USLC-11)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2060±50 2060±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 93 Min. 67
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 700} {Min. 500}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.7
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

20-36 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC228USLC-11, PC238USLC-11)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
negative pres- At Max. speed with no load (High idle) mmHg Max. -305 Max. -305
sure circuit
Discharged • At cranking
volume of sup- mℓ Min. 70 Min. 70
ply pump • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 575 Max. 575
supply pump • At cranking (Min. 150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 150 Max. 150
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min. 150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min. 150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

107E-3 SERIES 20-37

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC228USLC-11, PC238USLC-11) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (Oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-38 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC240LC-11)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC240LC-11)

Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2160±50 2160±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 107 Min. 80
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 800} {Min. 600}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure
VGT control MPa 0.3 to 1.0 0.3 to 1.0
hydraulic pres- At Min. speed with no load (Low idle) {kgf/cm2}
sure {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

107E-3 SERIES 20-39

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC240LC-11) 20 STANDARD VALUE TABLE

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
negative pres- At Max. speed with no load (High idle) mmHg Max. -305 Max. -305
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate • Measuring time: 30 seconds
from supply mℓ Max. 750 Max. 750
pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 150 Max. 150
Return rate • Measuring time: 30 seconds
mℓ
from injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA

20-40 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC240LC-11)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Cooling system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Fan speed At rated horsepower rpm 2059 2059

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-41

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC290LC-11, PC290LCI-11) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC290LC-11,

PC290LCI-11)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2180±50 2180±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 1050±25 1050±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 120 Min. 93
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 900} {Min. 700}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve oil
pressure, VGT MPa Min. 1.2 Min. 1.2
At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

20-42 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
20 STANDARD VALUE TABLE (PC290LC-11, PC290LCI-11)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 150 Max. 150
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

107E-3 SERIES 20-43

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3
(PC290LC-11, PC290LCI-11) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Cooling system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Fan speed At rated horsepower rpm 2258 2258

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-44 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8,
20 STANDARD VALUE TABLE WA270-8E0)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8,

WA270-8E0)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2250±50 2250±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 825±25 825±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 93 Min. 67
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 700} {Min. 500}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve
driving oil MPa Min. 1.2 Min. 1.2
pressure, VGT At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

107E-3 SERIES 20-45

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8,
WA270-8E0) 20 STANDARD VALUE TABLE

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

20-46 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8,
20 STANDARD VALUE TABLE WA270-8E0)

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-47

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8,
WA320-8E0) 20 STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8,

WA320-8E0)
Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2250±50 2250±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 825±25 825±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 93 Min. 67
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 700} {Min. 500}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.7
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve
driving oil MPa Min. 1.2 Min. 1.2
pressure, VGT At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

20-48 107E-3 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8,
20 STANDARD VALUE TABLE WA320-8E0)

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

107E-3 SERIES 20-49

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8,
WA320-8E0) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-50 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8)

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8)

Performance
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2250±50 2250±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 ℃ At Min. speed
with no load 850±25 850±25
(Low idle)

Air intake and exhaust system

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Air intake re- kPa Max. 3.73 Max. 7.45

Whole speed range
sistance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 107 Min. 80
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 800} {Min. 600}
Exhaust tem-
perature (tur- Whole speed range (20 °C) °C Max. 650 Max. 700
bine outlet)
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 ℃ - Max. 2.2
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- - Max. 0.5
let)

Valve clear- Intake valve 0.25±0.05 -

mm
ance Exhaust valve 0.51±0.05 -
EGR valve
driving oil MPa Min. 1.2 Min. 1.2
pressure, VGT At Min. speed with no load (Low idle)
driving oil {kgf/cm2} {Min. 12.2} {Min. 12.2}
pressure

VGT control oil MPa 0.3 to 1.0 0.3 to 1.0

At Min. speed with no load (Low idle)
pressure {kgf/cm2} {3.1 to 10.2} {3.1 to 10.2}

Main body
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.41 Min. 1.69

pressure • Engine speed: 250 to 280 rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}

107E-3 SERIES 20-51

STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8) 20 STANDARD VALUE TABLE

Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine

Blowby pres- • At rated horsepower kPa Max. 0.98 Max. 1.96

sure • Disconnection of KCCV {mmH2O} {Max. 100} {Max. 200}

Fuel system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
207 to 650 207 to 650
At Max. speed with no load (High idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low-pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
The pressure At Max. speed with no load (High idle)
difference be-
tween the front kPa Max. 81 Max. 81
and rear pres- At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
sure of main
filter

Return circuit At Max. speed with no load (High idle) kPa Max. 18.6 Max. 18.6
pressure At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure of
At Max. speed with no load
negative pres- mmHg Max. -305 Max. -305
(High idle)
sure circuit
Supply pump • At cranking
discharged mℓ Min. 70 Min. 70
volume • Measuring time: 30 seconds

• At Min. speed with no load (Low idle)

Return rate of • Measuring time: 30 seconds
mℓ Max. 750 Max. 750
supply pump • At cranking (Min.150 rpm)
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
Max. 125 Max. 125
Return rate of • Measuring time: 30 seconds
mℓ
injector • At cranking (Min.150 rpm)
Max. 45 Max. 45
• Measuring time: 30 seconds
• At Min. speed with no load (Low idle)
mℓ Max. 8 Max. 8
Leakage from • Measuring time: 30 seconds
pressure limit-
er valve • At cranking (Min.150 rpm)
- Max. 5 drops Max. 5 drops
• Measuring time: 30 seconds

20-52 107E-3 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8)

Lubrication system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80 ºC power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 Max. 0.3
tion rate • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit Repair limit
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)

107E-3 SERIES 20-53

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST

STANDARD
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
Running-in standard
Engine SAA4D107E-3
Procedure
Item
1 2 3 4
Running time min 2 10 2 3
min-1
Engine speed 1075{1075} 1100{1100} 1200{1200} 1600{1600}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 147{15} 245{25}
Output kW{HP} 0{0} 8{10.9} 13.1{17.7} 29{39.4}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA4D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
99.2±5 kW/ 584±29.2 Nm/
Specification value 2200 min-1 1450 min-1 2270±30 min-1 1075±25 min-1
-
(Gross value) {133±6.7 HP/ {59.6±3 kgfm/ {2270±30 rpm} {1075±25 rpm}
2200 rpm} 1450 rpm}
min-1
Engine speed 2200{2200} 1450{1450} - -
{rpm}
Dynamometer load N{kg} 600.7{61.3} 815.7{83.2} - -
Output (Gross value) kW{HP} 99.2{133} - - -
Torque (Gross value) Nm{kgfm} - 584±29.2{59.6±3} - -
sec/
Fuel consumption 43 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 120 80 to 120 80 to 120 80 to 120
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 600 Max. 650 - -

20-54 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDOC, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-55

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA4D107E-3 (HB215LC-3) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA4D107E-3 (HB215LC-3)
Running-in standard
Engine SAA4D107E-3
Procedure
Item
1 2 3 4
Running time min 2 10 2 3
min-1
Engine speed 700{700} 1000{1000} 1200{1200} 1600{1600}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 147{15} 245{25}
Output kW{HP} 0{0} 8{10.7} 13.1{17.6} 29{38.9}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA4D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
110.3±5 kW/ 640±32 Nm/
Specification value 2000 min-1 1500 min-1 2060±50 min-1 700±25 min-1
-
(Gross value) {148±6.7 HP/ {65.3±3.3 kgfm/ {2060±50 rpm} {700±25 rpm}
2000 rpm} 1500 rpm}
min-1
Engine speed 2000{2000} 1500{1500} - -
{rpm}
Dynamometer load N{kg} 735{75} 893.7{91.2} - -
Output (Gross value) kW{HP} 110.3{148} - - -
Torque (Gross value) Nm{kgfm} - 640±32{65.3±3.3} - -
sec/
Fuel consumption 40 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 120 80 to 120 80 to 120 80 to 120
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 670 Max. 680 - -

20-56 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA4D107E-3 (HB215LC-3)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDOC, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-57

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA4D107E-3 (PC170LC-11) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA4D107E-3 (PC170LC-11)
Running-in standard
Engine SAA4D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050 {1050} 1000 {1000} 1200 {1200} 1600 {1600} 2100 {2100}
{rpm}
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 571 {58.3}
Output kW{HP} 0 {0} 7.4 {9.9} 22 {29.5} 53 {71.0} 90 {121.0}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA4D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
90±4.5 kW/ 499±25 Nm/
Specification value 2100 min-1 1500 min-1 2320±30 min-1 1050±25 min-1
-
(Gross value) {121±6.1 HP/ {50.9±2.5 kgfm/ {2320±30 rpm} {1050±25 rpm}
2100 rpm} 1500 rpm}
min-1
Engine speed 2100 {2100} 1500 {1500} - -
{rpm}
Dynamometer load N{kg} 571 {58.3} 697 {71.1} - -
Output (Gross value) kW{HP} 90 {121.0} - - -
Torque (Gross value) Nm{kgfm} - 499±25 {50.9±2.5} - -
sec/
Fuel consumption 46 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 120 80 to 120 80 to 120 80 to 120
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 550 Max. 600 - -

20-58 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA4D107E-3 (PC170LC-11)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDOC, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-59

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA4D107E-3 (WA200-8) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA4D107E-3 (WA200-8)
Running-in standard
Engine SAA4D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 825{825} 1000{1000} 1200{1200} 1600{1600} 2200{2200}
{rpm}
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 634.9{64.8}
Output kW{HP} 0{0} 7.4{9.9} 22{29.5} 53{71.0} 95.2{128}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA4D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
95.2±4.8 kW/ 599±30.0 Nm/
Specification value 2000 min-1 1350 min-1 2250±50 min-1 825±25 min-1
-
(Gross value) {128±6.4 HP/ {61.1±3.1 kgfm/ {2250±50 rpm} {825±25 rpm}
2000 rpm} 1350 rpm}
min-1
Engine speed 2000{2000} 1350{1350} - -
{rpm}
Dynamometer load N{kg} 634.9{64.8} 836.1{85.3} - -
Output (Gross value) kW{HP} 95.2{128} - - -
599±30.0{61.1±3.1
Torque (Gross value) Nm{kgfm} - - -
}
sec/
Fuel consumption 44 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 120 80 to 120 80 to 120 80 to 120
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 580 Max. 650 - -

20-60 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA4D107E-3 (WA200-8)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDOC, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-61

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (BR380JG-3) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (BR380JG-3)
Running-in criteria
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2050{2050}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 1033{105}
Output kW{HP} 0{0} 7.4{9.92} 22{29.5} 53{71.1} 158.6{213}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Maximum torque
no load load
158.6±7.9 kW/ 941 Nm/
Specification value 2050 min-1 1500±50 min-1 2180±50 min-1 1050±25 min-1
-
(Gross value) ｛213±10.6 HP/ ｛96.0 kgfm/ {2180±50 rpm} {1050±25 rpm}
2050 rpm｝ 1500±50 rpm｝
min-1 1500±50
Engine speed 2050｛2050｝ - -
｛rpm｝ ｛1500±50｝

Dynamometer load N{kg} 1033{105} 1314{134.0} - -

Output (Gross value) kW{HP} 158.6{213} - - -
Torque (Gross value) Nm{kgfm} - 941{96.0} - -
sec/
Fuel consumption 27 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 680 - -

20-62 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (BR380JG-3)

REMARK
• The output and torque described in this table are different from the specification values because they are
standard in the state without the fan attached.
• This table shows the criteria for air cleaner installed state, KDPF unmounted state, SCR unmounted state,
and alternator unloaded state.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA for the lubrication oil in the running-in operation.

107E-3 SERIES 20-63

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2200{2200}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 775{78.5}
Output kW{HP} 0{0} 7.4{10} 22{30} 53{71} 127{170}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
127±6.4 kW/ 767±38.4 Nm/
Specification value 2200 min-1 1400 min-1 2280±30 min-1 975±25 min-1
-
(Gross value) ｛170.3±8.5 HP/ ｛78.2±3.9 kgfm/ {2280±30 rpm} {975±25 rpm}
2200 rpm｝ 1400 rpm｝
min-1
Engine speed 2200｛2200｝ 1400｛1400｝ - -
｛rpm｝
Dynamometer load N{kg} 775{78.5} 1071{109.2} - -
Output (Gross value) kW{HP} 127{170} - - -
Torque (Gross value) Nm{kgfm} - 767{78.2} - -
sec/
Fuel consumption 39 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 650 - -

20-64 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-65

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,
D61PXI-24E0) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2200{2200}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 775{78.5}
Output kW{HP} 0{0} 7.4{10} 22{30} 53{71} 127{170}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
127±6.4 kW/ 767±38.4 Nm/
Specification value 2200 min-1 1400 min-1 2280±30 min-1 975±25 min-1
-
(Gross value) ｛170.3±8.5 HP/ ｛78.2±3.9 kgfm/ {2280±30 rpm} {975±25 rpm}
2200 rpm｝ 1400 rpm｝
min-1
Engine speed 2200｛2200｝ 1400｛1400｝ - -
｛rpm｝
Dynamometer load N{kg} 775{78.5} 1071{109.2} - -
Output (Gross value) kW{HP} 127{170} - - -
Torque (Gross value) Nm{kgfm} - 767{78.2} - -
sec/
Fuel consumption 39 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 650 - -

20-66 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0,
20 STANDARD VALUE TABLE D61PXI-24E0)

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-67

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 825{825} 1000{1000} 1200{1200} 1600{1600} 2100{2100}
｛rpm｝
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 1047 {106.7}
Output kW{HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 165 {221}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
165±8.2 kW/ 941±47.0 Nm/
Specification value 2100 min-1 1450 min-1 2200±25 min-1 825±25 min-1
-
(Gross value) ｛221±11 HP/ ｛96.0±4.8 kgfm/ {2200±25 rpm} {825±25 rpm}
2100 rpm｝ 1450 rpm｝
min-1
Engine speed 2100{2100} 1450{1450} - -
｛rpm｝
Dynamometer load N{kg} 1047 {106.7} 1314 {134} - -
Output (Gross value) kW{HP} 165 {221} - - -
941±47.0
Torque (Gross value) Nm{kgfm} - - -
{96.0±4.8}
sec/
Fuel consumption 26 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 120 80 to 120 80 to 120 80 to 120
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 710 - -

20-68 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-69

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (PC210LC-11, PC210LCI-11) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (PC210LC-11, PC210LCI-11)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
｛rpm｝
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 821 {83.8}
Output kW{HP} 0 {0} 7.4 {10} 22 {29.6} 53 {71} 123.2 {165.2}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Maximum speed Minimum speed
Test item Rated horsepower Maximum torque
with no load with no load
123.2±6.16 kW/ 730.8 Nm/
Specification value 2000 min-1 1500±50 min-1 2060±50 min-1 1050±25 min-1
-
(Gross value) ｛165.2±8.31 HP/ ｛74.5 kgfm/ {2060±50 rpm} {1050±25 rpm}
2000 rpm｝ 1500±50 rpm｝
min-1
Engine speed 2000{2000} 1500±50{1500±50} - -
｛rpm｝
Dynamometer load N{kg} 821 {83.8} 1169 {119.2} - -
Output (Gross value) kW{HP} 123.2 {165.2} - - -
Torque (Gross value) Nm{kgfm} - 730.8 {74.5} - -
sec/
Fuel consumption 30 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 680 - -

20-70 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (PC210LC-11, PC210LCI-11)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, KDPF, and the SCR are not installed,
and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-71

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (PC228USLC-11, PC238USLC-11) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
｛rpm｝
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 821 {83.8}
Output kW{HP} 0 {0} 7.4 {10} 22 {29.6} 53 {71} 123.2 {165.2}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Maximum speed Minimum speed
Test item Rated horsepower Maximum torque
with no load with no load
123.2±6.16 kW/ 730.8 Nm/
Specification value 2000 min-1 1500±50 min-1 2060±50 min-1 1050±25 min-1
-
(Gross value) ｛165.2±8.31 HP/ ｛74.5 kgfm/ {2060±50 rpm} {1050±25 rpm}
2000 rpm｝ 1500±50 rpm｝
min-1
Engine speed 2000{2000} 1500±50{1500±50} - -
｛rpm｝
Dynamometer load N{kg} 821 {83.8} 1169 {119.2} - -
Output (Gross value) kW{HP} 123.2 {165.2} - - -
Torque (Gross value) Nm{kgfm} - 730.8 {74.5} - -
sec/
Fuel consumption 30 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 680 - -

20-72 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (PC228USLC-11, PC238USLC-11)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, KDPF, and the SCR are not installed,
and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-73

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (PC240LC-11) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (PC240LC-11)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
｛rpm｝
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 941 {96}
Output kW{HP} 0 {0} 7.4 {10} 22 {29.6} 53 {71} 141 {189}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
141±7 kW/ 837.8 Nm/
Specification value 2000 min-1 1500±50 min-1 2160±50 min-1 1050±25 min-1
-
(Gross value) ｛189±9.47 HP/ ｛85.4 kgfm/ {2160±50 rpm} {1050±25 rpm}
2000 rpm｝ 1500±50 rpm｝
min-1
Engine speed 2000{2000} 1500±50{1500±50} - -
｛rpm｝
Dynamometer load N{kg} 941 {96} 1169 {119.2} - -
Output (Gross value) kW{HP} 141 {189} - - -
Torque (Gross value) Nm{kgfm} - 837.8 {85.4} - -
sec/
Fuel consumption 30 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 680 - -

20-74 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (PC240LC-11)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-75

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (PC290LC-11, PC290LCI-11) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (PC290LC-11, PC290LCI-11)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1050{1050} 1200{1200} 1600{1600} 2050{2050}
｛rpm｝
Dynamometer load N{kg} 0 {0} 98 {10} 245 {25} 440 {45} 1033 {105}
Output kW{HP} 0 {0} 7.4 {10} 22 {29.6} 53 {71} 158.6 {212.6}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
158.6±7.9 kW/ 941 Nm/
Specification value 2050 min-1 1500±50 min-1 2180±50 min-1 1050±25 min-1
-
(Gross value) ｛212.6±10.5 HP/ ｛96.0 kgfm/ {2180±50 rpm} {1050±25 rpm}
2050 rpm｝ 1500±50 rpm｝
min-1
Engine speed 2050{2050} 1500±50{1500±50} - -
｛rpm｝
Dynamometer load N{kg} 1033 {105} 1314 {134.0} - -
Output (Gross value) kW{HP} 158.6 {215.7} - - -
Torque (Gross value) Nm{kgfm} - 94 {96.0} - -
sec/
Fuel consumption 27 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 680 - -

20-76 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (PC290LC-11, PC290LCI-11)

REMARK
• Output value and torque in this table are the standard values when fan is not installed. These values differ
from actual specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-77

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (WA270-8, WA270-8E0) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (WA270-8, WA270-8E0)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 764{78}
Output kW{HP} 0{0} 7.4{10} 22{30} 53{71} 114.5{153.5}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
114.5±5.7 kW/ 690±35 Nm/
Specification value 2000 min-1 1300 min-1 2250±50 min-1 825±25 min-1
-
(Gross value) {153.5±7.6 HP {70.4±3.5 kgfm/ {2250±50 rpm} {825±25 rpm}
/2000 rpm} 1300 rpm}

min-1
Engine speed 2000{2000} 1300{1300} - -
｛rpm｝
Dynamometer load N{kg} 764 {78} 964 {98} - -
Output (Gross value) kW{HP} 114.5 {153.5} - - -
Torque (Gross value) Nm{kgfm} - 690 {70.4} - -
sec/
Fuel consumption 42 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 600 Max. 670 - -

20-78 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (WA270-8, WA270-8E0)

REMARK
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-79

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (WA320-8, WA320-8E0) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (WA320-8, WA320-8E0)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2100{2100}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 807{82.3}
Output kW{HP} 0{0} 7.4{10} 22{30} 53{71} 127{170}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
127±6.4 Nm/ 767±38 Nm/
Specification value 2100 min-1 1400 min-1 2250±50 min-1 825±25 min-1
-
(Gross value) {170.3±8.5 HP {78.2±3.9 kgfm/ {2250±50 rpm} {825±25 rpm}
/2100 rpm} 1400 rpm}

min-1
Engine speed 2100{2100} 1400{1400} - -
｛rpm｝
Dynamometer load N{kg} 807{82.3} 1071{109.2} - -
Output (Gross value) kW{HP} 127{170} - - -
Torque (Gross value) Nm{kgfm} - 767{78.2} - -
sec/
Fuel consumption 39 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 700 - -

20-80 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (WA320-8, WA320-8E0)

REMARK
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-81

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D107E-3 (WA380-8) 20 STANDARD VALUE TABLE

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D107E-3 (WA380-8)
Running-in standard
Engine SAA6D107E-3
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
min-1
Engine speed 1050{1050} 1000{1000} 1200{1200} 1600{1600} 2100{2100}
｛rpm｝
Dynamometer load N{kg} 0{0} 98{10} 245{25} 440{45} 910{93}
Output kW{HP} 0{0} 7.4{10} 22{30} 53{71} 143.4{192.3}

REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard

Engine SAA6D107E-3
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
143.4±7.2 kW/ 941±47 Nm/
Specification value 2100 min-1 1450 min-1 2250±50 min-1 850±25 min-1
-
(Gross value) {192.3±9.6 HP/ {96±4.8 kgfm/ {2250±50 rpm} {850±25 rpm}
2100 rpm} 1450 rpm}
min-1
Engine speed 2100{2100} 1450{1450} - -
｛rpm｝
Dynamometer load N{kg} 910 {93} 1314 {134} - -
Output (Gross value) kW{HP} 143.4 {192.3} - - -
Torque (Gross value) Nm{kgfm} - 941 {96} - -
sec/
Fuel consumption 29 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature

Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 710 - -

20-82 107E-3 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D107E-3 (WA380-8)

REMARK
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

107E-3 SERIES 20-83

 50 DISASSEMBLY AND ASSEMBLY

107E-3 SERIES 50-1

 50 DISASSEMBLY AND ASSEM-
CONTENTS BLY

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 50-3
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-9
HOW TO READ THIS MANUAL.............................................................................................................. 50-9
COATING MATERIALS LIST..................................................................................................................50-11
SPECIAL TOOLS LIST ......................................................................................................................... 50-15
SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-17
ENGINE SYSTEM ....................................................................................................................................... 50-18
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)................................................. 50-18
METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)............................................ 50-18
METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3).................................................. 50-45
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)................................................. 50-92
METHOD FOR DISASEMBLING ENGINE GENERALLY (6D107E-3)............................................ 50-93
METHOD FOR ASEMBLING ENGINE GENERALLY (6D107E-3).................................................50-118
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3) .....................................................50-161
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3).........................................50-161
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)........................................50-164
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3) .....................................................50-167
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (6D107E-3).........................................50-167
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (6D107E-3)........................................50-169
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3) ......................................................50-172
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3) ..........................................50-172
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3) .........................................50-174
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3) ......................................................50-177
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (6D107E-3) ..........................................50-177
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (6D107E-3) .........................................50-179
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3).........................................................50-181
METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3) ............................................50-181
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3) ...........................................50-182
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3).........................................................50-185
METHOD FOR REMOVING ENGINE REAR OIL SEAL (6D107E-3) ............................................50-185
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (6D107E-3) ...........................................50-185

50-2 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

107E-3 SERIES 50-3

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

50-4 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

107E-3 SERIES 50-5

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

50-6 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

107E-3 SERIES 50-7

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

50-8 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY HOW TO READ THIS MANUAL

RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.
Reading the signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.

107E-3 SERIES 50-9

 50 DISASSEMBLY AND ASSEM-
HOW TO READ THIS MANUAL BLY

Symbol Item Remark

REMARK Remarks This signal word contains useful information to know.

Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

50-10 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, pol-
20 g Polyethy- ypropylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 (contained lene con- chloride), rubber, metal, and non-metal
2 pieces) tainer parts which require immediate and
strong adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from com-
ing loose and as sealant.
790-129-9060 Adhesive
Set of adhe- 1 kg • Use to bond and seal metal, glass and
LT-3 Pail
sive and hard- Hardener plastics.
ener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene con- • Use to seal plugs for blank holes.
tainer
Holts • Heat-resistant seal used to repair en-
790-129-9120 75 g Tube
MH705 gines
• Instantaneous adhesive
Polyethy-
• Curing time: From 5 sec. to 3 min.
LT-1D 790-129-9140 50 g lene con-
tainer • Use to bond mainly metals, rubbers,
plastics, and woods.
• Instantaneous adhesive

Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

790-129-9130 2g lene con- tained after 30 minutes)
201 tainer • Use to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhe-
sive with excellent resistance to heat
Loctite
428-99-80070 20 cc Tube and impact
499
• Use for the bushing mounting faces of
axle supports.

Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.

107E-3 SERIES 50-11

 50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various threaded parts, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
THREEBOND 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the cir-
LG-9 cle gear top seal which is not clamped
THREEBOND 790-129-9310 200 g Tube by bolts, gaps in the weld which must be
1206D
caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when insert-
THREEBOND 790-129-9320 200 g Tube ing radiator hoses
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with solid

gaskets.
THREEBOND 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211

Molybdenum disulfide lubricant

Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts,
LM-P — 200 g Tube and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S — 190 g Pail
metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.

50-12 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

Seizure prevention compound

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Pail
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust mani-
fold and the turbocharger, etc.

Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI • Lithium grease with extreme pressure lu-
G0-LI (*)
SYGA-16CNLI Various Various brication performance, general purpose
*: For cold dis- type.
tricts SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.

Molybdenum Bellows-
• Caution: Do not use this grease for roll-
SYG2-400M 400 gx 10 ing bearings like swing circle bearings,
disulfide type con-
grease SYG2-400M-A 400 gx 20 tainer etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Pail • Caution: Use this grease for work equip-
ment pins only when installing them, but
do not use it afterwards.
Hyper white SYG2-400T-A
grease • Higher seizure resistance, heat resist-
SYG2-16CNT Bellows-
ance, and waterproof than molybdenum
G2-T SYG0-400T-A 400 g type con-
disulfide grease
G0-T(*) (*) 16 kg tainer
Pail
• Not so conspicuous on machine since
*: For cold dis- SYG0-16CNT color is white.
tricts (*)
Biogrease SYG2-400B
G2-B SYGA-16CNB
Bellows- • Since this grease is bacterially biode-
G2-BT (*) SYG2-400BT 400 g type con- gradable in short period, the impact on
*: For use at (*) tainer microorganisms, animals, and plants is
16 kg
high tempera- SY- Pail kept to the minimum.
ture and under GA-16CNBT
high load (*)
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superi-
THREEBOND — 200 g Tube or thermal oxidative stability to prevent
1855
deterioration of rubber and plastic.
• Use for oil seals of the transmission, etc.

107E-3 SERIES 50-13

 50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Urea (organic) grease with heat
resistance and long service life, inclu-
G2-U-SENS sion type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.

Primer
Komatsu code Part No. Capacity Container Main features and applications
Loctite Glass con- • Use to accelerate hardening of instanta-
428-99-80080 100 mℓ
712 tainer neous adhesive.
SUNSTAR • Use as primer for cab side (Expira-
Glass con-

For adhered window glass

Paint Surface 22M-54–27260 150 mℓ tion date: 4 months after its produc-
tainer
Primer 435-98 tion date)
SUNSTAR • Use as primer for black ceramic-coat-
PRIMER ed glass surface and for hard poly-
22M-54-27240 150 mℓ Steel can
435-41 for carbonate-coated surface (Expiration
glass date: 6 days after its production date)
SUNSTAR • Use as primer for sash (alumite sur-
sash primer 22M-54-27250 900 mℓ Steel can face treatment) (Expiration date:6
GP-402 months after its production date)

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
Polyethy- • Use as adhesive for glass (Expiration
For adhered window glass

Sika Japan Si-

20Y-54-39850 310 mℓ lene con- date: 6 months after its production
kaflex 256HV
tainer date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Super 22M-54-27210 320 mℓ (special date: 6 months after its production
560 container) date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Seal 416–926–6950 320 mℓ (special date: 6 months after its production
#560 container) date)

Caulking material
Komatsu code Part No. Capacity Container Main features and applications
SUNSTAR Polyethy- • Use to seal for joint between glasses
For adhered window glass

Penguin Seal 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its
No.2505 tainer production date)
Polyethy-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
cone Sealant date: 6 months after its production)
tainer
GE TOSHIBA • Translucent white seal used for joint
SILICONES 22M-54-27220 333 mℓ Cartridge between glasses (Expiration date: 12
TOSSEAL381 months after its production date)

50-14 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY SPECIAL TOOLS LIST

SPECIAL TOOLS LIST

How to read the tool list
• Part Number:
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity
■: Not substitutable, and work cannot be performed without the tool.
●: Tools extremely useful if available or tools that can be substituted with commercially available tool.
• New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch
○: Tools marked with ○ in the sketch column have the sketches.
Sketches are introduced in “Sketches of special tools”, and all sketches of “79*T-***-***”are described.

New/Redesign
Necessity

Sketch
Sym- Details of work and re-

Q'ty
Work Part No. Part name
bol marks

790-501-2001
A Repair stand ■ 1
795-799-1150
Adapter (only for Ko-
790T-901-6020 ○
matsu repair stand)
B ■ 1
Adapter (only for Cum-
795-799-7210
mins repair stand)
Disassemble and as-
semble engine gener- 795-102-2103 Removal and installa-
ally C Spring pusher ● 1 tion of intake and ex-
795-799-8800 haust valves
Removal and installa-
D 795-100-2800 Piston ring tool ■ 1
tion of piston ring
Piston holder (diameter
E 795-921-1100 ■ 1 Installation of piston
75 to 175 mm)
F 795-799-6700 Puller ■ 1 Removal of injector
Disassemble and as-
semble engine gener-
ally Removal and installa-
G 795-799-6700 Seal puller ■ 1
tion of rear oil seal
Remove and install en-
gine rear oil seal
Disassemble and as-
semble engine gener-
ally Removal and installa-
H 795-799-6400 Seal puller ■ 1
tion of front oil seal
Remove and install en-
gine front oil seal

107E-3 SERIES 50-15

 50 DISASSEMBLY AND ASSEM-
SPECIAL TOOLS LIST BLY

New/Redesign
Necessity

Sketch
Sym- Details of work and re-

Q'ty
Work Part No. Part name
bol marks

790-331-1120 Wrench (angle) ● 1 Angle tightening of

J
795-799-2240 Angle gauge ● 1 bolts

Disassemble and as- Commercially Valve clearance adjust-

K Feeler gauge ● 1
semble engine gener- available ment
ally
Commercially Adjustment of gear
L Dial gauge and stand ● 1
available backlash and end play
M 795-799-8150 Remover ● 1 Remover
Disassemble and as-
semble engine gener-
ally N 795-799-6130 Support is attached ■ 1 Support
Remove and install
supply pump assembly
P 795-799-9300 Lifting tool ● 1 Lifting tool
R 01580-11210 Nut ■ 1
Ratchet (12.5 angle,
Commercially number of teeth 20 or Remove and install al-
S ■ 1
available more, length approxi- ternator belt
Disassemble and as- mately 450 mm)
semble engine gener-
ally T 01011-81210 Bolt (M12x110) ■ 1
U 795-799-2270 Remover, installer ● 1 Remover, installer
V 795-799-1131 Gear ■ 1 Gear
W 795-799-7110 Torque wrench ● 1 Torque wrench
X 795-790-4510 Gauge ● 1 Gauge

50-16 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es.
B: Adapter

107E-3 SERIES 50-17

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

ENGINE SYSTEM
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)
NOTICE
• Before starting your work, check the shapes, quantity, locations, etc. of the parts because they may
vary depending on the machine model.
• Before disassembling the engine, check its parts for cracking, damage, etc. and clean it thoroughly
and carefully for accurate inspection of its parts and quick disassembly and assembly.
• Before cleaning the engine, carefully seal the openings or remove electric parts and wiring connec-
tors so that water does not enter them.
• Clean all the parts. Check that there is neither dent, nor defect, nor cavity, or etc. Also, make sure
that the oil passages and water passages are complete.

METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)

Engine as- Starting motor
Preparation
sembly assembly

Exhaust mani- A
VGT EGR cooler
fold

Engine oil cool-

Alternator
er

Auto-tensioner

Fan pulley

Engine con-
troller

Supply pump

50-18 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)

Water pump Rocker arm

A Cylinder head B
Engine repair Cylinder head
cover, rocker Crosshead Engine oil pan
stand assembly
housing

Thermostat Push rod Front cover C

Wiring har-
Injector as-
ness assem-
sembly
bly

Fuel filter as-

sembly

High-pressure
pipe

Common rail

Flywheel
Flywheel Rear oil seal
housing

EGR valve

B Piston and
Piston cooling
connecting Crankshaft Tappet Cylinder block
nozzle
rod assembly

C Engine oil
Front oil seal pump assem- Camshaft Gear housing
bly

Preparation
1. Set the engine assembly (1) on a rigid and stable stand
[1].
REMARK
The weight may vary depending on the machine model.

4 Engine assembly:
440 kg
2. Drain the engine oil.
REMARK
The oil level may vary depending on the machine model.

6 Engine oil:
Approximately 20 ℓ

107E-3 SERIES 50-19

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

Starting motor assembly

3. Remove the bolts (1) (2 pieces), and remove the gasket
(3) and starting motor assembly (2).

Alternator belt
4. Install the ratchet (S) to the part A of the auto-tensioner (2)
(width across flats: 12.7 mm).
5. Rotate the ratchet (S) in the direction (R) to loosen the ten-
sion of the alternator belt (1), and remove the alternator
belt (1).
k Firmly set the ratchet (S) to the part A of the auto-
tensioner (2), and then rotate it. (The spring of the
auto-tensioner (2) is strong. If the ratchet (S) is
loosely installed and rotated, it can accidentally
come off and this is extremely dangerous.)
k After removing the alternator belt (1), return the au-
to-tensioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Alternator
6. Remove the nut (1), bolts (2) and (3), and remove the al-
ternator (4).
REMARK
For machines with the 85A alternator, be careful that the
spacers (5) (3 pieces) may fall off when removing the nut
(1), bolts (2) and (3).

50-20 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)

Tubes and hoses

7. Disconnect the connector EXHAUST GAS TEMPERA-
TURE (1).
8. Loosen the clamp (2), and disconnect the hose (3).
9. Remove the bolts (4) (3 pieces) and (5), and remove EGR
piping (6) and gasket (18).

10. Loosen the clamp (7), and remove VGT blower connector
(8).
11. Remove the joint bolts (9) (3 pieces), and remove the tube
(10).
12. Remove the bolts (11) (2 pieces).
13. Pull EGR piping (12) toward you, and disconnect it from
EGR cooler (13).

14. Remove the bolts (14) (2 pieces) and (15), and remove
EGR piping (16) and gasket (17).

107E-3 SERIES 50-21

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

15. Remove the wiring harness (17a) from the bracket (17).
16. Remove the bolts (18) (3 pieces), and remove VGT heat
insulation plate (19) together with the bracket (17).
REMARK
The spacer (1 piece) is provided under VGT heat insula-
tion plate (19). Be careful to prevent it from falling off when
removing the plate.

17. Remove the joint bolts (20) (2 pieces).

18. Remove the nut (21), and remove the tube (22).
19. Remove the joint bolt (23).
20. Remove the nut (24), and remove the tube (25).

21. Loosen the clamp (26).

22. Remove the bolt (27), and remove the tube (28).

23. Loosen the clamp (29).

24. Remove the bolt (30), and remove the tube (31).

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50 DISASSEMBLY AND ASSEM-
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VGT
25. Disconnect the connector VGT ACTUATOR (3).
26. Disconnect the connector TURBO SPEED SENSOR (4).
27. Remove the bolts (1) (3 pieces), and remove the bracket
(2).

28. Remove the nuts (5) (4 pieces), and remove VGT (7) and
gasket (8) together with the tube (6).

4 VGT:
25 kg
REMARK
O-rings (2 pieces) are provided in the cylinder block con-
necting portion of the tube (6).
Be careful to prevent O-rings from falling off into the en-
gine.

EGR cooler
29. Remove the bolts (1) (2 pieces) and (2) (2 pieces), and re-
move the spacer (1a), EGR cooler (2), and gasket (4).

107E-3 SERIES 50-23

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

Exhaust manifold
30. Disconnect the connector EXHAUST PRESS (1).
REMARK
The connector EXHAUST PRESS (1) is locked with the
slide stopper to prevent falling off.
31. Remove the nut (2) of the exhaust manifold pressure sen-
sor (4).
32. Remove the bolt (4), and remove the exhaust manifold
pressure sensor (4).

33. Remove the bolts (5) (8 pieces), and remove the spacer
(5a), exhaust manifold (6), and gasket (7).
REMARK
When removing, be careful not to drop the gasket (7).

Engine oil filter, engine oil cooler

34. Remove the bolts (1) (3 pieces), and remove the coolant
inlet connector (2).
35. Disconnect the engine oil filter hoses (3) and (4).
REMARK
The oil splash prevention cover may be attached just like
covering the engine oil filter hoses (3) and (4) depending
on the machine models. Remove them as required.
36. Remove the clamp (5).
37. Remove the bolt (6), and remove the engine oil filter (8) to-
gether with the bracket (7).
38. Remove the clamps (9) and (9a), and remove the engine
oil level sensor (10).
39. Remove the bolts (11) (2 pieces), and remove the bracket
(12).

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50 DISASSEMBLY AND ASSEM-
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40. Remove the bolts (13) (15 pieces), and remove the cover
(14) and cover gasket (15).
41. Remove the engine oil cooler (16) and engine oil cooler
gasket (17).
REMARK
The bracket may be installed to the cover (14) depending
on the machine models. Remove it as required.

Auto-tensioner
42. Remove the bolt (1), and remove the auto-tensioner (2).

Installing to the engine repair stand

43. Install the adapter (B) to the engine assembly (1).
Mounting bolts at engine side: M12 x 1.75
44. Sling the engine assembly (1), align the adapter (B) to the
repair stand (A), and install the engine assembly (1).
REMARK
The shape may vary depending on the machine model.

4 Engine assembly:
Approximately 350 kg
Alternator bracket
45. Remove the bolts (1) (4 pieces), and remove the alternator
bracket (2).
REMARK
The shape may vary depending on the machine model.
46. Remove the bolts (3) (4 pieces), and remove the sling
bracket (4).

107E-3 SERIES 50-25

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

Thermostat
47. Remove the bolts (1) (3 pieces), and remove the coolant
outlet connector (2).

48. Remove the thermostat (3).

Fan pulley
49. Remove the bolts (1) (4 pieces), and remove the fan pulley
(2).
REMARK
The shape may vary depending on the machine model.

Fan hub
50. Remove the bolts (1) (4 pieces), and remove the fan hub
(2).
REMARK
• The shape may vary depending on the machine model.
• The fan hub (2) is tightened together with the wiring
harness bracket (3) of the coolant temperature sensor.

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50 DISASSEMBLY AND ASSEM-
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Water pump
51. Remove the bolts (1) (2 pieces), and remove the water
pump (2).

Crankshaft pulley
52. To prevent the crankshaft pulley (4) from rotating, fix the
flywheel (2) by using the object (a) that is not deformed by
the tightening torque.

53. Loosen the bolts (5) (6 pieces), and remove (a).

54. Remove the bolts (5) (6 pieces), and remove the plate (5a)
and crankshaft pulley (4).

EGR valve
55. Remove the clamp (1).
56. Remove the clamps (2) (3 pieces), and remove the engine
oil level gauge (5) from the bracket (4).
57. Remove the bolts (3) (2 pieces), and remove the bracket
(4) and engine oil level gauge (5).

107E-3 SERIES 50-27

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

58. Disconnect the connector EGR VALVE (6).

59. Remove the joint bolt (7), and remove the hose (10).
60. Remove the bolts (8) (4 pieces), and remove EGR valve
(9).

Wiring harness assembly

61. Disconnect the connector COOLANT TEMP (2).
62. Remove the bracket (3).
63. Remove the clamp (4).
64. Disconnect the connector OIL PRESSURE SWITCH (5).
65. Disconnect the connector EPS BACKUP (CAM) (6).
66. Disconnect the connector EPS MAIN (CRANK) (7).
REMARK
The connectors (5), (6), and (7) are locked with the slide
stopper to prevent falling off.
67. Disconnect the connector INJECTOR CYL 1&2 (8).
68. Disconnect the connector INJECTOR CYL 3&4 (9).
69. Disconnect the connector FUEL RAIL PRESS (10).
70. Disconnect the connector AMB AIRPRESSURE (11).
71. Disconnect the connector TMAP (12).
72. Disconnect the connector IMV (13).
73. Remove the wiring harness assembly (1) from the clip (14).
74. Remove the clamps (15) and (16).
75. Remove the bolt (17).
REMARK
The bolt (17) is the bolt with hexagonal socket (4 mm).
76. Disconnect the connector ECM J1 (18).
REMARK
The cover is attached to the connector ECM J1 (18). Remove it.
77. Disconnect the connector OEM CONNECTION (19).
REMARK
The connector OEM CONNECTION (19) is connected with
the clips (2 places) from the back side.

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50 DISASSEMBLY AND ASSEM-
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78. Remove the clamps (20), (21), and (22).

79. Disconnect the band (23).
80. Remove the clamp (24).

Fuel filter assembly

81. Disconnect the fuel filter hoses (2) and (3) from the supply
pump (1).
NOTICE
Do not reuse the hose as a rule since internal parts of
the hose fittings may be damaged when disconnecting
the fuel filter hose. Replace the hose with a new one
when reassembling.
REMARK
When removing the fuel filter hose, pull out the hose while
pressing lock (L) from both sides.
82. Remove the bolt (4), and remove the fuel filter (6) together
with the bracket (5).

Fuel splash prevention plate

83. Remove the bolts (1) (2 pieces), and remove the fuel
splash prevention plate (2).

107E-3 SERIES 50-29

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

84. Remove the bolt (3) (1 piece) and nuts (4) (3 pieces), and
remove the bracket assembly (5).

High-pressure pipe, common rail

85. Remove the fuel spray prevention caps (5) (10 pieces) of
the high-pressure pipes (1), (2), (3), (4), and (8).
86. Remove the high-pressure pipes (1), (2), (3), and (4).
87. Remove the bolts (6a) (3 pieces), and remove the spill
tube (6).
88. Remove the bolts (7a) (2 pieces), and remove the clamps
(7) (2 pieces).
89. Remove the high-pressure pipe (8).

90. Remove the bolts (9) (4 pieces), and remove the common
rail (10).

Air intake manifold cover

91. Remove the bolts (12) (4 pieces), and remove the air in-
take connector (11), gasket (10), intake air heater (9), gas-
ket (8), plate (7), and gasket (6).

92. Remove the bolts (4) (8 pieces), and remove the air intake
manifold cover (5).

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50 DISASSEMBLY AND ASSEM-
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Cylinder head cover, rocker housing

93. Remove the bolts (1a) (2 pieces), and remove the blowby
duct (1).
REMARK
O-ring (1b) is installed to the mating face of the blowby
duct (1). Be careful to prevent it from falling off when re-
moving the duct.
94. Remove the nuts (2) (4 pieces), and remove the spacer
(2a), isolator (2b), and cylinder head cover (3).

95. Remove the cylinder head cover (3) and rocker housing
assembly while VGT is not removed according to the fol-
lowing procedure.
REMARK
• VGT is protruded out of the cylinder head cover (3) up-
ward. If the stud bolt (2c) is installed, the cylinder head
cover (3) cannot be removed or installed freely and in-
terferes with VGT to prevent the cover from removing.
When removing the cylinder head cover (3) while VGT
is not removed, removal of the stud bolt (2c) is re-
quired.
• The stud bolt (2c) has width across flats (10 mm).
1) Remove the bolts (1a) (2 pieces), and remove the blowby duct (1).
REMARK
O-ring (1b) is installed to the mating face of the blowby duct (1). Be careful to prevent it from falling off
when removing the duct.
2) Remove the nuts (2) (4 pieces), and remove the spacer (2a), isolator (2b), stud bolt (2c) and cylinder
head cover (3).
96. Remove the gasket (11) from the cylinder head cover (3).

97. Remove the wiring harness nut (4) from the injector.
Installed position of wiring harness
Color of wiring har-
Cylinder No.
ness
White 1, 3
Black 2, 4

NOTICE
Do not remove the injector wiring harness connector
(7) from the rocker housing assembly unless it is re-
quired.

107E-3 SERIES 50-31

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

98. Remove the bolt (5), and remove the rocker housing assembly (6).
Rocker arm assembly, crosshead
99. Loosen the lock nut (4), and then loosen the adjustment
screw (5) so that the valve spring tension is not applied to
the bolt (1).
100. Remove the bolt (1), and remove the rocker arm assembly
(2).
101. Remove the crosshead (3).

REMARK
Record the mounting positions and shapes of the holes (a)
and (b). (For reinstallation in the same direction)

Push rod
102. Remove the push rod (1).

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50 DISASSEMBLY AND ASSEM-
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Injector assembly
103. Remove the retaining nut (5), and remove the inlet con-
nector (1).
REMARK
Use the remover (M) to remove the inlet connector.
104. Remove the bolt (3), and remove the holder (4).
105. Remove the injector (2).

REMARK
• Pull up the injector (2) by using the puller (F) to remove
it.
• Do not pry the top of the injector (2) to remove it.

Cylinder head assembly

106. Remove the bolts (1) (18 pieces), and remove the cylinder
head assembly (2).

4 Cylinder head assembly:

50 kg

107E-3 SERIES 50-33

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

107. Compress the valve spring (3) and remove the valve cotter
(4) by using the spring pusher (C).
108. Remove the upper seat (5) and valve spring (3).

109. Raise the cylinder head assembly, pull out the valve (6),
and remove the valve seal (7).
REMARK
Put marks on the valve (6) so that you can find combina-
tion with the cylinder head.

Engine controller
110. Remove the bolts (1) (4 pieces), and remove the engine
controller (2).
REMARK
Ground cable (3) is tightened together.

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)

111. Remove the bolts (4) (3 pieces), and remove the engine
controller mounting bracket (5).

Supply pump assembly

112. Remove the nuts (1) (3 pieces), and remove the supply
pump assembly (2).
REMARK
The supply pump assembly (2) comes off together with the
gear. The gear is not machined (no missing tooth) to align
the mark for 1.4 TOP adjustment.

113. Remove the gear from the supply pump assembly accord-
ing to the following procedure.
1) Fix the gear by using the support (N) and 1/2-inch
spinner handle [1], and loosen the nut (3).
REMARK
Do not remove the nut (3) from the shaft.

107E-3 SERIES 50-35

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

2) Install the bearing puller [2] between the flange and

gear (4).

3) Install the push puller [3] on the bearing puller [2] and
shaft.
4) Screw in the center bolt [4] until the gear is disengag-
ed from the shaft.
5) Remove the push puller [3] and bearing puller [2].

6) Remove the nut (3), lock washer (5) and gear (4) from
the shaft (6).

Engine oil pan

114. Move the engine repair stand to the position where the bolt
(1) is easily removed.
115. Remove the bolts (1) (24 pieces), and remove the engine
oil pan (2) and plate (2a).
REMARK
A mark is painted at the position (c) of the bolt for position-
ing when adjusting the valve clearance.

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50 DISASSEMBLY AND ASSEM-
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116. Remove the bolts (3) (2 pieces) and (7), and remove the
engine oil suction pipe (4).

117. Remove the bolts (5) (7 pieces), and remove the plate (6).

Front cover
118. Remove the front oil seal (1) according to the following procedure.
1) Remove the dust seal (12a).

2) Install the seal puller (H) to the crankshaft.

3) Screw in the tapping screw [1] of the seal puller (H) to
the seal carrier part of the front oil seal (1).
4) Turn the handle in the direction of the arrow, and re-
move the front oil seal (1).

107E-3 SERIES 50-37

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

119. Remove the bolt (5), and remove Bkup (cam) speed sen-
sor (2).
NOTICE
If the front cover (4) is removed with Bkup (cam) speed
sensor (2) installed, it may damage the tip of the cam-
shaft.
120. Remove the bolts (3) (13 pieces), and remove the front
cover (4).

Engine oil pump assembly

121. Remove the bolts (1) (4 pieces), and remove the engine oil
pump assembly (2).

Flywheel
122. To prevent the flywheel (2) from rotating, fix the flywheel by
using the object (a) that is not deformed by the tightening
torque.
123. Loosen the bolts (1) (8 pieces), and remove (a).

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50 DISASSEMBLY AND ASSEM-
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124. Remove the bolts (1) (2 pieces), and install the guide bolt
[1].
125. Sling the flywheel (2), and hold it.
126. Remove the remaining bolts (1) (6 pieces), sling the fly-
wheel (2), and remove it.

4 Flywheel (2):
35 kg
k Since the faucet joint portion of the flywheel (2) is
shallow, the flywheel may fall off suddenly. Be care-
ful not to get your fingers caught.
k Be careful that the guide bolt does not come off
when pulling the flywheel (2) out.
Rear oil seal
127. Install the seal puller (G) to the crankshaft.
128. Screw in the tapping screw [1] of the seal puller (G) to the
seal carrier part of the engine rear oil seal (1).
129. Turn the handle in the direction of the arrow, and remove
the engine rear oil seal (1).
REMARK
Be careful not to damage the crankshaft while removing it.

Flywheel housing
130. Remove the bolts (1) (20 pieces), sling the flywheel hous-
ing (2), and remove it.

107E-3 SERIES 50-39

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

Camshaft
131. Rotate the crankshaft, and align the timing mark (part A) of
the camshaft gear (1) with the chamfered teeth of the
crankshaft gear (4).
REMARK
This is to prevent interference with the connecting rod
when removing the camshaft.

132. Remove the bolts (5) (6 pieces), and remove the camshaft
gear (1).

133. Remove the bolts (6) (2 pieces), and remove the thrust
plate (2).

134. Remove the camshaft (3).

REMARK
Pull out the camshaft (3) while rotating it.

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50 DISASSEMBLY AND ASSEM-
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Gear housing
135. Remove the bolts (1) (8 pieces), and remove the gear
housing (2).

Piston cooling nozzle

136. Rotate the crankshaft to the position where the piston cool-
ing nozzle (2) is easily removed.
137. Remove the bolt (1), and remove the piston cooling nozzle
(2).

Piston and connecting rod assembly

138. Rotate the crankshaft so that the piston to be pulled out comes to the bottom dead center.
139. Scrub the carbon off the top wall of the cylinder bore by using fine sandpaper.
140. Apply a marking of assembly position to each of the con-
necting rod caps (1) on respective cylinders.
REMARK
Before removing the piston and connecting rod assembly,
measure the side clearance between the connecting rod
and crankshaft by using the feeler gauge (K).

141. Remove the bolts (2) (2 pieces).

142. Tap the connecting rod cap (1) with a plastic hammer, and
remove the connecting rod cap (1) and connecting rod
bearing together as a unit.
NOTICE
Store the connecting rod and connecting rod cap so
that their mating faces are not damaged. If their mating
faces are damaged, replace the connecting rod and
connecting rod cap.

107E-3 SERIES 50-41

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

143. Push the piston and connecting rod assembly from the en-
gine oil pan side, and then remove it from the cylinder
head side while supporting the piston (6) and preventing it
from falling off.
REMARK
• Pay attention not to damage the cylinder inner surface
with a corner of the connecting rod when removing.
• Put the cylinder No. mark on the piston (6).
144. Remove the remaining piston and connecting rod assem-
blies according to the same procedure.
NOTICE
Take care not to damage the sliding surfaces of the
pistons, bearings, etc.
145. Disassemble the piston and connecting rod assembly ac-
cording to the following procedure.
1) Remove the snap ring (3).
2) Support the connecting rod (4) by hand, pull out the
piston pin (5), and disconnect the piston (6) from the
connecting rod (4).
3) Remove the snap ring on the opposite side.

4) Remove the piston ring (7) by using the piston ring

tool (D).
REMARK
Store the piston (6), connecting rod (4), connecting
rod bearing, piston ring (7), and piston pin (5) for each
cylinder.

Crankshaft
146. Before removing the crankshaft, measure its end play (X)
by using a dial gauge.

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50 DISASSEMBLY AND ASSEM-
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147. Remove the bolts (2) (2 pieces).

148. Insert the bolt (2) into the bolt hole of the main bearing cap
(1), and remove the main bearing cap (1) while shaking it.
REMARK
• Mounting position numbers are stamped on the main
bearing cap (1), and No.1 starts from the front side of
the cylinder block.
• Check that the position number (the number is stam-
ped in part A) of the main bearing cap (1) is directed to-
ward the engine oil cooler.

149. Remove the lower main bearing (3) from the main bearing
cap (1).
REMARK
Write the mounting position number on the tab (a) of the
removed lower main bearing (3). (Never write the number
on the sliding surface of the lower main bearing (3).)
Write the installation position on the main bearing cap (1).

150. Sling the crankshaft (4), and remove it.

REMARK
• Sling the crankshaft (4) and remove it while taking care
not to hit it to the cylinder block (8) and damage it.
• Store the crankshaft (4) in a safe place to prevent dam-
age to the sliding surfaces.

4 Crankshaft (4):
45 kg

107E-3 SERIES 50-43

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

151. Remove the thrust bearing (5) (1 piece) and upper main
bearing (6).
REMARK
Write the mounting position numbers on the tabs (b) of the
removed upper main bearing (6) and thrust bearing (5).
(Never write the number on the sliding surface of the upper
main bearing (6).)
Group the main bearing cap (1), lower main bearing (3),
upper main bearing (6) and thrust bearing (5) on the instal-
lation position basis, and store them to prevent damage.

Tappet
152. Remove the tappets (1) and mark the installation position
on them.
REMARK
The tappet must be installed to the original position if it is
reused.

Cylinder block
153. Remove the cylinder block (1) from the repair stand (A)
and adapter (B).

4 Cylinder block (1):

100 kg

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50 DISASSEMBLY AND ASSEM-
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METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3)

Piston and A
Piston cooling
Cylinder block Tappet Crankshaft connecting rod
nozzle
assembly

Engine oil B
Gear housing Camshaft pump assem- Front oil seal
bly

Rocker arm Water pump

A Cylinder head C
Cylinder head Engine repair
Engine oil pan Crosshead cover, rocker
assembly stand
housing

B Front cover Push rod Thermostat

Injector as- Wiring harness

sembly assembly

Fuel filter as-

sembly

High-pressure
pipe

Common rail

Flywheel
Rear oil seal Flywheel
housing

EGR valve

Starting motor Engine assem-

Preparation
assembly bly

C Exhaust
EGR cooler VGT
manifold

Engine oil
Alternator
cooler

Auto-tensioner

Fan pulley

Engine con-
troller

Supply pump

107E-3 SERIES 50-45

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

Preparation
1. Install the adapter (B) to the repair stand (A).
2. Install the cylinder block (1) to the adapter (B).

4 Cylinder block:
100 kg

Tappet
3. Apply engine oil to the tappet (1).
2 Tappet (1):
Engine oil (EO15W-40)

4. Install the tappet (1).

REMARK
• The tappet (1) must be installed to the original position
if it is reused.
• The tappet (1) may come off from the mounting hole
when assembling, do not reverse the cylinder block
more than 90 °.

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)

Crankshaft
5. Install the upper main bearing (6) and thrust bearing (5) (1
piece).
REMARK
• Align the protruding portions of the upper main bearing
(6) and thrust bearing (5) with the notch (b) of the cylin-
der block (8) for installing.
• Check that foreign material is not attached to the back
surfaces of the upper main bearing (6) and thrust bear-
ing (5) before installation.
• Apply engine oil to the inner surfaces of the upper main
bearing (6) and thrust bearing (5). However, do not ap-
ply to the back surfaces.
• When reusing the upper main bearing (6) and thrust
bearing (5), check the mark placed at disassembly, and
install it to the original position.
2 Inner surfaces of upper main bearing (6) and thrust
bearing (5):
Engine oil (EO15W-40)
6. Sling the crankshaft (4), and install it.
NOTICE
Be careful not to damage the thrust bearing (5) when
installing it.

4 Crankshaft (4):
45 kg
7. Align the protruding portion of the lower main bearing (3)
with the notch (a) of the main bearing cap (1) for installing.
REMARK
Check that the dowel ring (7) is installed to the main bear-
ing cap (1).

8. Apply engine oil to journal part (c) of the crankshaft (4).

2 Journal part (c):
Engine oil (EO15W-40)

107E-3 SERIES 50-47

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

9. Check the punching mark No. (A part) of the main bearing

cap (1), and install it.
REMARK
• Perform installation in the order of [1] to [5] from the
front side of the cylinder block (8).
• Install with the mark No. (A part) facing the oil cooler
side.
• Push it in by hitting it lightly with a plastic hammer or
rubber hammer.

10. Measure the stem length (a) of the bolt (2) by using the
gauge (X) before screwing in the bolt (2), and check that
the length is within the allowable limit.
Allowable limit of bolt (2) length : less than 120.0 mm
NOTICE
If the bolt (2) is longer than the allowable limit, do not
reuse it but replace it.

11. Tighten the bolts (2) in the order shown in the figure.
REMARK
Apply engine oil to the threaded portion and seat surface
of the bolt (2).
2 Bolt (2):
Engine oil (EO15W-40)

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• When the bolt is reused

3 1st time:
60±5 Nm {6.1±0.5 kgfm}
3 2nd time:
80±5 Nm {8.2±0.5 kgfm}
3 3rd time:
90±5 ° (by using the angle tightening wrench
(J))

3 1st time:
• When the bolt is new

120±10 Nm {12.2±1.02 kgfm}

3 2nd time:
360 ° (Loosen)
3 3rd time:
60±5 Nm {6.1±0.5 kgfm}
3 4th time:
85±5 Nm {8.7±0.5 kgfm}
3 5th time:
120±5 ° (by using the angle tightening wrench (J))
• When the wrench (J) is not used
Put marks on the main bearing cap (1) and bolt (2)

3 When the bolt is reused:

with paint, etc., and retighten the bolt (2).

90±5 °
3 When the bolt is new:
120±5 °
12. Put punch mark on the head of bolt when the bolt is
reused.
REMARK
When using a new bolt, do not put punch mark on the
head of the bolt.
13. After tightening the bolt (2), rotate the crankshaft (4) to check that it rotates smoothly.
14. Measure the end play of the crankshaft (4) by using the di-
al gauge.
End play X: 0.24±0.175 mm

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Piston and connecting rod assembly

15. Install the piston ring (7) to the piston by using the piston
ring tool (D).

16. Install the oil ring (9) according to the following procedure.
1) Fit the oil ring (9) so that its abutment joint is 180 °
away from the end of the expander (8).

2) Install the second ring (10) as directing the punching

mark “TOP” near the abutment joint upward.
3) Install the top ring (11) as directing the punching mark
“dot” near the abutment joint upward.
4) Install each ring directing the abutment joint to the di-
rection other than the direction of thrust and opposite
direction of thrust, and axial direction of piston.

17. Install the piston (6) and connecting rod (4) according to
the following procedure.
REMARK
Direct “FRONT” mark at the head of the piston (6) upward,
and check that the connecting rod (4) faces the direction
indicted in the figure.

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1) Apply engine oil to the piston pin hole of the connect-

ing rod (4) and piston pin (5).
2 Piston pin hole of connecting rod (4):
Engine oil (EO15W-40)
2 Piston pin (5):
Engine oil (EO15W-40)

2) Insert the piston pin (5), and install the piston (6) to
the connecting rod (4).
3) Install the snap rings (3) on both sides.

18. Install the connecting rod bearings (13) to the connecting

rod (4) and connecting rod cap (2).
REMARK
• Do not damage the mating faces of the connecting rod
(4) and connecting rod cap (2) when disassembling. If
these are damaged, replace the connecting rod (4) and
connecting rod cap (2).
• Check that foreign material is not attached to the back
side of the connecting rod bearing (13).
• Align the protruding portion of the connecting rod bear-
ing (13) with the notch A of the connecting rod (4) and
connecting rod cap (2) for installing.
19. Set the crankshaft of the cylinder to be installed at the bot-
tom dead center, and apply engine oil to the piston ring (7),
piston skirt part (a), and cylinder inner surface (b).
2 Piston ring (7):
Engine oil (EO15W-40)
2 Piston skirt part (a):
Engine oil (EO15W-40)
2 Cylinder inner surface (b):
Engine oil (EO15W-40)

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20. Insert the piston and connecting rod assembly directing

“FRONT” mark of the piston (6) to the front of the cylinder
block.
REMARK
• Check the direction of the abutment joint of the piston
ring (7) again.
• Be careful not to damage the cylinder wall when insert-
ing the connecting rod (4).
• Compress the piston ring (7) by using the piston holder
(E), and push in the head of the piston (6) with a wood
bar, etc.

21. Tighten the bolt (1) according to the following procedure,

and install the connecting rod cap (2).
REMARK
Apply engine oil to the threaded portion of the bolt (1) and
inner surface of the connecting rod bearing (13).
2 Threaded portion of bolt (1):
Engine oil (EO15W-40)
2 Inner surface of connecting rod bearing (13):
Engine oil (EO15W-40)

• Perform angle tightening by using the wrench (J).

3 1st time:
Bolt (1) (Tighten both bolts alternately.):

30±3 Nm {3.06±0.31 kgfm}

3 2nd time:
60±5 Nm {6.12±0.51 kgfm}
3 3rd time:
60±5 ° (by using the wrench (J))

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• When not using the wrench (J), put marks on the con-
necting rod cap (2) and bolt (1) with paint, or etc., and
then retighten the bolt (1) to 60±5 °.
22. Check that the crankshaft rotates smoothly without any ab-
normality after installing the piston and connecting rod as-
sembly.

23. Measure the side clearance between the connecting rod

assembly and crankshaft by using the feeler gauge (K).
Side clearance: 0.10 to 0.33 mm

Piston cooling nozzle

24. Rotate the crankshaft to the position where the piston cooling nozzle (2) is easily installed.
25. Install the piston cooling nozzle with the bolt (1).
3 Bolt (1):
15±2 Nm {1.5±0.2 kgfm}

Gear housing
26. Apply liquid gasket to the mounting face (A part) of the
gear housing (2).
REMARK
• Apply a continuous bead of liquid gasket 1 to 2 mm in
diameter.
• If liquid gasket is applied too much around the blowby
oil groove (B part), it may block the groove. Do not ap-
ply the liquid gasket too much.
2 Gear housing:
Liquid gasket (LG-7)
27. Check that the dowel rings of the gear housing (2) are se-
curely inserted into the dowel holes (C) (2 places) of upper and lower cylinder blocks.
NOTICE
Tighten the bolt when the dowel ring is not properly inserted, it may damage the dowel ring.
28. Push the gear housing (2) for the mating surface with the cylinder block to be entirely attached.

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29. Tighten the gear housing (2) lightly with the bolts (1) (8
pieces).
REMARK
Do not apply the torque to the bolt (1) before the mating
surface is entirely attached.

30. Tighten the mounting bolts in the order shown in the figure.
3 Mounting bolt M12 (not marked):
77±7 Nm {7.9±0.7 kgfm}
3 Mounting bolt M10 (marked with □: ℓ = 30, marked
with ○: ℓ = 50):
47±5 Nm {4.8±0.5 kgfm}
3 Mounting bolt M8 (marked with △):
24±4 Nm {2.5±0.4 kgfm}

Camshaft
31. Rotate the crankshaft so that No.1 cylinder comes to the top dead center (TDC).
32. Apply engine oil to all the camshaft bores (a), camshaft
journals (b), and lobe faces (c).
2 Camshaft bore (a):
Engine oil (EO15W-40)
2 Camshaft journal (b):
Engine oil (EO15W-40)
2 Lobe surface (c):
Engine oil (EO15W-40)

33. Push in the camshaft (3) lightly and install the camshaft
while rotating it.
REMARK
Install the camshaft (3) while taking care not to damage
the cam bushing.

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34. Install the thrust plate (2) with the bolts (6) (2 pieces).
3 Bolt (6):
24±4 Nm {2.4±0.4 kgfm}

35. Install it aligning the timing mark A part of the camshaft

gear (1) and the chamfered teeth (1 place) of the crank-
shaft gear (4).

36. Install the camshaft gear (1) with the bolts (5) (6 pieces).
3 Bolt (5):
36±4 Nm {3.7±0.4 kgfm}

37. Measure the end play and backlash of the camshaft (3) by
using the dial gauge.
REMARK
The amount of the end play is determined by thickness of
the thrust plate (2) and groove of the camshaft (3).
End play: 0.23±0.13 mm
Backlash: 0.178±0.102 mm

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Flywheel housing
38. Apply liquid gasket to the mounting flange surface of the
flywheel housing (2) and around the mounting bolt holes.
REMARK
Apply a continuous bead of liquid gasket 1 to 2 mm in di-
ameter.
2 Flywheel housing:
Liquid gasket (LG-7)
39. Install the flywheel housing (2) with the bolts (1) (20
pieces).

40. Tighten the bolts (1) in the order shown in the figure.
REMARK
Install the bolts (1) carefully since there are 5 types of the
bolts.
3 Bolt (1) M12 (marked with ▲: ℓ = 80, marked with
■: ℓ = 110):
85±10 Nm {8.7±1.0 kgfm}
3 Bolt (1) M10 (marked with ○: ℓ = 40, marked with □:
ℓ = 80, marked with △: ℓ = 110):
49±5 Nm {5.0±0.5 kgfm}

Measurement of radial runout

41. Install the dial gauge (L) to the crankshaft end surface.
42. Set the probe of the dial gauge perpendicularly to the fau-
cet joint portion of the flywheel housing.
43. Set the dial gauge pointer to “0”, rotate the crankshaft by 1
turn, and measure the difference between the lowest and
the highest values of the pointer of dial gauge points.
REMARK
• Radial runout0.20 mm or less
• When the crankshaft is rotated by 1 turn, check that the
pointer of the dial gauge indicates the same value as
that of the rotation start.
Measurement of facial runout
44. Similarly to measurement of the radial runout, set the
probe of the dial gauge perpendicularly to the end face of
the flywheel housing.
REMARK
When measuring, move the crankshaft to either end of
front or rear to eliminate error caused by the end play.
45. Set the dial gauge pointer to “0”, rotate the crankshaft by 1
turn, and measure the difference between the lowest and
the highest values of the pointer of dial gauge points.
REMARK
Facial runout: 0.20 mm or less
Rear oil seal

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NOTICE
• Do not remove the pilot [1] installed to the rear oil seal
(1) until the rear oil seal is inserted into the crankshaft.
• Before installing the rear oil seal, degrease, clean and
dry the crankshaft sealing face and seal lip face to pre-
vent oil leakage.

46. Insert the pilot [1] into the crankshaft (2), and push the rear
oil seal (1) into the flywheel housing (3).
47. Push in the rear oil seal (1) further, and remove the pilot
[1].

48. Install the rear oil seal (1) to the proper depth in the fly-
wheel housing (3) by using the seal puller (G).
REMARK
• Insert the rear oil seal (1) with careful attention that
there are no bend etc. on it.
• Protrusion X of rear oil seal (1) from flywheel housing
(3)0.38 mm or less

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Flywheel
49. Install the guide bolt [1].
50. Sling the flywheel (2), and align it with the installing posi-
tion.
51. Tighten the flywheel (2) lightly with the bolts (1) (8 pieces).
2 Bolt (1):
Engine oil (EO15W-40)

4 Flywheel (2):
35 kg

52. To prevent the flywheel (2) from rotating, fix the flywheel by
using the object (a) that is not deformed by the tightening
torque.

53. Tighten the bolts (1) in the order shown in the figure.
3 Bolt (1):
137±7 Nm {14.0±0.7 kgfm}
54. Check that the bolts (1) (8 pieces) are tightened, and re-
move (a).

Measurement of radial runout

55. Install the dial gauge (L) to the flywheel housing.
56. Set the probe of the dial gauge perpendicularly to the fau-
cet joint portion (a) or outside perimeter of the flywheel.
57. Rotate the flywheel by 1 turn, and measure the difference
between the lowest and the highest values that the pointer
of dial gauge points.
REMARK
• Radial runout0.13 mm or less
• When the flywheel is rotated by 1 turn, check that the
pointer of the dial gauge indicates the same value as
that of the rotation start.
Measurement of facial runout
58. Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end
face (b) near the outside perimeter of the flywheel.

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REMARK
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the end
play.
59. Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values that
the pointer of dial gauge points.
REMARK
Facial runout: 0.20 mm or less
Engine oil pump assembly
60. Fill the space in the oil pump rotor and idler shaft bore with
engine oil, and rotate it by 2 turns.
2 Space in oil pump rotor:
Engine oil (EO15W-40)
2 Idler shaft bore:
Engine oil (EO15W-40)

61. Install the engine oil pump assembly (2) with the bolts (1)
(4 pieces).

62. Tighten the bolts (1) in the order shown in the figure.
3 1st time:
8±1 Nm {0.8±0.1 kgfm} (Figure A)
3 2nd time:
24±4 Nm {2.4±0.4 kgfm} (Figure B)
63. Lock either gear, and measure the backlash (C) between
the pump and idler gear.
Backlash (C): 0.2±0.05 mm

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Front cover
64. Apply liquid gasket to the mounting face (part A) of the
front cover (4).
REMARK
• Apply a continuous bead of liquid gasket 1 to 2 mm in
diameter.
• Apply liquid gasket so that it does not enter oil circuit
(part B).
2 Front cover:
Liquid gasket (LG-7)

65. Install the front cover (4) with the bolts (3) (13 pieces).
66. Tighten the bolts (3) in the order shown in the figure.
3 Bolt (3):
24±4 Nm {2.4±0.4 kgfm}

67. Install the Bkup (cam) speed sensor (2) with the bolt (5).
3 Bolt (5):
8±2 Nm {0.8±0.2 kgfm}

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68. By using the seal puller (H), install the front oil seal (1).
REMARK
• Before installing the front oil seal (1), check that the
end corner and lip sliding surface of the crankshaft are
free from a flaw, burr, fin, rust, and etc.
• When installing the front oil seal (1), do not apply oil or
grease, etc. to the crankshaft and seal lip. Wipe off oil
thoroughly from the crankshaft.
• The deviation of the front oil seal (1) from the front cov-
er (4) must meet the following criteria.
Protrusion (x): 0.38 mm or less
Facial runout (y): 0.25 mm or less

69. Install the dust seal (12a).

REMARK
Check the installing dimension (L).
Installing dimension (L): 12+0.1/0 mm

Engine oil pan

70. Install the plate (6) with the bolts (5) (7 pieces).
3 Bolt (5):
43±6 Nm {4.4±0.6 kgfm}

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71. Install the engine oil suction pipe (4) with the bolts (3) (2
pieces) and (7).
3 Bolt (3):
24±4 Nm {2.4±0.4 kgfm}
3 Bolt (7):
43±6 Nm {4.4±0.6 kgfm}

72. Remove the liquid gasket protruding from the places be-
tween the cylinder block and gear housing and between
the cylinder block and front cover (4 places on a part) by
using a scraper.
REMARK
When removing and installing only the engine oil pan, re-
move the old liquid gasket filled in borders (4 places on a
part) as well by using a scraper, etc.
73. Apply liquid gasket to the places between the cylinder
block and gear housing and between the cylinder block
and front cover (4 places on a part).
2 (a) part of engine oil pan :
Liquid gasket (LG-7)
Gasket bead diameter: 3 mm
74. Install the gasket (5) to the mounting face.
REMARK
• Do not apply oil when installing the gasket.
• Install the gasket with the silicon bead (B) facing the oil
pan side.
• Apply liquid gasket to the clinching parts (4 places on b
part) on both sides of the gasket.
2 (b) parts on both sides of gasket:
Liquid gasket (LG-7)
75. Tighten the engine oil pan (2) and plate (2a) lightly with the
bolts (1) (24 pieces).
• When the bolt is reused
Install the painted bolt to the position (c).
• When the bolt is new or unpainted
Paint the bolt to be installed to the position (c).
REMARK
The position (c) is used for positioning the valve clear-
ance when adjusting it.

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76. Tighten the bolts (1) (24 pieces) in the order shown in the
figure.
REMARK
Be careful that the mounting bolts (○ part) (6 pieces) of the
plate (2a) have different length respectively.
3 Bolt (1):
28±2 Nm {2.9±0.2 kgfm}

Crankshaft pulley
77. To prevent the crankshaft pulley (4) from rotating, fix the
flywheel (2) by using the object (a) that is not deformed by
the tightening torque.

78. Install the crankshaft pulley (4) while aligning its dowel
hole with the dowel pin (b) of the crankshaft.

79. Install the plate (5a) and crankshaft pulley (4) with the
bolts (5) (6 pieces).
Tightening order of bolt (5)
3 1st time:
55±5 Nm {5.61±0.51 kgfm} (Tighten diagonally)
3 2nd time:
180 ° (Loosen)
3 3rd time:
55±5 Nm {5.61±0.51 kgfm} (Tighten diagonally)
3 4th time:
90±5 ° (Retighten diagonally)

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REMARK
Perform angle tightening by using the wrench (J).

When the wrench (J) is not used

Put marks on the crankshaft pulley (4) and bolt (5) with a
felt-tip pen and retighten the bolt (5) to 90±5 °.
80. Check that the bolts (5) (6 pieces) are tightened, and re-
move (a).

Engine controller
81. Install the engine controller mounting bracket (5) with the
bolts (4) (3 pieces).
3 Bolt (4):
24±4 Nm {2.4±0.4 kgfm}

82. Install the engine controller (2) and ground cable (3) with
the bolts (1) (4 pieces).
3 Bolt (1):
24±4 Nm {2.4±0.4 kgfm}

Cylinder head assembly

83. Assemble the cylinder head assembly according to the following procedure.

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1) Install the valve seal (7).

2) Apply engine oil to the stem (b) of the valve (6) and
the valve guide inner surface (c).
2 Stem (b) of valve (6):
Engine oil (EO15W-40)
2 Valve guide inner surface (c):
Engine oil (EO15W-40)

3) Install the valve (6).

4) Raise the cylinder head, and install the valve spring

(3) and upper seat (5).

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5) Compress the valve spring (3) and install the valve

cotter (4) by using the spring pusher (C).
REMARK
Check that the valve cotter is fitted securely to the
groove of the valve stem by hitting the valve stem part
lightly with a plastic hammer.

84. Before tightening the cylinder head mounting bolt, meas-

ure the stem lengths (a) of all the mounting bolts, and
check that the lengths are within the allowable limit.
Allowable limit of bolt length: Less than132.1 mm
NOTICE
If a bolt is longer than the allowable limit, do not reuse
it but replace it.

85. Check that the cylinder head mounting face and inside of
the cylinders are free from dirt and foreign materials, and
install the cylinder head gasket (8).
REMARK
Check that the cylinder head gasket (8) is aligned with the
holes of the cylinder head mounting face.
86. Install the cylinder head assembly (2) to the cylinder block.

4 Cylinder head assembly (2):

50 kg
87. Screw in the bolt (1) manually by 3 to 4 threads.
REMARK
Apply engine oil to the threaded portion of the bolt (1) and
to the seat surface of the head of the bolt (1).
2 Threaded portion of bolt (1):
Engine oil (EO15W-40)
2 Seat surface of the head of bolt (1):
Engine oil (EO15W-40)

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88. Tighten the bolt (1) in the order according to the following
procedure.
3 1st time:
90±3 Nm {9.2±0.3 kgfm}
3 2nd time:
90±3 Nm {9.2±0.3 kgfm}
3 3rd time:
90±5 ° (Perform angle tightening by using the
wrench (J).)

REMARK
When not using the wrench (J), put marks on the cylinder
head assembly (2) and bolt (1) with paint, or etc., and then
retighten the bolt (1) to 90±5 °.

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Injector assembly
89. Install the gasket (6) and O-ring (7) to the injector (2).
NOTICE
When replacing the injector (2) with a new one, replace
the inlet connector (1) with a new one as well.
REMARK
Check that the injector sleeve (f) is free from scratches or
dirt.
90. Apply engine oil to O-ring (7) and cylinder head side of the
injector (2).
2 O-ring (7) and cylinder head side of injector:
Engine oil (EO15W-40)
91. Direct fuel inlet hole of the injector (2) toward air intake
manifold side, and install it to the cylinder head.
92. Install the holder (4) and screw in the bolt (3) manually by
3 to 4 threads.

93. Check the inlet connector (1) on the following points. If any
abnormality is found, replace the inlet connector (1).
• When burrs or wear are found on the front end part (a)
or rear end part (b) of the inlet connector (1)
• When foreign materials are attached to the edge filter
at the rear end part (c) of the inlet connector (1)
• When cracks or deterioration are found on O-ring in
the upper part (d) of the inlet connector (1)
• When wear or uneven contact are found on the seat
surface (e) at the tip of the inlet connector (1)
REMARK
If high-pressure fuel leaks through the inlet connector (1),
the seat surface has fine streaks or cracks.

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94. Apply engine oil to O-ring (8) and cylinder head side of the
inlet connector (1).
2 O-ring (8) and cylinder head side of inlet connector
(1):
Engine oil (EO15W-40)
95. Insert the inlet connector (1) into the mounting hole of the
injector (2), and tighten the retaining nut (5) lightly.
NOTICE
• After tightening it lightly, it should be tightened to
the specified torque. Be sure to tighten each one to
the specified torque. If the tightening torque is in-
sufficient or too much, it may cause fuel leakage
inside the engine.
• Install the inlet connector (1) so that its positioning
ball fits in the guide groove part on the head side.
3 Retaining nut (5) (tightening lightly):
15±5 Nm {1.53±0.51 kgfm}
96. Tighten the bolts (3) alternately.
3 Bolt (3):
8±0.8 Nm {0.82±0.08 kgfm}
97. Tighten the retaining nut (5) of the inlet connector (1).
3 Retaining nut (5) (tightening to the specified torque):
50±5 Nm {5.1±0.5 kgfm}
Push rod
98. Pour the engine oil to the socket part of the push rod (1).
2 Socket part of push rod (1):
Engine oil (EO15W-40)
99. Install the push rods (1).
REMARK
Check that the push rod (1) is fitted to the tappet.

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Rocker arm assembly, crosshead

100. Install the crosshead (3).
101. Install the rocker arm assembly (2) with the bolt (1).

NOTICE
• Check that the ball part (c) of the adjustment screw
(4) of the rocker arm assembly (2) securely fits in
the socket of the push rod, and then tighten the
bolt (1).
• Shapes of holes in the parts (a) and (b) of the
crosshead (3) are not identical. So when reusing
them for the same air intake valve or exhaust valve,
be sure to install them in the same direction.
3 Bolt (1):
36±5 Nm {3.7±0.5 kgfm}

Adjustment of valve clearance

102. Remove the plug (1) under the starting motor and install
the gear (V).

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103. Check that the part (a) of the crankshaft pulley (6) and en-
gine oil pan mounting bolt (7) are painted.
REMARK
If they are not painted, paint the part (a) (10th slit counting
from the wide slit (b)) of the crankshaft pulley (6), and en-
gine oil pan mounting bolt (7).

104. Rotate the crankshaft forward by using the gear (V), and
align the part (a) of the crankshaft pulley (6) with the posi-
tion of the engine oil pan mounting bolt (7) as a straight
line.
NOTICE
When the crankshaft is set as above, it is not set to the
compression top dead center (TDC) of No. 1 or No. 4
cylinder. (76 to 88 ° before top dead center)

105. Adjust the valve clearance according to the following procedure.

Valve layout drawing
REMARK
• If you can move the rocker arm of the air intake valves
(IN side) with the hand by the valve clearance amount,
check the valves marked with ○ in the valve layout
drawing.
• If you can move the rocker arm of the air exhaust valve
(EX side) with the hand by the valve clearance amount,
check the valves marked with ● in the valve layout
drawing.

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1) While fixing the adjustment screw (5), loosen the lock

nut (4).
2) Insert the feeler gauge (K) into the clearance between
the rocker arm (2) and crosshead (3).
3) Adjust the valve clearance with the adjustment screw
(5).
REMARK
• Turn the adjustment screw (5) with the feeler
gauge (K) inserted, and adjust it with the adjust-
ment screw (5) until the feeler gauge (K) can move
lightly.
• Adjust the valve clearance within the target value
range.
Air intake valve: 0.25±0.05 mm
Exhaust valve: 0.51±0.05 mm
4) While fixing the adjustment screw (5), tighten the lock nut (4).
3 Lock nut (4):
24±4 Nm {2.45±0.41 kgfm}
REMARK
• After tightening the lock nut (4), check the valve clearance again.
• Repeat the above steps until the valve clearance is adjusted within the target value range.
106. After adjusting the valve clearances at 4 places, rotate the crankshaft forward by using the gear (V), and
align the part (a) of the crankshaft pulley (6) with the position of the engine oil pan mounting bolt (7) as a
straight line.
107. Adjust the remaining 4 other valve clearances according to the step 105.

REMARK
When ○ mark in the valve layout drawing is adjusted according to the above step, adjust the remaining
valve marked with ●. When ● mark has already been adjusted, adjust ○ mark.
108. After adjustment of the valve clearance is performed, re-
move the gear (V), and install the plug (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

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Rocker housing, head cover

109. Install the rocker housing assembly (6) with the bolts (5) (5
pieces).
3 Bolt (5):
24±4 Nm {2.45±0.41 kgfm}
110. Install the nut (4) of the injector wiring harness.
Installed position of wiring harness
Color of wiring harness Cylinder No.
White 1, 3
Black 2, 4

3 Nut (4):
1.5±0.25 Nm {0.15±0.03 kgfm}
REMARK
• Check that the injector wiring harness does not inter-
fere with the rocker arm.
• If the injector wiring harness connector (7) is removed,
apply liquid gasket to O-ring part (8) and flange surface
(9) of the injector wiring harness connector (7) when in-
stalling.
• Apply a continuous bead of liquid gasket 3 mm in diam-
eter to O-ring part (8) until O-ring groove is completely
hidden.
• If O-ring (8) is damaged, replace an entire wiring har-
ness assembly.
2 O-ring part (8) of injector wiring harness connector (7):
Liquid gasket (LG-7)
2 Flange surface (9) of injector wiring harness connector (7):
Liquid gasket (LG-7)
111. Install the injector wiring harness connector (7) with the bolt (10).
3 Bolt (10):
10±2 Nm {1±0.2 kgfm}
112. Install the gasket (11) to the cylinder head cover (3).

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113. Install the cylinder head cover (3), isolator (2b), and spacer
(2a) with the nuts (2) (4 pieces).
3 Nut (2):
24±4 Nm {2.45±0.41 kgfm}
114. Install the blowby duct (1) with the bolts (1a) (2 pieces).

REMARK
Install O-ring (1b) to the mating face of the blowby duct (1).
3 Bolt (1a):
7±2 Nm {0.7±0.2 kgfm}
Supply pump assembly
115. Install the gear (4) to the supply pump assembly according
to the following procedure.
REMARK
Before installation, clean dust and foreign materials on the
mating surfaces of the shaft (6) and gear (4), and keep the
mating surfaces dry.
1) Install the gear (4) to the shaft (6).
2) Install the lock washer (5) and nut (3), and finger-tight-
en them lightly.

3) Fix the gear by using the support (N) and 1/2-inch

spinner handle [1], and tighten the nut (3).
3 Supply pump/gear mounting nut:
105±5 Nm {10.7±0.51 kgfm}

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116. Install the supply pump assembly (2) with the mounting
nuts (1) (3 pieces).
REMARK
• If grease is applied too much to O-ring (7), it will ooze
out. Do not apply grease too much. (Apply grease with-
in O-ring groove range of the part A.)
• When replacing the stud bolt (8), apply Loctite to the
thread portion of the stud bolt (8) on the cylinder block

2 Stud bolt (8):

side.

Liquid adhesive (LT-2)

3 Stud bolt (8):
12±2 Nm {1.2±0.2 kgfm}
• When installing the nut (1), the nut (1) may fall off or
slip since it is difficult to install the nut (1) on the cylin-

3 Nut (1):
der block side.

24±4 Nm {2.45±0.41 kgfm}

Air intake manifold cover

117. Install the gasket (1).

REMARK
Direct the part number tag (a) toward the rear side when
installing the gasket (1).

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118. Install the air intake manifold cover (5) with the bolts (4) (8
pieces).
3 Bolt (4):
24±4 Nm {2.45±0.41 kgfm}

Common rail pressure sensor, pressure limiter

REMARK
Perform this work only when replacing the common rail pressure sensor (2) and pressure limiter (3).
119. Replace the common rail pressure sensor (2) according to the following procedure.
1) Clean the area around the common rail pressure sen-
sor (2), and remove dirt, etc. thoroughly before remov-
ing it.
2) Remove the common rail pressure sensor (2).
NOTICE
• Do not remove the common rail pressure sen-
sor (2) from the common rail (1) for a purpose
other than replacement.
• Be sure to replace the common rail pressure
sensor (2) removed from the common rail (1)
with a new common rail pressure sensor (2).
3) Check the connector of the common rail pressure sensor (2) for crack, breakage, damage of the seal,
foreign materials on the pin and corrosion, bend and breakage of the pin.
4) Install a new common rail pressure sensor (2).
2 Threaded portion of common rail pressure sensor (2):
Gear oil (#90)
3 Common rail pressure sensor (2):
70±5 Nm {7.1±0.5 kgfm}
120. Replace the pressure limiter (3) according to the following procedure.
1) Clean the area around the pressure limiter (3), and remove dirt, etc. thoroughly before removing it.
2) Remove the pressure limiter (3).
NOTICE
Do not reuse the pressure limiter (3) if leakage exceeds the specified value.
3) Check that there is no damage on the high-pressure
sealing surfaces (A) on the pressure limiter (3) and
common rail.
4) Install the pressure limiter (3).
REMARK
Excessive tightening can cause leakage. Take care
not to tighten excessively.
2 Threaded portion of pressure limiter (3):
Gear oil (#90)
3 Pressure limiter (3):
100±4 Nm {10.2±0.4 kgfm}

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High-pressure pipe, common rail

k Check the high-pressure pipe for the following, and
then install it. If the high-pressure pipe has any defect,
replace it with a new one since fuel may leak.
k Do not reuse the high-pressure pipe by bending it.
k Be sure to use the Komatsu genuine high-pressure
pipe fixing clamps and observe the specified tightening
torque.
k Install each high-pressure pipe and wiring harness
10 mm or more apart from each other.
k Visually check that the taper seal part (a) of the con-
necting part (2 mm from the tip-end) is free from the
longitudinal slits (b) or the spotty dents (c).
k Make sure that the part (d) (the end of the taper seal: 2
mm from the tip-end) is free from steps you can feel by
your fingernails (free from fatigue).
121. Tighten the common rail (10) lightly with the bolts (9) (4
pieces).
REMARK
Apply liquid gasket to the threaded portion of the bolts (9)
(2 pieces) on the engine side when installing the common
rail.
2 Threaded portion of bolt (9):
Liquid gasket (LG-7)

122. Tighten the high-pressure pipes (1), (2), (3), (4) and (8)
lightly.
3 Bolt (9) and sleeve nut (tightening lightly):
0.2 to 0.8 Nm {0.02 to 0.08 kgfm}
123. Tighten the high-pressure pipes (1), (2), (3), and (4) ac-
cording to the following procedure.
1) High-pressure pipe ((1): Connector side) → ((2): Con-
nector side) → ((1): Common rail side) → ((2): Com-
mon rail side)
2) High-pressure pipe ((3): Connector side) → ((4): Con-
nector side) → ((3): Common rail side) → ((4): Common rail side)
3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
124. Tighten the clamp (7) lightly with the bolts (7a) (2 pieces).
125. Tighten the fuel high-pressure pipe (8) in the order of the supply pump side to the common rail side.

3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
126. Tighten the bolts (9) (4 pieces).

3 Bolt (9):
24±4 Nm {2.45±0.41 kgfm}
127. Tighten the bolts (7a) (2 pieces).

3 Bolt (7a):
24±4 Nm {2.45±0.41 kgfm}

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128. Install the spill tube (6) with the bolts (6a) (3 pieces).

3 Joint bolt:
24±4 Nm {2.45±0.41 kgfm}
129. Install the fuel spray prevention cap (5).

k Direct the slit of the fuel splash prevention cap (5) outward or downward when installing it.
Fuel splash prevention plate
130. Install the bracket assembly (5) with the bolt (3) (1 piece)
and nuts (4) (3 pieces).
3 Bolt (3):
59 to 74 Nm {6 to 7.5 kgfm}
3 Nut (4):
11.8 to 14.8 Nm {1.2 to 1.5 kgfm}

131. Install the fuel splash prevention plate (2) with the bolts (1)
(2 pieces).
3 Bolt (1):
27 to 34 Nm {2.8 to 3.5 kgfm}

Water pump
132. Install the seal ring (3) to the water pump (2).

133. Tighten the water pump (2) lightly with the bolts (1) (2
pieces).
134. Tighten the bolt (1) according to the following procedure.

3 1st time:
8±1 Nm {0.8±0.1 kgfm}
3 2nd time:
30±4 Nm {3.1±0.4 kgfm}

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Fan hub
135. Install the fan hub (2) and wiring harness bracket (3) with
the bolts (1) (4 pieces).
3 Bolt (1):
32±5 Nm {3.3±0.5 kgfm}

Fan pulley
136. Install the fan pulley (2) with the bolts (1) (4 pieces).

3 Bolt (1):
43±6 Nm {4.4±0.6 kgfm}

Thermostat
137. Install the thermostat (3).

138. Install the coolant outlet connector (2) with the bolt (1).

3 Bolt (1):
10±2 Nm {1.0±0.2 kgfm}

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EGR valve, tubes

139. Install the gasket (11).

140. Install EGR valve (9) with the bolts (8) (4 pieces).

3 Bolt (8):
24±4 Nm {2.45±0.41 kgfm}
141. Install the hose (10) with the joint bolt (7).

3 Joint bolt (7):

19.6 to 29.4 Nm {2.0 to 3.0 kgfm}

Wiring harness assembly

142. Install the connector, clamp, and band, and install the wir-
ing harness assembly (1).
REMARK
Install the sensor, lock it with stopper to prevent falling off,
and check that the connector is securely connected.
143. Install the connector COOLANT TEMP (2).
144. Install the bracket (3).
145. Install the clamp (4).
146. Install the connector OIL PRESSURE SWITCH (5).
147. Install the connector EPS BACKUP (CAM) (6).
148. Install the connector EPS MAIN (CRANK) (7).
149. Install the connector INJECTOR CYL 1&2 (8).
150. Install the connector INJECTOR CYL 3&4 (9).
151. Install the connector FUEL RAIL PRESS (10).
152. Install the connector AMB AIRPRESSURE (11).
153. Install the connector TMAP (12).
154. Install the connector IMV (13).
155. Install the wiring harness assembly (1) to the clip (14).
156. Install the wiring harness assembly (1) with the clamps (15) and (16).
157. Install the connector ECM J1 (18).
158. Install the bolt (17).

REMARK
The bolt (17) is the bolt with hexagonal socket (4 mm).

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159. Install the connector OEM CONNECTION (19).

REMARK
Connect the connector OEM CONNECTION (19) with the
clips (2 places) on the back side.

160. Install the wiring harness assembly (1) with the clamps
(20), (21) and (22).
161. Install the wiring harness assembly (1) with the band (23).
162. Install the clamp (24).

163. Install the connector EGR VALVE (25).

Air intake connector, intake air heater

164. Install the gasket (6), plate (7), gasket (8), intake air heater
(9), gasket (10), and air intake connector (11) with the bolts
(12) (4 pieces).
REMARK
Be sure to install the plate (7) in the correct order.
If the plate (7) is installed between the air intake connector
(11) and intake air heater (9), it does not function properly.
3 Bolt (10):
24±4 Nm {2.45±0.41 kgfm}
Alternator bracket
165. Install the sling bracket (4) with the bolts (3) (4 pieces).

3 Bolt (3):
43±6 Nm {4.4±0.6 kgfm}
166. Install the alternator bracket (2) with the bolts (1) (4
pieces).
REMARK
After installing all the tubes, install the alternator.

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3 Bolt (1):
24±4 Nm {2.45±0.41 kgfm}
Removing from the engine repair stand
167. Sling the engine assembly (1) by using the lifting tool (P),
hold it, and disconnect it from the repair stand (A).

4 Engine assembly:
Approximately 350 kg
168. Remove the adapter (B) from the engine assembly (1).

169. Place the engine assembly (1) on a rigid and stable stand
[1], and fix it.

Engine oil cooler

170. Install the engine oil cooler gasket (17), engine oil cooler
(16), cover gasket (15), and cover (14) with the bolts (13)
(15 pieces).

171. Tighten the bolts (13) in the order shown in the figure.

REMARK
Install the bolts (13) carefully since there are 3 types of the
bolts.
(Not marked: 7 pieces, marked with ▲: 4 pieces, marked
with ■: 4 pieces)
3 1st time:
15±4 Nm {1.5±0.4 kgfm}
3 2nd time:
27±4 Nm {2.8±0.4 kgfm}

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172. Install the bracket (12) with the bolts (11) (2 pieces).

3 Bolt (11):
77±12 Nm {7.85±1.22 kgfm}
173. Install the engine oil level sensor with the clamps (9) and
(9a).

Coolant inlet connector, auto-tensioner

174. Install the seal ring (3).
175. Install the coolant inlet connector (5) with the bolts (4) (3
pieces).
3 Bolt (4):
43±6 Nm {4.4±0.6 kgfm}

176. Install the auto-tensioner (2) with the bolt (1).

REMARK
3 Bolt (1):
43±6 Nm {4.4±0.6 kgfm}
Check that the belt mounting parts of the auto-tensioner
pulley and crankshaft pulley are parallel by visual check or
using a ruler.

EGR cooler
177. Tighten EGR cooler (2) lightly with the bolts (1) (2 pieces).

REMARK
Tighten the exhaust manifold to the specified torque, and
then tighten EGR cooler (2) to the specified torque.

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Exhaust manifold
178. Tighten the gaskets (1), (11), exhaust manifold (2),
spacers (3a) and (8a) lightly with the bolts (3) (8 pieces)
and (8) (2 pieces).
REMARK
Adjust the cylinder head, exhaust manifold (2), and EGR
cooler (10) by loosening and tightening the bolts (3), (8),
and (9) so that they are not forcibly installed.

179. Tighten the bolts (3) (8 pieces) to the specified torque in

the order shown in the drawing.
3 1st time:
53±5 Nm {5.4±0.5 kgfm} (Tighten the bolts in the
order of [1] to [8].)
3 2nd time:
53±5 Nm {5.4±0.5 kgfm} (Retighten only the bolts
[1] to [4] as shown in the drawing.)
180. Tighten the bolt (8) to the specified torque.

3 Bolt (8):
43±6 Nm {4.4±0.6 kgfm}
181. Tighten the bolt (9) to the specified torque.

3 Bolt (9):
24±4 Nm {2.45±0.41 kgfm}
182. Install the exhaust manifold pressure sensor (5) with the bolt (4).

3 Bolt (4):
24±4 Nm {2.45±0.41 kgfm}
183. Install the nut (6) of the exhaust manifold pressure sensor (5).

3 Nut (6):
18±3 Nm {1.84±0.31 kgfm}
184. Install the connector EXHAUST PRESS (7).

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EGR cooler piping

185. Tighten the tube (28) lightly with the bolt (27).
186. Tighten the hose clamp (26).

3 Hose clamp (26):

5±1 Nm {0.5±0.1 kgfm}

187. Install the tube (31) with the bolt (30).

3 Bolt (30):
24±4 Nm {2.45±0.41 kgfm}
188. Tighten the hose clamp (29).

3 Hose clamp (29):

5±1 Nm {0.5±0.1 kgfm}

189. Install the gasket (17) and tube (16) with the bolts (14) (2
pieces) and (15).
3 Bolt (14):
24±4 Nm {2.45±0.41 kgfm}
3 Bolt (15):
24±4 Nm {2.45±0.41 kgfm}
190. Install the tube (28) to the tube (16) with the bolts (11) (2
pieces).
3 Bolt (11):
24±4 Nm {2.45±0.41 kgfm}
191. Tighten the bolt (27).

3 Bolt (27):
24±4 Nm {2.45±0.41 kgfm}

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192. Install the hose (3) to the tube (16).

193. Install the tube (6) to the hose (3).
194. Tighten the tube (6) lightly with the bolt (5).
195. Install the gasket (18) and tube (6) with the bolts (4) (3
pieces).
3 Bolt (4):
24±4 Nm {2.45±0.41 kgfm}
196. Tighten the bolt (5) to the specified torque.

3 Bolt (5):
24±4 Nm {2.45±0.41 kgfm}
197. Tighten the hose clamp (2).

3 Hose clamp (2):

10.5±0.5 Nm {1.1±0.05 kgfm}
198. Install the connector EXHAUST GAS TEMPERATURE (1).

VGT
199. Install the tube (6) with the bolts (6a) (2 pieces).

3 Bolt (6a):
10±2 Nm {1.12±0.20 kgfm}
200. Install the gasket (8) and VGT (7) with the nuts (5) (4
pieces).

4 VGT (7):
15 kg
3 Nut (5):
43±6 Nm {4.4±0.6 kgfm}
REMARK
Install the nuts (5) diagonally.

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201. Install the tube (9) with the joint bolts (10), (11), and (12).

3 Joint bolt (10):

24±4 Nm {2.45±0.41 kgfm}
3 Joint bolt (11):
24±4 Nm {2.45±0.41 kgfm}
3 Joint bolt (12):
15±2 Nm {1.53±0.2 kgfm}
202. Install the tube (13) with the joint bolt (14) and sleeve nut
(15).
3 Joint bolt (14):
15±2 Nm {1.53±0.2 kgfm}
3 Sleeve nut (15):
35±5 Nm {3.57±0.51 kgfm}
203. Install the tube (22) with the joint bolts (20) (2 pieces) and
sleeve nut (21).
3 Joint bolt (20):
24±4 Nm {2.45±0.41 kgfm}
3 Sleeve nut (21):
35±5 Nm {3.57±0.51 kgfm}
204. Install the bracket (2) with the bolts (1) (3 pieces).
205. Install the connector VGT ACTUATOR (3).
206. Install the connector TURBO SPEED SENSOR (4).

207. Install the bracket (17) and VGT heat insulation plate (19)
with the bolts (18) (3 pieces).
3 Bolt (18):
8.8 to 10.8 Nm {0.9 to 1.1 kgfm}
208. Install the wiring harness (17a) to the bracket (17).

209. Install VGT blower connector (24) with the clamp (23).

3 Clamp (23):
10±2 Nm {1.02±0.2 kgfm}

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Alternator
210. Install the alternator (4) with the nut (1), bolts (2) and (3).

REMARK
For machines with the 85A alternator, be sure to install the
spacers (5) (3 pieces) when installing the nut (1), bolts (2)

3 Bolt (2):
and (3).

43±6 Nm {4.4±0.6 kgfm} (60A specifications)

3 Bolt (2):
98 to 123 Nm {10 to 12.5 kgfm} (85A specifica-
tions)
3 Bolt (3):
43±6 Nm {4.4±0.6 kgfm} (60A specifications)
3 Bolt (3):
98 to 123 Nm {10 to 12.5 kgfm} (85A specifica-
tions)
Alternator belt
211. Install the ratchet (S) to the part A of the auto-tensioner (2)
(width across flats: 12.7 mm).
212. Rotate the ratchet (S) in the direction (R) to loosen the ten-
sion of the alternator belt (1), and install the alternator belt
(1).
k Firmly set the ratchet (S) to the part A of the auto-
tensioner (2), and then rotate it. (The spring of the
auto-tensioner (2) is strong. If the ratchet (S) is
loosely installed and rotated, it can accidentally
come off and this is extremely dangerous.)
k After installing the alternator belt (1), return the au-
to-tensioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Starting motor assembly
213. Install the gasket (3) and starting motor assembly (2) with
the bolts (1) (2 pieces).
3 Bolt (1):
43±6 Nm {4.4±0.6 kgfm}

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Engine oil filter

214. Install the engine oil filter hoses (3) and (4).

3 Sleeve nut:
127±15 Nm {13±1.53 kgfm}
215. Install the engine oil filter (8) together with the bracket (7)
with the bolt (6).
3 Bolt (6):
77±12 Nm {7.85±1.22 kgfm}
216. Install the clamp (5).

Fuel filter assembly

217. Install the fuel filter hoses (2) and (3) to the supply pump
(1).
NOTICE
Do not reuse the fuel filter hoses (2) and (3) as a rule
since internal parts of the hose fittings may be dam-
aged when disconnecting the fuel filter hoses (2) and
(3). Replace the fuel filter hoses (2) and (3) with new
ones when reassembling.
REMARK
• Insert the fuel filter hoses (2) and (3) straight while
pushing the lock (L) without prying or shaking it.
• If it is difficult to insert them, do not push them in forci-
bly but pull them out once, and check concave and
convex parts for abnormality or dirt.
218. Install the fuel filter (6) together with the bracket (5) with
the bolt (4).
3 Bolt (4):
59 to 74 Nm {6 to 7.5 kgfm}

Engine oil level gauge, tube

219. Apply liquid adhesive to the guide (a) when removing, in-
stalling or replacing the engine oil level gauge (5) and tube
(6), and drive them in.
2 Mounting parts of engine oil level gauge (5) and
tube (6):
Liquid adhesive (LT-4)

107E-3 SERIES 50-89

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3) BLY

220. Install the bracket (4) with the bolts (3) (2 pieces).

3 Bolt (3):
24±4 Nm {2.45±0.41 kgfm}
221. Install the engine oil level gauge (5) with the clamps (2) (3
pieces).
222. Install the hose (1) to the bracket (4) with the clamp (1).

Tightening torque of sensor

223. When removing, installing, or replacing the sensor, tighten it to the following torque.

Sensor name Tightening torque

Coolant temperature sensor 20±3 Nm {2.04±0.31 kgfm}
Engine oil pressure switch 8±2 Nm {0.82±0.2 kgfm}
Ne (crankshaft) speed sensor 8±2 Nm {0.82±0.2 kgfm}
Ambient pressure sensor 8±2 Nm {0.82±0.2 kgfm}
Charge (Boost) pressure and temperature sensor 8±2 Nm {0.82±0.2 kgfm}
Exhaust manifold pressure sensor 20±3 Nm {2.04±0.31 kgfm}
EGR orifice temperature sensor 20±3 Nm {2.04±0.31 kgfm}
Check for fuel leakage
• When the supply pump (1), common rail (2), and high-
pressure pipe was removed or installed, check for fuel
leakage according to the following procedure after as-
sembling the engine.
• Clean the engine and the parts around it, and degrease
them in advance so that you can easily find the leak-
age if any.
224. Spray the color checker (developer) to the supply pump
(1), common rail (2), injector, and connecting part of the
high-pressure pipe.
225. Start the engine, keep its speed at 1000 rpm or below, and
stop it when the speed is stabilized.
REMARK
It may be 1050 rpm depending on the machine model.
226. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If there is a fuel leakage, repair it, and perform the testing from step 224 again.
227. Start the engine, and run it at low idle.
228. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If there is a fuel leakage, repair it, and perform the testing from step 224 again.

50-90 107E-3 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)

229. Start the engine, and keep it running at high idle.

230. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If there is a fuel leakage, repair it, and perform the testing from step 224 again.
231. Start the engine and keep it running at high idle, and apply a load to the engine.

REMARK
When checking the engine for leakage as it is installed on the machine, stall the torque converter or relieve
the main pump.
232. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If there is a fuel leakage, repair it, and perform the testing from step 224 again.
• If no fuel leakage is detected, check is completed.

107E-3 SERIES 50-91

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

NOTICE
• Before starting your work, check the shapes, quantity, locations, etc. of the parts because they may
vary depending on the machine model.
• Before disassembling the engine, check its parts for cracking, damage, etc. and clean it thoroughly
and carefully for accurate inspection of its parts and quick disassembly and assembly.
• Before cleaning the engine, carefully seal the openings or remove electric parts and wiring connec-
tors so that water does not enter them.
• Clean all the parts. Check that there is neither dent, nor defect, nor cavity, or etc. Also, make sure
that the oil passages and water passages are complete.

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50 DISASSEMBLY AND ASSEM-
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METHOD FOR DISASEMBLING ENGINE GENERALLY (6D107E-3)

Preparation Starting
Engine • Set it on motor
assembly blocks assembly
• Drain the
coolant
• Drain the oil Oil tube for Exhaust
VGT hydraulic VGT EGR cooler manifold A
actuator assembly

Alternator Oil cooler

assembly

Tensioner
assembly

Fan pulley

Vibration
damper

Engine
controller

Supply
pump

Fan

107E-3 SERIES 50-93

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Water pump Rocker arm

assembly

Head cover Cylinder

Engine
A repair stand
and rocker Crosshead head Oil pan B
housing assembly

Thermostat Push rod Front cover C

Wiring
Injector
harness
assembly
assembly

Fuel filter
assembly

High-
pressure
pipe

Common
rail

Boost pump

Flywheel Rear oil seal Flywheel

housing

EGR valve

Piston and Piston

Cylinder
B connecting cooling Crankshaft Tappet
block
rod assembly nozzle

Front oil Oil pump Gear

C seal assembly
Camshaft
housing

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

Preparation
1. Set engine assembly (1) on a rigid and stable stand [1].
REMARK
The weight depends on the applicable machine model.

4 Engine assembly:
650 kg
2. Drain the engine coolant and engine oil.
REMARK
The oil level depends on the applicable machine model.

6 Engine oil:
Approximately 23 ℓ
Starting motor assembly
3. Remove mounting bolts (1), and remove starting motor as-
sembly (2).

Fan
4. Remove fan (3).

5. Insert tool S in part A (width across flats 12.7 mm) of the

auto-tensioner (2), rotate it in the direction opposite to the
winding-up direction (R) to loosen the tension of alternator
belt (1), and remove alternator belt (1).
k Be sure that tool S is installed securely to part (A)
of auto-tensioner (2) before turning it. (Since the
spring force of auto-tensioner (2) is strong, tool S
may come off and is very dangerous if it is turned
when not attached securely.)
k After removing alternator belt (1), return auto-ten-
sioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.

107E-3 SERIES 50-95

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Only for the hydraulic excavator.

6. Install tool R to tool T.
REMARK
• Because tool S contacts the aftercooler piping when in-
stalling the alternator belt, and necessary swing angle
cannot be provided.
• Tighten it by hands until tool R reaches to the bracket.

7. Install tool S to A part (width across flats 12.7 mm) of auto-

tensioner (1).

8. Turn tool S in the direction opposite to the winding-up di-

rection (R) to loosen the tension of alternator belt (2), and
remove alternator belt (2).
k Be sure that tool S is installed securely to part (A)
of auto-tensioner (1) before turning it. (Since the
spring force of auto-tensioner (1) is strong, tool S
may come off and is very dangerous if it is turned
when not attached securely.)
k After removing alternator belt (2), return auto-ten-
sioner (1) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (2) during work.

Alternator
9. Remove mounting bolts (1) and (2), and alternator (3).

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50 DISASSEMBLY AND ASSEM-
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Tubes and hoses

10. Disconnect tube clamp (1).
11. Remove mounting bolts (4) (4 pieces) and mounting bolt
(6) on the side of EGR cooler, and remove hose (3), EGR
piping flange (5) and tube (7) in the state that they have
been installed.
12. Loosen hose clamp (2), and disconnect hose (3).
13. Remove VGT return tube (13).
14. Disconnect tube (8) from VGT side.
15. Disconnect tube clamp (9).
16. Loosen hose clamp (10) and remove tube (8).

17. Remove tube (11).

VGT side is tightened together with it.

18. Remove tube (12).

VGT side is tightened together with it.

107E-3 SERIES 50-97

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

VGT
19. Disconnect wiring harness connectors (1), (2), and (3).
Connector (1): VGT position sensor (SVGT)
Connector (2): VGT speed sensor (VGT_REV)
Connector (3): Connector box (INTER CONNECT)
20. Disconnect hoses (4) and (5).
Hose (4): VGT control pressure circuit
Hose (5): VGT drive hydraulic circuit

21. Sling VGT (6), and remove it.

4 VGT:
25 kg

Heat insulation plate

22. Remove heat insulation plate (1).

EGR cooler
23. Remove the joint bolt, and remove tube (1).
24. Remove tube (2) at the bottom side of EGR cooler.

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50 DISASSEMBLY AND ASSEM-
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25. Remove mounting bolts (3), and disconnect EGR cooler

(4) and exhaust manifold.
REMARK
When disconnecting, be careful not to drop the gasket.
26. Remove EGR cooler (4) and bracket (5).

Auto-tensioner
27. Remove mounting bolt (1), and remove auto-tensioner (2).

Oil filter and oil cooler

28. Remove coolant inlet connector (1).
29. Disconnect oil filter hoses (2) and (3), and remove oil filter.

30. Remove mounting bolts (4) (15 pieces), and remove cover
(5) and cover gasket (6).
31. Remove oil cooler (7) and cooler gasket (8).

107E-3 SERIES 50-99

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Exhaust manifold assembly

32. Remove exhaust manifold (1).
REMARK
When disconnecting, be careful not to drop the gasket.

Installation to engine repair stand

33. Install tool B to engine assembly (1).
Mounting bolts at engine side: M12 x 1.75
34. Sling engine assembly (1), set tool B to tool A, and install
engine assembly (1).
REMARK
The weight depends on the applicable machine model.

4 Engine assembly:
Approximately 520 kg
Fan pulley
35. Remove fan pulley (1).

Vibration damper
36. Remove mounting bolts (1), and remove vibration damper
(2).

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

Alternator bracket
37. Remove alternator bracket (1).
38. Remove sling bracket (2).

Fan hub
39. Remove mounting bolts (1) (4 pieces), and remove fan
hub (2).
The fan hub is tightened together with wiring harness
bracket (3).

Thermostat
40. Remove mounting bolt (1), and remove coolant outlet con-
nector (2).

41. Remove thermostat (3).

107E-3 SERIES 50-101

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Water pump
42. Remove mounting bolt (1), and remove coolant inlet con-
nector (2).
43. Remove mounting bolt (3), and remove water pump (4).

EGR valve
44. Disconnect tube clamp (1).
45. Disconnect tube clamp (2).
46. Disconnect tube (4) from boost pump (3).
47. Disconnect tube (5).
48. Disconnect clamps (7) and (8) of dipstick pipe (6).
49. Remove mounting bolt (9), and remove bracket (10).
50. Disconnect tubes (11) and (12).

51. Disconnect connector (INNTER-CONNECT) (13).

52. Remove mounting bolts (14), and remove EGR valve (15).

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50 DISASSEMBLY AND ASSEM-
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Wiring harness assembly

53. Disconnect the connector, clamp, and band, and discon-
nect wiring harness assembly (1).
(2): Coolant temperature sensor connector
(3): Wiring harness bracket

(4): Wiring harness clamp

(5): Engine oil pressure switch connector
(6): Bkup (camshaft) speed sensor connector
(7): Ne (crank) speed sensor connector

(8) and (18): Wiring harness clamp

(9): Ambient pressure sensor connector
(10): Wiring harness connector

(11): Band
(12) and (13): Wiring harness bracket
(14) and (15): Wiring harness connector
(16): Common rail pressure sensor connector
(12): Charge (boost) pressure and temperature sensor
connector

(19): Wiring harness connector

(20): Band
(21): Wiring harness clamp
(22): Wiring harness bracket
(23): Wiring harness connector (ECM)
• Wiring harness clamp (21) is tightened together with
wiring harness bracket (22).
• Lock wiring harness connector (ECM) (23) with hexag-
onal socket head bolt (24) (4 mm).

107E-3 SERIES 50-103

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Fuel filter assembly

54. Disconnect fuel filter hoses (2) and (3) from supply pump
(1).
NOTICE
Do not reuse the hose as a rule since internal parts of
the hose fittings may be damaged when disconnecting
the fuel filter hose. Replace the hose with a new one
when reassembling.
REMARK
When removing the fuel filter hose, pull out the hose while
pressing lock (L) from both sides.
High-pressure pipe and common rail
55. Remove fuel spray prevention caps (8) (14 pieces) of high-
pressure pipes (1) to (7).
56. Remove fuel high-pressure pipes (1) to (6).
57. Remove tube clamps (9) (2 places), and remove fuel high-
pressure pipe (7).
58. Disconnect tube clamps (10), and remove spill tube (11).
59. Remove mounting bolts and nuts (at 4 places each), and
remove common rail (12).

Intake manifold cover

60. Remove mounting bolts (1) (4 pieces), and remove tube
(2) and intake air heater (3).
61. Remove the mounting bolts, and remove intake manifold
cover (4) and air intake manifold connector (5).

Head cover and rocker housing

62. Remove blowby duct (1).
63. Remove nuts (2) (6 pieces), and remove head cover (3).

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

64. Remove harness nuts (4) from the injector.

Installed position of harness
Color of wiring har-
Cylinder No.
ness
White 1, 3, 5
Black 2, 4, 6

NOTICE
Do not remove injector wiring harness connector (7)
from the rocker housing unless it is required.
65. Remove mounting bolt (5), and remove rocker housing assembly (6).
Rocker arm assembly, crosshead
66. Remove mounting bolt (1), and remove rocker arm assem-
bly (2).
REMARK
Loosen locknut (4), and loosen adjustment screw (5) by 2
or 3 turns so that a force of valve spring is not applied to
the rocker arm assembly mounting bolts.
67. Remove crosshead (3).
REMARK
Make a record of the locations and shapes of holes (a) and
(b) (to install them in same directions when reassem-
bling.).

Push rod
68. Remove push rods (1).

107E-3 SERIES 50-105

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Injector assembly
69. Remove retaining nut (5), and remove inlet connector (1).
REMARK
Use tool M to remove the inlet connector.
70. Remove mounting bolt (3) of injector (2), and remove hold-
er (4).
71. Remove injector (2).
REMARK
Pull up the injector by using tool F to remove it. (Do not pry
the top of the injector to remove it.)

Cylinder head assembly

72. Remove mounting bolt (1), and remove cylinder head as-
sembly (2).

4 Cylinder head assembly:

75 kg

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

73. Compress valve spring (3) by using tool C, and remove

valve collet (4).
74. Remove upper seat (5) and valve spring (3).

75. Raise the cylinder head assembly, remove valve (6), and
remove valve seal (7).
REMARK
Put marks on valve (6) so that you can find matching cylin-
der head.

Engine controller
76. Remove the mounting bolts (4 pieces), and remove engine
controller (2).
Ground cable (1) is tightened together.

107E-3 SERIES 50-107

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

77. Remove engine controller mount bracket (3).

Supply pump
78. Remove nuts (1) (3 pieces), and remove supply pump (2).
REMARK
• Pull supply pump (2) sideways when removing it. Oth-
erwise the supply pump may interfere with the tip of
boost pump (17).
• Supply pump (2) comes off together with gear. The
gear has not been worked (missing tooth, etc.) to align
the mark for 1, 6 TOP.

79. Remove the gear from the supply pump according to the
following procedure.
1) Fix the gear by using tool N and 1/2 inch spinner han-
dle [1], and loosen nut (3).
REMARK
Do not remove nut (3) from the shaft.

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

2) Install puller [2] between the flange and gear (4).

3) Install puller [3] on puller [2] and the shaft.

4) Screw in center bolt [4] until the gear is disengaged
from the shaft.
5) Remove pullers [2] and [3].

6) Remove nut (3), lock washer (5) and gear (4) from
shaft (6).

Boost pump
80. Remove mounting bolts (1) (2 pieces), and remove boost
pump (2).

107E-3 SERIES 50-109

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Oil pan
81. Move the engine repair stand to the position where the oil
pan mounting bolts are easily removed.
82. Remove mounting bolts (1) (32 pieces), and remove oil
pan (2).

83. Remove suction tube (3).

84. Remove plate (4).
REMARK
Remove the Torx screw (1 place) by using Torx wrench.

Front cover
85. Remove front oil seal (1) according to the following proce-
dure.
1) Remove dust seal (12a).
2) Install tool H to the crankshaft.
3) Screw in tapping screw [1] of tool H to the seal carrier
section of front oil seal (1).
4) Turn the handle clockwise, and remove front oil seal
(1).
86. Remove Bkup (cam) speed sensor (2).
NOTICE
If the front cover is removed with Bkup (cam) speed
sensor installed, it may damage the tip of camshaft.

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50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)

87. Remove mounting bolt (3), and remove front cover (4).

Oil pump assembly

88. Remove mounting bolt (1), and remove oil pump assembly
(2).

Flywheel
89. Remove mounting bolt (1), and insert guide bolt [1].
90. Set sling to flywheel (2), and pull it (2) out.
REMARK
When pulling out the flywheel, be careful for the guide
bolts not to come off.
91. Sling flywheel (2), and remove it.

4 Flywheel:
35 kg
k Since the faucet joint part of the flywheel is shal-
low, the flywheel may fall off suddenly. Be careful
not to get your finger caught.

107E-3 SERIES 50-111

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Rear oil seal

92. Install tool G to the crankshaft.
93. Screw in tapping screws [1] of tool G to the seal carrier
part of rear oil seal (1).
94. Turn the handle clockwise, and remove rear oil seal (1).

Flywheel housing
95. Remove mounting bolt (1), and remove flywheel housing
(2).

Camshaft
96. Rotate the crankshaft, and align timing mark (part A) of
camshaft gear (1) with the chamfered blade of crankshaft
gear (4).
REMARK
This is to prevent interference with the connecting rod
when removing the camshaft.

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50 DISASSEMBLY AND ASSEM-
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97. Remove camshaft gear (1).

98. Remove thrust plate (2).

99. Remove camshaft (3) while rotating it.

Gear housing
100. Remove mounting bolt (1), and remove gear housing (2).

Piston and connecting rod assembly

101. Rotate the crankshaft so that the piston to be pulled out comes to the bottom dead center.
102. Scrub the carbon off the top wall of the cylinder bore by using fine sandpaper.

107E-3 SERIES 50-113

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

103. Apply a marking of assembly position to each of connect-

ing rod caps (1) on respective cylinders.
REMARK
Before removing the piston and connecting rod assembly,
measure the side clearance between the connecting rod
and crankshaft by using tool K.

104. Remove mounting bolt (2).

105. Tap connecting rod cap (1) with a plastic hammer, and re-
move connecting rod cap (1) and connecting rod bearing
as a unit.
NOTICE
Store the connecting rod and connecting rod cap so
that their mating faces is not damaged. If their mating
faces are damaged, replace the connecting rod and
connecting rod cap.

106. Push in the piston and connecting rod assembly by using a

wooden bar, etc. from the oil pan side, and then remove it
from the cylinder head side while supporting piston (6).
REMARK
• Remove it while being careful not to damage the inner
surface of the cylinder with a corner of the connecting
rod.
• Put the cylinder No. mark on the piston.
107. Remove the remaining piston and connecting rod assem-
blies according to the same procedure.
NOTICE
Take care not to damage the sliding surfaces of the
pistons, bearings, etc.
108. Disassemble the piston and connecting rod assembly according to the following procedure.
1) Remove snap ring (3).
2) Support connecting rod (4) by hand, pull out piston pin
(5), and disconnect piston (6) from connecting rod (2).
3) Remove the snap ring on the opposite side.

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50 DISASSEMBLY AND ASSEM-
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4) Remove piston ring (7) by using tool D.

REMARK
Store the piston, connecting rod, bearing, piston ring,
and piston pin for each cylinder.

Piston cooling nozzle

109. Remove the mounting bolt (1), and remove piston cooling
nozzle (2).

Crankshaft
110. Before removing the crankshaft, measure its end play (X)
by using a dial gauge.

107E-3 SERIES 50-115

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

111. Remove mounting bolt (2) of main cap (1).

112. Insert the bolt into the bolt hole of main cap (1), and re-
move the main cap while shaking it.
REMARK
• Mounting position numbers are stamped on the main
cap, and No. 1 starts from the front side of the cylinder
block.
• Check that the position number (the number is stam-
ped in part A) of the main cap is directed toward the oil
cooler.

113. Remove lower bearing (3) from main cap (1).

REMARK
Record the position number on the bearing claw part A of
the removed bearing. (Do not write down on the bearing
sliding surface.)

114. Sling crankshaft (4) by using a nylon sling, and remove it.

REMARK
• Remove it while being careful not to damage the cylin-
der block when slinging and removing the crankshaft,
• Store the crankshaft in a safe place to prevent damage
to the sliding surfaces.

4 Crankshaft:
60 kg

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50 DISASSEMBLY AND ASSEM-
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115. Remove upper thrust bearing (5) (1 piece) and upper bear-
ing (6).
REMARK
Mark the installation position on the main cap, upper bear-
ing, and upper thrust bearing (use the back side for the
bearing), and group them on a cap basis. And take care
not to damage these parts.

Tappet
116. Remove tappets (1) and mark the installation position on
them.
REMARK
Tappet must be installed to the original position if it is
reused.

Cylinder block
117. Remove cylinder block (1) from tools A and B.

4 Cylinder block:
140 kg

107E-3 SERIES 50-117

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

METHOD FOR ASEMBLING ENGINE GENERALLY (6D107E-3)

Piston Piston and

Cylinder
block
Tappet Crankshaft cooling connecting A
nozzle rod assembly

Gear Oil pump Front oil

housing
Camshaft
assembly seal B

Rocker arm Water pump

assembly

Cylinder Head cover

Engine
A Oil pan head Crosshead and rocker
repair stand C
assembly housing

B Front cover Push rod Thermostat

Wiring
Injector
harness
assembly
assembly

Fuel filter
assembly

High-pressu
re pipe

Common
rail

Boost pump

Flywheel Rear oil seal Flywheel

housing

EGR valve

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50 DISASSEMBLY AND ASSEM-
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Starting Preparation
• Set it on Engine
motor
blocks assembly
assembly
• Drain the
coolant
Exhaust Oil tube for • Drain the oil
C manifold EGR cooler VGT VGT hydraulic
assembly actuator

Oil cooler Alternator

assembly

Tensioner
assembly

Fan pulley

Vibration
damper

Engine
controller

Supply
pump

Fan

Parts must be installed to the original position.

107E-3 SERIES 50-119

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3) BLY

Preparation
1. Install tool B to tool A.
2. Install cylinder block (1) to tools A and B.

4 Cylinder block:
140 kg

Tappet
3. Apply engine oil to tappet (1).
2 Tappet:
Engine oil (EO15W-40)

4. Install tappets (1).

REMARK
• Tappet must be installed to the original position if it is
reused.
• Tappet may come off when assembling, do not reverse
the cylinder block more than 90 °.

Piston cooling nozzle

5. Install piston cooling nozzle (2), and tighten it with bolt (1).
3 Mounting bolt:
15±2 Nm {1.5±0.2 kgfm}

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Crankshaft
6. Install upper bearing (6), upper thrust bearing (5) (1 piece).
REMARK
• Set the protruding part of the bearing to the notch of
the cylinder block for installation.
• Check that foreign material is not attached to the back
surface of the bearing before installation.
• Apply engine oil to inside wall of bearing. However, do
not apply it to the back side at this time.
• When reusing the bearing, check the mark placed at
disassembly, and install it to the original position.
2 Inner surface of bearing:
Engine oil (EO15W-40)
7. Sling crankshaft (4) by using nylon sling, and install it.
NOTICE
Be careful not to damage the upper thrust bearing
when installing it.

4 Crankshaft:
60 kg

8. Install the lower bearing (3) to the main cap while matching
its protrusion to the notch.
REMARK
Check that dowel ring (7) is installed to the main cap.
9. Apply engine oil to journal surface of the crankshaft.
2 Journal surface:
Engine oil (EO15W-40)

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10. Check the punching mark No. of main cap (1), and install
it.
REMARK
• Perform installation in the order of [1] to [7] from the
front side of the cylinder block.
• Install with the mark No. (A part) facing the oil cooler
side.
• Push it in by hitting it lightly with a plastic hammer or
rubber hammer.

11. Measure the stem lengths (a) of all mounting bolts by us-
ing tool X before screwing in main cap mounting bolt (2),
and check that the lengths are within the allowable limit.
Allowable limit of bolt length: Less than 120.0 mm
NOTICE
If a bolt is longer than the allowable limit, do not reuse
it but replace it.

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12. Tighten main cap mounting bolts (2) in the order shown in
the figure.
REMARK
Apply engine oil to threaded part and seat of bolt.
2 Main cap mounting bolt:
Engine oil (EO15W-40)

3 1st time:
• When the bolt is reused

60±5 Nm {6.1±0.5 kgfm}

3 2nd time:
80±5 Nm {8.2±0.5 kgfm}
3 3rd time:
90±5 ° (Angle tightening tool J is used.)

3 1st time:
• When the bolt is new

120±10 Nm {12.2±1.02 kgfm}

3 2nd time:
360 ° loosen
3 3rd time:
60±5 Nm {6.1±0.5 kgfm}
3 4th time:
85±5 Nm {8.7±0.5 kgfm}
3 5th time:
120±5 ° (Angle tightening tool J is used.)

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• When tool J is not used

Put the mark on the main cap and bolt with paint, and

3 When the bolt is reused:

retighten the bolt.

90±5 °
3 When the bolt is new:
120±5 °
13. Put punch mark on the head of bolt when the bolt is
reused.
REMARK
When using a new bolt, do not put punch mark on the
head of bolt.
14. After tightening the bolt, rotate the crankshaft to check for smooth rotation.
15. Measure the end play of crankshaft by using dial gauge.
End play X: 0.24±0.175 mm

Piston and connecting rod assembly

16. Install piston ring (7) to the piston by using tool D.
17. Install the oil ring according to the following procedure.

1) Fit oil ring (9) so that its abutment joint is 180 ° away
from the end of expander (8).

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2) Install second ring (10) as directing the punching mark

“TOP” near the abutment joint upward.
3) Install top ring (11) as directing the punching mark
“dot” near the abutment joint upward.
4) Install each ring directing the abutment joint to the di-
rection other than the direction of thrust and opposite
direction of thrust, and axial direction of piston.
5) Apply engine oil to piston ring and piston skirt.
2 Piston ring:
Engine oil (EO15W-40)
2 Piston skirt:
Engine oil (EO15W-40)
18. Install the piston and connecting rod according to the fol-
lowing procedure.
REMARK
Direct “FRONT” mark at the head of piston (6) upward,
and check that connecting rod (4) faces the direction in-
dicted in the figure.

1) Apply engine oil to piston pin hole and piston pin.

2 Piston pin hole:
Engine oil (EO15W-40)
2 Piston pin:
Engine oil (EO15W-40)

2) Insert piston pin (5), and assemble piston (6) to con-

necting rod (4).
3) Attach snap rings (3) on both sides.

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19. Install the bearing to connecting rod and connecting rod

cap.
REMARK
• Do not damage the mating faces of the connecting rod
and connecting rod cap when disassembling. If these
are damaged, replace the connecting rod.
• Check that foreign material is not attached to the back
side of the bearing.
• Install the bearing to the connecting rod and connect-
ing rod cap while matching its protrusion to the notch-
es.
20. Set the crankshaft of the cylinder to be installed at the bottom dead center, and apply engine oil to inner
surface of cylinder.
2 Inner surface of cylinder:
Engine oil (EO15W-40)
21. Insert piston and connecting rod assembly directing
“FRONT” mark of piston (6) to the front of cylinder block.
REMARK
• Check the direction of the piston ring abutment joint
again.
• Be careful not to damage the cylinder wall when insert-
ing the connecting rod.
• Be careful not to hit the cooling nozzle when installing
it.
• Compress the piston rings by using tool E, and push in
the piston head with a wood bar, etc.

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22. Tighten bolt (1) according to the following procedure, and

install connecting rod cap (2).
REMARK
Apply engine oil to the threaded part of the bolt and the in-
ner surface of connecting rod bearing.
2 Connecting rod threaded part:
Engine oil (EO15W-40)
2 Inner surface of connecting rod bearing:
Engine oil (EO15W-40)

• Perform angle tightening by using tool J.

3 1st time:
Mounting bolts (Tighten both bolts alternately.)

30±3 Nm {3.06±0.31 kgfm}

3 2nd time:
60±5 Nm {6.12±0.51 kgfm}
3 3rd time:
60±5 ° (Angle tightening tool J is used.)
• When not using tool J, put marks on the cap and bolt
with paint, or etc., and then retighten the bolts 60±5 °.
23. Check that crankshaft rotates smoothly without any abnor-
mality after installing piston and connecting rod assembly.

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24. Measure the side clearance between connecting rod and

crankshaft by using tool K.
Side clearance: 0.10 to 0.33 mm

Gear housing
25. Apply liquid gasket to mounting face (A part) of gear hous-
ing (2).
REMARK
• Apply liquid gasket 1 to 2 mm in diameter.
• If liquid gasket applied too much around the oil groove
(B part) of blowby, it may block the groove. Do not ap-
ply the liquid gasket too much.
2 Gear housing:
Liquid gasket (LG-7)
26. Check that dowel rings of the gear housing are securely in-
serted into the dowel holes (C) (2 places) of upper and
lower cylinder blocks.
NOTICE
Tighten the bolt when dowel rings are not properly inserted, it may damage the dowel rings.
27. Push the gear housing for mating surface with the cylinder block to be entirely attached.
REMARK
Do not apply the torque to the mounting bolt before the mating surface is entirely attached.
28. Tighten the mounting bolts in the order shown in the figure.
3 Mounting bolt M12 (not marked):
77±7 Nm {7.9±0.7 kgfm}
3 Mounting bolt M10 (marked with □: ℓ = 30, marked
with ○: ℓ = 50):
47±5 Nm {4.8±0.5 kgfm}
3 Mounting bolt M8 (marked with △):
24±4 Nm {2.5±0.4 kgfm}

Camshaft
29. Rotate the crankshaft so that No.1 cylinder comes to top dead center (TDC).

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30. Apply engine oil to camshaft bore, camshaft journal, and

lobe face. Push the camshaft (3) lightly, and install it by ro-
tating.
REMARK
Install camshaft while taking care not to damage the cam
bushing.
2 Camshaft sliding surface:
Engine oil (EO15W-40)

31. Install thrust plate (2).

3 Mounting bolt:
24±4 Nm {2.4±0.4 kgfm}

32. Install it aligning timing mark A part of camshaft gear (1)

and chamfered teeth (1 place) of crankshaft gear (4).
3 Mounting bolt:
36±4 Nm {3.7±0.4 kgfm}

33. Measure the end play and backlash of camshaft by using

dial gauge.
REMARK
The amount of end play is determined by thickness of
thrust plate and groove of camshaft.
End play: 0.23±0.13 mm
Backlash: 0.178±0.102 mm

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Flywheel housing
34. Apply liquid gasket to the mounting flange surface of the
flywheel housing (2) and around the mounting bolt holes.
REMARK
Apply liquid gasket 1 to 2 mm in diameter.
2 Flywheel housing:
Liquid gasket (LG-7)
35. Install flywheel housing (2) with mounting bolt (1).

36. Tighten mounting bolts (1) in the order shown in the figure.
REMARK
Install the mounting bolts carefully since there are 5 types
of mounting bolts.
3 Mounting bolt M12 (marked with ▲: ℓ = 80, marked
with ■: ℓ = 110):
85±10 Nm {8.7±1.0 kgfm}
3 Mounting bolt M10 (marked with ○: ℓ = 40, marked
with □: ℓ = 80, marked with △: ℓ = 110):
49±5 Nm {5.0±0.5 kgfm}

Measurement of radial runout

37. Set tool L to the end surface of crankshaft.
38. Apply the probe of the dial gauge perpendicularly to the
spigot joint part of the flywheel housing.
39. Set the dial gauge pointer to “0”, rotate the crankshaft by 1
turn, and measure the difference between the lowest and
the highest values of the pointer of dial gauge points.
REMARK
• Radial runoutMax. 0.20 mm
• When the crankshaft is rotated by 1 turn, check that the
dial gauge indicates the same value as it of the starting
rotation.
Measurement of facial runout
40. Similarly to measurement of the radial runout, set the
probe of the dial gauge perpendicularly to the end face of
the flywheel housing.
REMARK
When measuring, move the crankshaft to either end of
front or rear to eliminate error caused by the end play.
41. Set the dial gauge pointer to “0”, rotate the crankshaft by 1
turn, and measure the difference between the lowest and
the highest values of the pointer of dial gauge points.
REMARK
Facial runout: Max. 0.20 mm or less
Rear oil seal

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NOTICE
• Do not remove pilot [1] attached to rear oil seal (1) until
it is inserted into the crankshaft.
• Before installing the rear oil seal, degrease, clean and
dry the crankshaft sealing face and the seal lip face to
prevent oil leakage.

42. Install pilot [1] to crankshaft (2), and insert rear oil seal (1)
into flywheel housing (3).
43. Push in rear oil seal (1) further, and remove pilot [1].

44. Install rear oil seal (1) to the proper depth in flywheel hous-
ing (3) by using tool G.
REMARK
• Insert rear oil seal (1) with careful attention that there
are no bend etc. on it.
• Protrusion X of rear seal (1) from flywheel housing
(3)0.38 mm

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Flywheel
45. Install guide bolt [1], and flywheel (2).
2 Flywheel mounting bolt:
Engine oil (EO15W-40)

4 Flywheel:
35 kg

46. Tighten mounting bolts (1) in the order shown in the figure.
3 Mounting bolt:
137±7 Nm {14.0±0.7 kgfm}
REMARK
Tighten the bolts by using plate [2] for preventing rotation
of the flywheel.

Measurement of radial runout

47. Set tool L to the flywheel housing.
48. Set the probe of the dial gauge perpendicularly to the spi-
got joint part (a) or outside perimeter of the flywheel.
49. Rotate the flywheel by 1 turn, and measure the difference
between the lowest and the highest values the pointer of
dial gauge points.
REMARK
• Radial runoutMax. 0.13 mm
• When the flywheel rotated 1 turn, check that the dial
gauge indicates the same value as it of the starting ro-
tation.
Measurement of facial runout
50. Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end
face (b) near the outside perimeter of the flywheel.

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REMARK
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the end
play.
51. Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values the
pointer of dial gauge points.
REMARK
Facial runout: Max. 0.20 mm or less
Oil pump assembly
52. Fill the space in the oil pump rotor and idler shaft bore with
engine oil, and rotate it by 2 turns.
2 Space in oil pump rotor:
Engine oil (EO15W-40)
2 Idler shaft bore:
Engine oil (EO15W-40)

53. Install oil pump assembly (2) with mounting bolt (1).

54. Tighten the mounting bolts in the order shown in the figure.
3 Mounting bolt 1st time:
8±1 Nm {0.8±0.1 kgfm} (Figure A)
3 Mounting bolt 2nd time:
24±4 Nm {2.4±0.4 kgfm} (Figure B)
55. Lock either gear, and measure backlash (C) between the
pump and idler gear.
Backlash (C): 0.2±0.05 mm

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Front cover
56. Apply liquid gasket to front cover (4) mounting face (part
A).
REMARK
• Apply liquid gasket 1 to 2 mm in diameter.
• Apply liquid gasket so that it does not enter oil circuit
(part B).
2 Front cover:
Liquid gasket (LG-7)

57. Tighten mounting bolts (3) in the order shown in the figure.
3 Mounting bolt:
24±4 Nm {2.4±0.4 kgfm}
58. Install Bkup (cam) speed sensor (2).
3 Mounting bolt:
8±2 Nm {0.8±0.2 kgfm}

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59. Install front oil seal (1) by using tool H.

REMARK
• Before installing the front oil seal, check that the end
corner and the lip sliding surface of the crankshaft are
free from a flaw, burr, fin, rust, and etc.
• When installing the front oil seal, do not apply oil or
grease, etc. to the crankshaft and seal lip. Also, thor-
oughly wipe off oil or grease from the crankshaft.
• The deflection of front oil seal (1) from front cover (4)
must meet the following criteria.
Protrusion (x): Max. 0.38 mm
Facial runout (TIR) (y): Max. 0.25 mm

60. Install dust seal (12a).

REMARK
Check the installing dimension (L).
Installed dimension (L): 12 +0.1/0 mm

Oil pan
61. Install plate (4).
REMARK
Tighten the Torx screw (1 place) at (A) by using Torx
wrench.
3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}
62. Install suction tube (3).
3 Flange mounting bolt:
24±4 Nm {2.4±0.4 kgfm}

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63. Remove the liquid gasket protruding from the place be-
tween the cylinder block and the gear housing and be-
tween the cylinder block and the front cover (4 places on ■
part) by using a scraper.
REMARK
When removing and installing only the oil pan, remove the
old liquid gasket filled in borders (4 places on ■ part) as
well by using a scraper.
64. Apply liquid gasket to the place between the cylinder block
and the gear housing and between the cylinder block and
the front cover (4 places on ■ part).
2 Oil pan ■ part:
Liquid gasket (LG-7)
Bead diameter of liquid gasket: 3 mm
65. Install gasket (5) to the mounting face.
REMARK
• Do not apply oil when installing the gasket.
• Install the gasket with silicon bead (B) facing the oil
pan side.
• Apply liquid gasket to the clinching parts (4 places on
▲ part) on both sides of the gasket.
2 ▲ parts on both sides of gasket:
Liquid gasket (LG-7)
66. Install oil pan (2) and plates (6) (2 pieces) with mounting
bolts (1).

67. Tighten mounting bolts (1) in the order shown in the figure.
REMARK
Be careful that mounting bolts (○ part) (6 pieces) of plate
(6) have different length respectively.
3 Oil pan mounting bolt:
28±2 Nm {2.9±0.2 kgfm}

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Vibration damper
68. Install vibration damper (2) while aligning its dowel hole to
dowel pin (a) of the crankshaft.
69. Tighten mounting bolts (1) according to the following pro-
cedure.
3 Mounting bolt 1st time, tighten diagonally:
55±5 Nm {5.6±0.5 kgfm}
3 Mounting bolt 2nd time, loosen the bolt:
180 °
3 Mounting bolt 3rd time, tighten diagonally:
55±5 Nm {5.6±0.5 kgfm}
3 Mounting bolt 4th time, tighten:
90±5 °(Angle tightening tool J is used.)
REMARK
When not using an angle tightening tool J, put a mark on
the vibration damper and mounting bolt paint, or etc., and
retighten bolt 90±5 °

Engine controller
70. Install engine controller mounting bracket (3) with mount-
ing bolts (4).
REMARK
Stud bolt (A) is tightened to 1 place. Be careful not to
mount it to the wrong position.
3 Mounting bolt:
24±4 Nm {2.4±0.4 kgfm}

71. Install engine controller (2) and ground (1) with mounting
bolts (5).
3 Mounting bolt:
24±4 Nm {2.4±0.4 kgfm}

Cylinder head assembly

72. Assemble the cylinder head assembly according to the following procedure.

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1) Install valve seal (7).

2) Apply engine oil to the valve stem and the inside of
the valve guide, and install valve (6).
2 Valve stem, valve guide:
Engine oil (EO15W-40)

3) Raise the cylinder head, and install valve spring (3)

and upper seat (5).

4) Compress valve spring (3) and remove valve collet (4)

by using tool C.
REMARK
Check that the valve collet is fitted securely to the
groove of the valve stem by hitting the valve stem part
lightly with a plastic hammer.

73. Before tightening cylinder head mounting bolt, measure

the stem lengths (a) of all mounting bolts, and check that
the lengths are within the allowable limit.
Allowable limit of bolt length: Less than 132.1 mm
NOTICE
If a bolt is longer than the allowable limit, do not reuse
it but replace it.

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74. Check that the cylinder head mounting face and inside of
the cylinders are free from dirt and foreign matter, and set
cylinder head gasket (8).
REMARK
Check that the holes of the gasket is fitted to those of the
cylinder head.
75. Install cylinder head assembly (2) to the cylinder block.

4 Cylinder head assembly:

75 kg
76. Tighten the mounting bolt (1) at least 2 to 3 turns first by
fingers.
REMARK
Apply engine oil to the threaded part of the mounting bolt
and to the bolt head seat surface.
2 Threaded part and head seat surface of mounting
bolt:
Engine oil (EO15W-40)

77. Tighten mounting bolts (1) in the order according to the fol-
lowing procedure.
3 Mounting bolt 1st time:
90±3 Nm {9.2±0.3 kgfm}
3 Mounting bolt 2nd time:
90±3 Nm {9.2±0.3 kgfm}
3 Mounting bolt 3rd time:
90±5 ° (Perform angle tightening by using tool J.)

REMARK
When not using an angle tightening tool J, put a mark on
cylinder head and bolt paint, or etc., and retighten bolt
90±5 °.

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Injector assembly
78. Attach the gasket (6) and O-ring (7) to the injector (2).
NOTICE
When replacing the injector with a new one, replace
the inlet connector with a new one as well.
REMARK
Check that the injector sleeve is free from scratches and
dirt.
79. Apply engine oil to O-ring (7) of injector (2) and the cylin-
der head side.
2 O-ring and head side of injector:
Engine oil (EO15W-40)
80. Direct fuel inlet hole of injector (2) toward intake manifold side, and install it to cylinder head.
81. Install holder (4) and tighten mounting bolts (3) by 3 to 4 threads.
82. Check inlet connector on the following points. If any abnor-
mality is found, replace it.
• When burrs or wear are found on front-end part (a) or
rear-end part (b) of inlet connector.
• When foreign matters are found in the edge filter at
rear-end (c) of the inlet connector.
• When cracks or deterioration are found on the O-ring
of inlet connector upper part (d)
• When wear or uneven contact are found on seat sur-
face (e) at tip-end of the inlet connector.
REMARK
If high-pressure fuel leaks through the inlet connector, seat
surface has fine streaks or cracks due to erosion.

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83. Apply engine oil to the O-ring and the head side of inlet
connector (1).
2 O-ring and head side of inlet connector:
Engine oil (EO15W-40)
84. Insert inlet connector (1) to mounting hole of injector (2),
and tighten retaining nut (5) lightly.
NOTICE
• Retightening is to be performed after tightening.
Retighten each of them to the specified torque. If
tightening torque is insufficient or too much, it will
cause fuel leakage inside the engine.
• Install inlet connector so that its positioning ball
fits in guide groove part on the head side.
3 Retaining nut (5) (tightening lightly):
15±5 Nm {1.53±0.51 kgfm}
85. Tighten mounting bolts (3) alternately.
3 Holder mounting bolt:
8±0.8 Nm {0.82±0.08 kgfm}
86. Tighten retaining nut (5) of inlet connector (1).
3 Retaining nut (5) (tightening to the specified tor-
que):
50±5 Nm {5.1±0.5 kgfm}
Push rod
87. Pour engine oil to push rod socket part.
2 Push rod socket part:
Engine oil (EO15W-40)
88. Install push rod (1).
REMARK
Check that the push rod is fitted to the tappet.

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Rocker arm assembly, crosshead

89. Install crosshead (3).
90. Install rocker arm assembly (2), and tighten it with mount-
ing bolts (1).
NOTICE
• Check that the spherical part of the adjustment
screw fits properly in the socket of the push rod,
and tighten the mounting bolt.
• Shape of hole in parts (a) and (b) of crosshead is
not identical. So when reusing them for the same
intake valve or exhaust valve, be sure to install
them in the same direction.
3 Mounting bolt:
36±5 Nm {3.7±0.5 kgfm}

Adjusting valve clearance

91. Remove plug (1) under the starting motor and install tool V.

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92. Rotate the crankshaft forward by using tool V, and align

the yellow paint part (line) of vibration damper (6) with the
position of engine oil pan mounting bolt (7) as a straight
line.
REMARK
Yellow paint is painted on the tip of bolt (7).
NOTICE
When the crankshaft is set as above, it is not set to the
compression top dead center (TDC) of No. 1 or No. 6
cylinder. (76 to 88 ° before top dead center)

93. Adjust the valve clearance according to the following procedure.

REMARK
• If you can move the rocker arm of air intake valves (IN) with the hand by the valve clearance amount,
check the valves marked with ○ in the valve layout drawing.
• If you can move the rocker arm of air exhaust valve (EX side) with the hand by the valve clearance
amount, check the valves marked with ● in the valve layout drawing.
Valve layout drawing

1) Loosen lock nut (4) with adjustment screw (5) fixed.

2) Insert tool K (feeler gauge) into the clearance between
rocker arm (2) and crosshead (3).
3) Adjust the valve clearance with adjustment screw (5).
REMARK
• Turn adjustment screw (5) with feeler gauge inser-
ted, and adjust it with adjustment screw (5) until
the feeler gauge can move lightly.
• Adjust the valve clearance within the target value
range.
Intake valve: 0.25±0.05 mm

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Exhaust valve: 0.51±0.05 mm

4) With adjustment screw (5) fixed, tighten lock nut (4).
3 Locknut:
24±4 Nm {2.45±0.41 kgfm}
REMARK
Tighten lock nut (4), and then check the valve clearance again.
94. In the same way as step 2), rotate the crankshaft forward by using tool V, and align the yellow paint part
(line) of vibration damper (6) with the position of engine oil pan mounting bolt (7) as a straight line.
95. Adjust the clearances of the other valves according to steps 3).
REMARK
When ○ mark in the valve layout drawing is adjusted according to the above step, adjust the remaining
valve marked with ●. When ● mark has already been adjusted, adjust ○ mark.
96. After adjustment of valve clearance is performed, remove
tool V, and install plug (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

Rocker housing and head cover

97. Install rocker housing assembly (6) with mounting bolt (5).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
98. Install nut (4) of harness.
Installed position of harness
Color of wiring harness Cylinder No.
White 1, 3, 5
Black 2, 4, 6

3 Mounting nut:
1.5±0.25 Nm {0.15±0.03 kgfm}
REMARK
• Check that the wiring harness does not interfere with
the rocker arm.
• If the injector wiring harness connector (7) is removed,
apply liquid gasket to O-ring part (8) and flange surface
(9) of connector when installing.
• Apply liquid gasket of diameter 3 mm to O-ring part un-
til O-ring groove is completely hidden.
• If O-ring is damaged, replace an entire wiring harness
assembly.
2 O-ring part (8) and flange surface (9) of connector:
Liquid gasket (LG-7)

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3 Connector flange mounting bolt (10):

10±2 Nm {1±0.2 kgfm}
99. Install gasket, and install head cover (3) with mounting nut
(2).
3 Mounting nut:
24±4 Nm {2.45±0.41 kgfm}
100. Install blowby duct (1).

3 Mounting bolt:
7±2 Nm {0.7±0.2 kgfm}

Boost pump
101. Install gasket, and install boost pump (2) with mounting nut
(1).
3 Mounting bolt:
77±12 Nm {7.9±1.2 kgfm}

Supply pump
102. Install gear (4) to the supply pump according to the follow-
ing procedure.
REMARK
Before installation, clean dusts and foreign material on the
mating surfaces of shaft (6) and gear (4), and keep the
mating surfaces dry.
1) Install gear (4) to shaft (6).
2) Install lock washer (5) and nut (3), and finger-tighten it
lightly.

3) Fix the gear by using tool N and 1/2 spinner handle

[1], and tighten nut (3).
3 Supply pump gear mounting nut:
105±5 Nm {10.7±0.51 kgfm}

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 50 DISASSEMBLY AND ASSEM-
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103. Install supply pump (2) with mounting nuts (1) (3 pieces).

REMARK
• If grease is applied too much to O-ring (7), it will ooze
out. Do not apply grease too much. (Apply it only to O-
ring groove area of A part.)
• When replacing supply pump stud bolt (8), apply Loc-
tite to stud bolt (8).
• Since it is difficult to install nuts on the cylinder block
side when installing supply pump assembly mounting
nuts (1), be sure to use a new socket for the installa-
tion.
3 Stud bolt:
12±2 Nm {1.2±0.2 kgfm}
3 Supply pump assembly mounting nut:
24±4 Nm {2.45±0.41 kgfm}

Intake manifold cover

104. Install gasket (1).

REMARK
Direct the part number tag toward rear side when installing
the gasket.

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105. Install intake manifold cover (2).

3 Intake manifold cover mounting bolt:

24±4 Nm {2.45±0.41 kgfm}

Common rail pressure sensor and pressure limiter

106. Before removing common rail pressure sensor (2), clean
the area around it, and remove dirt, etc. thoroughly.
107. Remove common rail pressure sensor (2).

NOTICE
• Do not remove common rail pressure sensor (2)
from common rail (1) for a purpose other than re-
placement.
• Be sure to replace common rail pressure sensor (2)
removed from common rail (1) with a new sensor.
108. Check the common rail pressure sensor connector for
crack, breakage, damage of the seal, foreign matter on the
pin and corrosion, bend and breakage of the pin.
109. Install a new common rail pressure sensor.

2 Threaded part of common rail pressure sensor:

Gear oil (#90)
3 Common rail pressure sensor:
70±5 Nm {7.1±0.5 kgfm}
110. Before removing pressure limiter (3), thoroughly remove dirt and dusts on and around it.
111. Remove pressure limiter (3).
NOTICE
Do not reuse the pressure limiter (3) if leakage exceeds the specified value.
112. Check that there is no damage on high-pressure sealing
surfaces (A) on pressure limiter (3) and common rail.
113. Install pressure limiter (3).

REMARK
Excessive tightening can cause leakage. Take care not to
tighten excessively.
2 Threaded portion of pressure limiter:
Gear oil (#90)
3 Pressure limiter:
100±4 Nm {10.2±0.4 kgfm}

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High-pressure pipe and common rail

k Do not bend the fuel high-pressure pipe to correct be-
fore installing.
k Be sure to use the Komatsu genuine fuel high-pressure
pipe clamps and observe the specified tightening tor-
que.
k Install each fuel high-pressure pipe and wiring harness
at least 10 mm apart from each other.
REMARK
If slits (b) or dents such as spots (c) are visually recogniz-
able in taper seal part (a) (2 mm from the tip) of its connec-
tion, or if level difference in part (d) (within 2 mm from tap-
er seal end face) due to fatigue is large enough to catch
your finger nails because such fuel high-pressure pipe can
induce fuel leakage, replace the fuel high-pressure pipe.
114. Lightly tighten common rail (10) and fuel high-pressure
pipes (1) to (6).
REMARK
Apply liquid gasket to threaded part of mounting bolts (2
pieces) on the engine side when installing the common
rail.
2 Threaded part of common rail mounting bolt::
Liquid gasket (LG-7)
3 Mounting bolt and sleeve nut (lightly tightening):
0.2 to 0.8 Nm {0.02 to 0.08 kgfm}
115. Tighten fuel high-pressure pipes (1) to (6) according to the following procedure.
1) Fuel high-pressure pipe ((1): Connector side) → ((2): Connector side) → ((3): Connector side) → ((1):
Common rail side) → ((2): Common rail side) → ((3): Common rail side)
2) Fuel high-pressure pipe ((4): Connector side) → ((5): Connector side) → ((6): Connector side) → ((4):
Common rail side) → ((5): Common rail side) → ((6): Common rail side)
3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
116. Lightly tighten fuel high-pressure pipe (7) and tube clamp (9).
117. Tighten fuel high-pressure pipe (7) in the order of the supply pump side to the common rail side.
3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
118. Tighten common rail (10).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
119. Fasten tube clamp (9) to the specified torque.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
120. Install fuel spray prevention cap (8).

k Direct the slit of fuel spray prevention cap outward or downward when installing it.

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Fan hub
121. Install fan hub (2) with mounting bolts (1).

REMARK
Tighten a place after harness bracket is installed.
3 Mounting bolt:
32±5 Nm {3.3±0.5 kgfm}

Water pump
122. Install seal ring, and install water pump (1) according to
the following procedure.
3 Mounting bolt (2) 1st time:
8±1 Nm {0.8±0.1 kgfm}
3 Mounting bolt (2) 2nd time:
30±4 Nm {3.1±0.4 kgfm}

Thermostat
123. Install thermostat (3).

124. Install coolant outlet connector (2) with mounting bolts (1).

3 Mounting bolt:
10±2 Nm {1.0±0.2 kgfm}

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EGR valve, tubes

125. Install gasket (1).

REMARK
Direct the part number tag toward rear side when installing
the gasket.

126. Install intake manifold connector (2) with mounting bolts

(3).
3 Intake manifold connector mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

127. Install gasket, and install EGR valve (4) with mounting nut
(5).
3 Intake manifold connector mounting bolt:
43±6 Nm {4.4±0.6 kgfm}

128. If there is any items removed from the cylinder block side,
tighten them with the following torques.
• If oil drain connector (13) has been removed and ring

3 Mounting bolt:
seal has been replaced.

77±12 Nm {7.9±1.2 kgfm}

3 Mounting bolt:
• If tube bracket (14) is removed.

24±4 Nm {2.45±0.41 kgfm}

129. Install tube (6).

3 Sleeve nut:
25±1.5 Nm {2.55±0.15 kgfm}
130. Fasten tube clamp (7).

3 Stud bolt:
77±12 Nm {7.9±1.2 kgfm}
131. Fasten tube clamp (8).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

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132. Install bracket (9) to EGR valve (4) with mounting bolts (10) (4 pieces).

3 Upper (EGR valve side) mounting bolt:

43±6 Nm {4.4±0.6 kgfm}
3 Middle and lower (engine side) mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
133. Install tube (11).

3 Sleeve nut:
25±1.5 Nm {2.55±0.15 kgfm}
134. Fasten tube clamp (12).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
135. Install spill tube (15).

3 Joint bolt:
24±4 Nm {2.45±0.41 kgfm}
136. Fasten tube clamp (16).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

Wiring harness assembly

137. Install the connector, clamp, and band, and install wiring harness assembly (1).

REMARK
Install the sensor, lock it with stopper to prevent falling off,
and check that the connector is securely connected.
(2): Coolant temperature sensor connector
(3): Wiring harness bracket
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
3 Fan hub mounting bolt:
32±5 Nm {3.3±0.5 kgfm}
(4): Wiring harness clamp
3 Mounting bolt:
10±2 Nm {1.0±0.2 kgfm}
(5): Engine oil pressure switch connector
(6): Bkup (camshaft) speed sensor connector
(7): Ne (crank) speed sensor connector
(8) and (18): Wiring harness clamp
3 Mounting bolt (8):
24±4 Nm {2.45±0.41 kgfm}
3 Mounting bolt (18):
43±6 Nm {4.4±0.6 kgfm}

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(9): Ambient pressure sensor connector

(10): Wiring harness connector

(11): Band
(12) and (13): Wiring harness bracket
(14) and (15): Wiring harness connector
(16): Common rail pressure sensor connector
(12): Charge (boost) pressure and temperature sensor
connector

(19): Wiring harness connector

(20): Band
(21): Wiring harness clamp
(22): Wiring harness bracket
Wiring harness clamp (21) is tightened together with wiring
harness bracket (22).
3 Mounting nut:
10±2 Nm {1.0±0.2 kgfm}
(23): Wiring harness connector (ECM)
Lock wiring harness connector (ECM) (23) with hexagonal socket head bolt (24) (4 mm).
3 Hexagonal socket head bolt (24):
3±1 Nm {0.31±0.1 kgfm}
(25): Bracket
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
(26): Wiring harness connector box (INTER CONNECT)

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Tube, intake air heater, and dipstick pipe

138. Install gasket, and install tube (1) and intake air heater (2).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
139. Install dipstick pipe (3) together with bracket (4) and (5).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

Alternator bracket
140. Install sling bracket (2).

3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}
141. Install alternator bracket (1).

REMARK
After installing the tube, install the alternator.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
Fan pulley
142. Install fan pulley (1).

3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}

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Removal from engine repair stand

143. Set tool P to engine assembly (1), and disconnect it from
tool A.

4 Engine assembly:
Approximately 520 kg (The weight varies depend-
ing on the machine model.)
144. Remove tool B from engine assembly (1).

Oil cooler
145. Install cooler gasket (8), oil cooler (7), cover gasket (6),
and cover (5).

146. Tighten the mounting bolts in the order shown in the figure.

REMARK
Install the mounting bolts carefully since there are 3 types
of mounting bolts.
(Not marked: 7 pieces, marked with ▲: 4 pieces, marked
with ■: 4 pieces)
3 Mounting bolt 1st time:
15±4 Nm {1.5±0.4 kgfm}
3 Mounting bolt 2nd time:
27±4 Nm {2.8±0.4 kgfm}
Coolant inlet connector and auto-tensioner.
147. Install seal ring, and coolant inlet connector (1).

3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}
148. Install auto-tensioner (2).

REMARK
Check that the belt mounting parts of the auto-tensioner
pulley and alternator pulley are parallel by visual check or
using a ruler.
3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}

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EGR cooler, and heat insulation plate.

149. Install heat insulation plate (1).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
150. Install bracket (2).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
151. Lightly tighten EGR cooler (3) to bracket (2).

REMARK
Tighten the exhaust manifold lightly, and tighten it to the
specified torque.
152. Install tube (4) to EGR cooler (3).

3 Mounting bolt:
9.5±2 Nm {0.97±0.2 kgfm}
3 Hose clamp :
5±1 Nm {0.5±0.1 kgfm}
Exhaust manifold assembly
153. Install a gasket, and lightly tighten exhaust manifold (1) to
cylinder head and EGR cooler (3) with mounting bolts (4)
and (5).
REMARK
Adjust the cylinder head, exhaust manifold, and EGR cool-
er by loosening and tightening the mounting bolts so that
there is no phase shift or play in them.

154. Tighten exhaust manifold mounting bolts (4) to the speci-

fied torque in the order shown in the figure.
3 Mounting bolt 1st time:
53±5 Nm {5.4±0.5 kgfm} (Tighten the bolts in the
order of [1] to [12] as shown in the drawing.)
3 Mounting bolt 2nd time:
53±5 Nm {5.4±0.5 kgfm} (Retighten only the bolts
[1] to [4] as shown in the drawing.)
155. Tighten mounting bolt (5) to the specified torque.

3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}
156. Tighten EGR cooler (3) to bracket to the specified torque.

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

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EGR cooler piping

157. Install tube (1).

3 Joint bolt:
12±2 Nm {1.2±0.2 kgfm}
3 Sleeve nut:
15±1 Nm {1.5±0.1 kgfm}

158. Install tube (2).

3 Hose clamp (3):

5±1 Nm {0.5±0.1 kgfm}
3 Tube mounting bolt (4):
9.5±2 Nm {0.96±0.2 kgfm}
159. Install tube clamp (5).

3 Mounting nut:
9.5±2 Nm {0.96±0.2 kgfm}

160. Install gasket and install tube (6) to EGR cooler side.

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
161. Install tube clamp (7) of tube (6) to bracket.

3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}
162. Connect tube (6) and EGR piping flange (8) with hose (9),
and fasten it with hose clamp (10).
3 Hose clamp:
10.5±0.5 Nm {1.1±0.05 kgfm}
163. Install gasket, and install EGR piping flange (8).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}

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VGT
164. Install gasket, and install VGT (1).

4 VGT:
25 kg
3 Mounting nut:
43±6 Nm {4.4±0.6 kgfm}
REMARK
Install the mounting nuts diagonally.
165. Install a gasket, and install VGT return tube (2).

3 Hose clamp:
5±1 Nm {0.5±0.1 kgfm}
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
166. Install tube (3).
VGT side is tightened together with it.
3 Joint bolt:
24±4 Nm {2.45±0.41 kgfm}
167. Install tube (4).
VGT side is tightened together with it.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
168. Install tube (5).
• VGT side is tightened together with it.
• Install eye joint (6) which is tightened together with
tube (5) so that its mounting angle becomes 15±5 °.
3 Joint bolt:
24±4 Nm {2.45±0.41 kgfm}

169. Install hoses (7) and (8) to EGR valve.

Hose (7): VGT control pressure circuit
3 Sleeve nut:
25±1.5 Nm {2.6±0.15 kgfm}
Hose (8): VGT drive hydraulic circuit
3 Sleeve nut:
15±1 Nm {1.5±0.1 kgfm}
170. Install connectors (9) and (10).
Connector (9): VGT position sensor (SVGT)
Connector (10): VGT speed sensor (VGT_REV)

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Alternator
171. Install alternator (3) with mounting bolts (1) and (2).

3 Mounting bolt (1):

43±6 Nm {4.4±0.6 kgfm}
3 Mounting bolt (2):
24±4 Nm {2.45±0.41 kgfm}

Fan
172. Insert a wrench in A part (width across flats12.7 mm) of the
auto-tensioner (2), and install the alternator belt (1) as ro-
tating it in the opposite direction (R) to the winding-up di-
rection.
k Be sure that the wrench is installed securely to part
(A) of auto-tensioner (2), and turn it. (Since the
spring force of auto-tensioner (2) is strong, it is so
dangerous to turn the wrench not being attached
securely that it may come off.)
k After installing alternator belt (1), slowly and care-
fully restore auto-tensioner (2).
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
173. Install fan (3).

Starting motor assembly

174. Install gasket, and install starting motor assembly (2) with
mounting bolt (1).
3 Mounting bolt:
43±6 Nm {4.4±0.6 kgfm}

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Oil filter
175. Install oil filter hose (1) and (2).

3 Sleeve nut:
177 to 245 Nm {17.7 to 24.5 kgfm}

Fuel filter assembly

176. Install fuel filter hoses (2) and (3) to supply pump (1).

NOTICE
Do not reuse the hose as a rule since internal parts of
the hose fittings may be damaged when disconnecting
the fuel filter hose. Replace the hose with a new one
when reassembling.
REMARK
• Insert the fuel filter hose straight while pushing lock (L)
without prying or shaking it.
• If it is difficult to insert it, do not push it in forcibly but
pull it out once, and check concave and convex parts
for damage and dirt.
Dipstick pipe and tube
177. Apply adhesive to the guide when removing and installing
dipstick pipe (1) and tube (2), and drive them in.
2 Mounting part of dipstick pipe and tube:
Adhesive (LT-4)
178. When removing and installing hose (3) and check valve (4)
of tube (2), or replacing them, set the gray part of check
valve (4) so that it comes to the left.
3 Hose clamp:
3.3±0.49 Nm {0.34±0.05 kgfm}

Sensor tightening torque

179. When removing and installing the sensor, or replacing it, tighten it to the following torque.

Sensor name Tightening torque

Coolant temperature sensor 20±3 Nm {2.04±0.31 kgfm}
Engine oil pressure switch 8±2 Nm {0.82±0.2 kgfm}
Ne (crankshaft) speed sensor 8±2 Nm {0.82±0.2 kgfm}
Ambient pressure sensor 8±2 Nm {0.82±0.2 kgfm}
Charge (Boost) pressure and temperature sensor 8±2 Nm {0.82±0.2 kgfm}
Check for fuel leakage

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• When fuel supply pump (1), common rail (2), and fuel
high-pressure pipe were removed or installed, check
for fuel leakage according to the following procedure
after assembling the engine.
• Clean the engine and the parts around it, and degrease
them in advance so that you can check it easily for
fuel leakage.
180. Spray color checker (developer) to the joints of the supply
pump, common rail, and fuel high-pressure pipe.
181. Start the engine, keep its speed at 1000 rpm or below, and
stop it when the speed is stabilized.
182. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 179 again.
183. Start the engine, and keep it running at low idle.
184. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 179 again.
185. Start the engine, and keep it running at high idle.
186. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 179 again.
187. Start the engine and keep it running at high idle, and apply a load to the engine.

REMARK
When checking the engine for leakage as it is installed on the machine, stall the torque converter or relieve
the main pump.
188. Check the fuel piping and component for fuel leakage.

REMARK
• Check fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 179. again.
• If no fuel leakage is detected, check is completed.

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REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3)

METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3)
Fuel filter, fuel filter hose, wiring harness connector
1. Disconnect the fuel filter hoses (9) and (10) from the sup-
ply pump assembly (2).
REMARK
Pull out the hose in the direction (a) while pressing the
locks (L) on both sides.
2. Disconnect the connector IMV (11).
3. Remove the bolt (12), and remove the fuel filter (14) to-
gether with the bracket (13).

Fuel splash prevention plate

4. Remove the bolts (1) (2 pieces), and remove the fuel
splash prevention plate (2).

5. Remove the bolt (3) (1 piece) and nuts (4) (3 pieces), and
remove the bracket assembly (5).

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Fuel high-pressure pipe

6. Remove the fuel spray prevention cap (15).
7. Remove the clamp (16), and remove the fuel high-pres-
sure pipe (18).

Spill tube
8. Remove the bolts (21) (3 pieces), and remove the bracket
(22).
9. Remove the joint bolts (19) (3 pieces), and remove the
spill tube (20).

Supply pump assembly

10. Remove the nuts (1) (3 pieces), and remove the supply
pump assembly (2).
REMARK
The supply pump assembly (2) comes off together with the
gear. The gear is not machined on its teeth (no missing
tooth) to align the mark for 1.4 TOP adjustment.

Gear
11. Remove the gear from the supply pump assembly according to the following procedure.

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50 DISASSEMBLY AND ASSEM-
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1) Fix the gear by using the support (N) and 1/2-inch

spinner handle [1], and loosen the nut (3).
REMARK
Do not remove the nut (3) from the shaft.

2) Install the bearing puller [2] between the flange and

gear (4).

3) Install the push puller [3] on the bearing puller [2] and
shaft.
4) Screw in the center bolt [4] until the gear is disengag-
ed from the shaft.
5) Remove the push puller [3] and bearing puller [2].

6) Remove the nut (3), lock washer (5) and gear (4) from
the shaft (6).

107E-3 SERIES 50-163

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3) BLY

METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)

Supply pump gear
1. Clean dusts and foreign materials on the mating surfaces
of the shaft (6) and gear (4), and keep the mating surfaces
dry.
2. Install the gear (4) to the shaft (6).
3. Finger-tighten the lock washer (5) and nut (3) until they are
seated.

4. Fix the gear by using the support (N) and 1/2-inch spinner
handle [1], and tighten the nut (3).
3 Nut (3):
105±5 Nm {10.7±0.51 kgfm}

Supply pump assembly

5. Install the supply pump assembly (2) with the nuts (1) (3
pieces).
REMARK
• If grease is applied too much to O-ring (7), it will ooze
out. Do not apply grease too much. (Apply grease with-
in O-ring groove range of the part A.)
• When replacing the stud bolt (8), apply Loctite to the
thread portion of the stud bolt (8) on the cylinder block

2 Stud bolt (8):

side.

Liquid adhesive (LT-2)

3 Stud bolt (8):
12±2 Nm {1.2±0.2 kgfm}
• When installing the nut (1), the nut (1) may fall off or
slip since it is difficult to install the nut (1) on the cylin-

3 Nut (1):
der block side.

24±4 Nm {2.45±0.41 kgfm}

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50 DISASSEMBLY AND ASSEM-
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Spill tube
6. Install the spill tube (20) with the joint bolts (19) (3 pieces).
3 Joint bolt (19):
24±4 Nm {2.45±0.41 kgfm}

Fuel high-pressure pipe

7. Finger-tighten the sleeve nuts of the fuel high-pressure pipe (18). (both sides)
8. Tighten the sleeve nut of the fuel high-pressure pipe (18) on the supply pump side first, and then tighten the
sleeve nut on the common rail side.
3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
9. Install the clamps (16) (2 pieces).
3 Clamp (16):
24±4 Nm {2.45±0.41 kgfm}
10. Install the fuel spray prevention cap (15).
REMARK
• Direct the slit of the fuel splash prevention cap outward or downward.
• The fuel splash prevention caps are installed so that fuel will not spout over the hot part of the engine
and catch fire when it leaks by any chance.
Fuel splash prevention plate
11. Install the bracket assembly (5) with the bolt (3) (1 piece)
and nuts (4) (3 pieces).
3 Bolt (3):
59 to 74 Nm {6 to 7.5 kgfm}
3 Nut (4):
11.8 to 14.8 Nm {1.2 to 1.5 kgfm}

12. Install the fuel splash prevention plate (2) with the bolts (1)
(2 pieces).
3 Bolt (1):
27 to 34 Nm {2.8 to 3.5 kgfm}

107E-3 SERIES 50-165

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3) BLY

Fuel filter, fuel filter hose, wiring harness connector

13. Install the fuel filter (14) together with the bracket (13) with
the bolt (12).
14. Install the connector IMV (11).
15. Install the fuel filter hoses (9) and (10).

NOTICE
• Connect the hose in the direction (b) while press-
ing the locks (L) on both sides.
• Since the internal parts of the fitting of the discon-
nected hoses or tubes may be damaged, do not re-
use them. For installation, replace them with new
ones.
• Be sure that dirt or dust is not sticking to the hose
connecting portions in advance.
• Push the connector and insert it straight in the di-
rection (b) without prying or shaking it. If it is diffi-
cult to insert them, do not push them in forcibly but
pull them out once, and check concave and convex
parts for abnormality or dirt.

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50 DISASSEMBLY AND ASSEM-
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REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3)

METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (6D107E-3)
Fuel filter hose and harness connector
1. Disconnect fuel filter hoses (9) and (10) from supply pump
(2).
REMARK
Pull out hose to the direction (a) while pressing lock (L) on
both sides.
2. Disconnect harness connector (11).

Fuel high-pressure pipe

3. Remove fuel spray prevention cap (12).
4. Disconnect tube clamp (13).
5. Remove fuel high-pressure pipe (16).

Spill tube
6. Disconnect tube clamp (14).
7. Remove spill tube (15).

107E-3 SERIES 50-167

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3) BLY

Supply pump assembly

8. Remove nuts (1) (3 pieces), and remove supply pump (2).
REMARK
• Pull supply pump (2) crosswise straight when removing
it. Otherwise the pump assembly may interfere with the
top of boost pump (17).
• Supply pump (2) comes off together with gear. The
gear is not worked on its teeth (missing tooth) to align
the mark for 1, 6 TOP.

Gear
9. When removing the gear from the supply pump (2), follow the procedure described below.
1) Fix the gear by using tool N and 1/2 inch spinner han-
dle [1], and loosen nut (3).
REMARK
Do not remove nut (3) from the shaft.

2) Install puller [2] between the flange and gear (4).

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50 DISASSEMBLY AND ASSEM-
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3) Install puller [3] on puller [2] and the shaft.

4) Screw in center bolt [4] until the gear is disengaged
from the shaft.
5) Remove pullers [2] and [3].

6) Remove nut (3), lock washer (5) and gear (4) from
shaft (6).

METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (6D107E-3)

Supply pump gear
1. Before installation, clean dusts and foreign material on the
mating surfaces of shaft (6) and gear (4), and keep the
mating surfaces dry.
2. Install gear (4) to shaft (6).
3. Install lock washer (5) and nut (3), and finger-tighten it
lightly.

4. Fix the gear by using tool N and 1/2 spinner handle [1],
and tighten nut (3).
3 Supply pump gear mounting nut :
105±5 Nm {10.7±0.51 kgfm}

107E-3 SERIES 50-169

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3) BLY

Supply pump
5. Install supply pump (2) with mounting nuts (1) (3 pieces).
REMARK
• If grease is applied too much to O-ring (7), it will ooze
out. Do not apply grease too much. (Apply it only to O-
ring groove area of A part.)
• When replacing supply pump stud bolt (8), apply Loc-
tite to stud bolt (8).
• Use a new socket for installing supply pump mounting
nut (1) since it is difficult to install the nuts on cylinder
block side.
• If an old socket is used, the nut may fall off or may not
be engaged due to excess clearance between the
socket and mounting nut (33).
3 Stud bolt:
12±2 Nm {1.2±0.2 kgfm}
3 Supply pump mounting nut:
24±4 Nm {2.45±0.41 kgfm}

Spill tube
6. Install tube clamp (14).
3 Tube clamp mounting bolt (14):
24±4 Nm {2.45±0.41 kgfm}
7. Install spill tube (15).
3 Joint bolt of spill tube (15):
24±4 Nm {2.45±0.41 kgfm}

Fuel high-pressure pipe

8. Finger-tighten the sleeve nuts of fuel high-pressure pipe (16). (both sides)
9. Tighten the sleeve nut of fuel high-pressure pipe (16) at supply pump side first, and then tighten the sleeve
nut at common rail side.
3 Sleeve nut:
35±3.5 Nm {3.57±0.36 kgfm}
10. Install tube clamps (13) (2 pieces).
3 Clamp mounting bolt:
24±4 Nm {2.45±0.41 kgfm}
11. Install fuel spray prevention cap (12).
REMARK
• Direct slits of fuel spray prevention caps outward and downward.
• The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the engine
and catch fire when it leaks by any chance.

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50 DISASSEMBLY AND ASSEM-
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Connector
12. Install connector harness(11).
13. Install fuel filter hoses (9) and (10).
REMARK
• Connect hose to the direction (a) while pressing lock
(L) on both sides.
• Since the internal parts of the fitting of the disconnec-
ted hoses or tubes may be damaged, do not reuse
them. For installation, replace them with new ones.
• Be sure that mud or dirt is not sticking to the hose joint
part in advance.
• Push the connector and insert it straight (in the direc-
tion (b)) without prying or shaking it. If it is difficult to in-
sert it, do not push it in forcibly but pull it out once, and
check concave and convex parts for damage and dirt.

107E-3 SERIES 50-171

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3) BLY

REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3)

METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3)
Alternator belt
1. Install the ratchet (S) to the part A of the auto-tensioner (2)
(width across flats: 12.7 mm).
2. Rotate the ratchet (S) in the direction (R) to loosen the ten-
sion of the alternator belt (1), and remove the alternator
belt (1).
k Firmly set the ratchet (S) to the part A of the auto-
tensioner (1), and then rotate it. (The spring of the
auto-tensioner (2) is strong. If the ratchet (S) is
loosely installed and rotated, it can accidentally
come off and this is extremely dangerous.)
k After removing the alternator belt (1), return the au-
to-tensioner (1) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Crankshaft pulley
3. To prevent the crankshaft pulley (4) from rotating, fix the
flywheel (2) by using the object (a) that is not deformed by
the tightening torque.

4. Loosen the bolts (5) (6 pieces), and remove (a).

5. Remove the bolts (5) (6 pieces), and remove the plate (5a)
and crankshaft pulley (4).

Engine front oil seal

6. Remove the engine front oil seal (6) according to the following procedure.

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50 DISASSEMBLY AND ASSEM-
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1) Remove the dust seal (12a).

2) Install the seal puller (H) to the crankshaft.

3) Screw in the tapping screw [1] of the seal puller (H) to
the seal carrier part of the engine front oil seal (6).
4) Turn the handle in the direction of the arrow, and re-
move the engine front oil seal (6).
REMARK
Be careful not to damage the crankshaft while remov-
ing it.

107E-3 SERIES 50-173

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3) BLY

METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3)

Engine front oil seal
1. By using the seal puller (H), install the engine front oil seal
(6).
REMARK
• Before installing the engine front oil seal (6), check that
the end corner and the lip sliding surface of the crank-
shaft are free from a flaw, burr, fin, and rust.
• When installing the engine front oil seal (6), do not ap-
ply oil or grease, etc. to the crankshaft and seal lip.
Wipe off oil thoroughly from the crankshaft.
• Measure the protrusion and facial runout of the engine
front oil seal (6) from the cover (7).
Protrusion (x): 0.38 mm or less
Facial runout (y): 0.25 mm or less

2. Install the dust seal (12a).

REMARK
Check the installing dimension (L).
Installing dimension (L): 12+0.1/0 mm

Crankshaft pulley
3. To prevent the crankshaft pulley (4) from rotating, fix the
flywheel (2) by using the object (a) that is not deformed by
the tightening torque.

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50 DISASSEMBLY AND ASSEM-
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4. Install the crankshaft pulley (4) while aligning its dowel

hole with the dowel pin (b) of the crankshaft.

5. Install the plate (5a) and crankshaft pulley (4) with the
bolts (5) (6 pieces).
Tightening order of bolt (5)
3 1st time:
55±5 Nm {5.61±0.51 kgfm} (Tighten diagonally)
3 2nd time:
180 ° (Loosen)
3 3rd time:
55±5 Nm {5.61±0.51 kgfm} (Tighten diagonally)
3 4th time:
90±5 ° (Retighten diagonally)
REMARK
Perform angle tightening by using the wrench (J).

When the wrench (J) is not used

Put marks on the crankshaft pulley and bolt with a felt-tip
pen and retighten the bolt to 90±5 °.
6. Check that the bolts (5) (6 pieces) are tightened, and re-
move (a).

107E-3 SERIES 50-175

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3) BLY

Alternator belt
7. Install the ratchet (S) to the part A of the auto-tensioner (2)
(width across flats: 12.7 mm).
8. Rotate the ratchet (S) in the direction (R) to loosen the ten-
sion of the alternator belt (1), and install the alternator belt
(1).
k Firmly set the ratchet (S) to the part A of the auto-
tensioner (2), and then rotate it. (The spring of the
auto-tensioner (2) is strong. If the ratchet (S) is
loosely installed and rotated, it can accidentally
come off and this is extremely dangerous.)
k After installing the alternator belt (1), return the au-
to-tensioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.

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50 DISASSEMBLY AND ASSEM-
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REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3)

METHOD FOR REMOVING ENGINE FRONT OIL SEAL (6D107E-3)
Fan
1. Remove fan (3).

Alternator belt
2. Insert a wrench in part A (width across flats12.7 mm) of the
auto-tensioner (2), rotate it in the counter-direction (R) to
the winding-up direction to decrease alternator belt (1) ten-
sion, and remove alternator belt (1).
k Be sure that the wrench is installed securely to part
(a) of auto-tensioner (2), and turn it. (Since the
spring force of auto-tensioner (2) is strong, it is so
dangerous to turn the wrench not being attached
securely that it may come off.)
k After removing alternator belt (1), slowly and care-
fully restore auto-tensioner (2).
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Vibration damper
3. Remove mounting bolts (5) (6 pieces), and remove vibra-
tion damper (4).

Engine front oil seal

4. Remove engine front oil seal (6) according to the following procedure.

107E-3 SERIES 50-177

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3) BLY

1) Remove dust seal (12a).

2) Install tool H to the crankshaft.

3) Screw in tapping screw [1] of tool H to the seal carrier
section of engine front oil seal (6).
4) Turn the handle clockwise, and remove engine front
oil seal (6).
REMARK
Be careful not to damage the crankshaft when pre-
forming the removal.

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50 DISASSEMBLY AND ASSEM-
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METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (6D107E-3)

Engine front oil seal
1. Install engine front oil seal (6) by using tool H.
REMARK
• Before installing the engine front oil seal, check that the
end corner and the lip sliding surface of the crankshaft
are free from a flaw, burr, fin, and rust.
• When installing the engine front oil seal, do not apply
oil or grease to the crankshaft and seal lip. Also, thor-
oughly wipe off oil or grease from the crankshaft.
• Measure the protrusion and facial runout of engine
front oil seal (6) from cover (7).
Protrusion (x): Max. 0.38 mm
Facial runout (y): Max. 0.25 mm

2. Install dust seal (12a).

REMARK
Check the installing dimension (L).
Installed dimension (L): 12+0.1/0 mm

Vibration damper
3. Install vibration damper (4) while aligning its dowel hole to
dowel pin (B) of the crankshaft.
Tightening procedure for vibration damper mounting bolts
(5)
Vibration damper mounting bolt:
3 1st time, tighten diagonally:
55±5 Nm {5.61±0.51 kgfm}
3 2nd time, loosen the bolt:
180 °
3 3rd time, tighten diagonally:
55±5 Nm {5.61±0.51 kgfm}
3 4th time, retighten diagonally:
90±5 °

107E-3 SERIES 50-179

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3) BLY

REMARK
Perform angle tightening by using tool J.
In the case of not using an angle tightening tool
Put marks on the vibration damper and bolts with a felt-tip
pen and retighten the bolts to 90±5 °.

Alternator belt
4. Insert a wrench in A part (width across flats12.7 mm) of the
auto-tensioner (2), and install the alternator belt (1) as ro-
tating it in the opposite direction (R) to the winding-up di-
rection.
k Be sure that the wrench is installed securely to part
(a) of auto-tensioner (2), and turn it. (Since the
spring force of auto-tensioner (2) is strong, it is so
dangerous to turn the wrench not being attached
securely that it may come off.)
k After installing alternator belt (1), slowly and care-
fully restore auto-tensioner (2).
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Fan
5. Install fan (3).

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)

REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)

METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3)
Flywheel
1. To prevent the flywheel (2) from rotating, fix the flywheel by
using the object (a) that is not deformed by the tightening
torque.
2. Loosen the bolts (1) (8 pieces), and remove (a).

3. Remove the bolts (1) (2 pieces), and install the guide bolt
[1].
4. Sling the flywheel (2), and hold it.
5. Remove the remaining bolts (1) (6 pieces), sling the fly-
wheel (2), and remove it.

4 Flywheel (2):
35 kg
k Since the faucet joint portion of the flywheel (2) is
shallow, the flywheel may fall off suddenly. Be care-
ful not to get your fingers caught.
k Be careful that the guide bolt does not come off
when pulling the flywheel (2) out.
Engine rear oil seal
6. Remove the engine rear oil seal (3) according to the following procedure.

107E-3 SERIES 50-181

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3) BLY

1) Install the seal puller (G) to the crankshaft.

2) Screw in the tapping screw [2] of the seal puller (G) to
the seal carrier part of the engine rear oil seal (3).
3) Turn the handle in the direction of the arrow, and re-
move the engine rear oil seal (3).
REMARK
Be careful not to damage the crankshaft while remov-
ing it.

METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3)

Engine rear oil seal
NOTICE
• Do not remove the pilot [3] installed to the engine rear
oil seal (3) until it is inserted into the crankshaft.
• Before installing the engine rear oil seal, degrease,
clean and dry the crankshaft sealing face and seal lip
face to prevent oil leakage.

1. Insert the pilot [3] into the crankshaft (4), and push the en-
gine rear oil seal (3) into the flywheel housing (5).
2. Push in the engine rear oil seal (3) further, and remove the
pilot [3].

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50 DISASSEMBLY AND ASSEM-
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3. Install the rear oil seal (3) to the proper depth in the fly-
wheel housing (5) by using the seal puller (G).
REMARK
• Insert the rear oil seal (3) with careful attention that
there are no bend etc. on it.
• Measure the protrusion of the rear oil seal (3) from the
flywheel housing (5).
X: 0.38 mm or less

Flywheel
4. Install the guide bolt [1].
5. Sling the flywheel (2), and align it with the installing posi-
tion.
6. Install the flywheel assembly (2) with the bolts (1) (8
pieces).
2 Bolt (1):
Engine oil (EO15W-40)

4 Flywheel (2):
35 kg

7. To prevent the flywheel (2) from rotating, fix the flywheel by

using the object (a) that is not deformed by the tightening
torque.

107E-3 SERIES 50-183

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3) BLY

8. Tighten the bolts (1) in the order shown in the figure.

3 Bolt (1):
137±7 Nm {14.0±0.71 kgfm}
9. Check that the bolts (1) (8 pieces) are tightened, and re-
move (a).

Measurement of radial runout

10. After installing the flywheel assembly (2), measure the ra-
dial runout by using the dial gauge (L).
Radial runout: 0.13 mm or less
11. Install the dial gauge (L) to the flywheel housing.
12. Set the probe of the dial gauge perpendicularly to the fau-
cet joint portion (a) or outside perimeter of the flywheel.
13. Rotate the flywheel 1 turn, and measure the difference be-
tween the lowest and the highest values of the pointer of
dial gauge points.
REMARK
When the flywheel is rotated by 1 turn, check that the
pointer of the dial gauge indicates the same value as that
of the rotation start.
Measurement of facial runout
14. Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end
face (b) near the outside perimeter of the flywheel.
Facial runout: 0.20 mm or less
REMARK
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the end
play.
15. Rotate the flywheel 1 turn, and measure the difference between the lowest and the highest values of the
pointer of dial gauge points.

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3)

REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3)

METHOD FOR REMOVING ENGINE REAR OIL SEAL (6D107E-3)
Flywheel
1. Remove mounting bolts (1), and insert guide bolt [1].
2. Set slings to flywheel assembly (2), and pull flywheel as-
sembly (2) out.
REMARK
Be careful that the guide bolt does not come off when pull-
ing the flywheel out.
3. Sling flywheel assembly (2), and remove it.

4 Flywheel assembly:
35 kg
Engine rear oil seal
4. Remove engine rear oil seal (3) according to the following procedure.
1) Install tool G to the crankshaft.
2) Screw in tapping screws [2] of tool G to the seal carri-
er part of engine rear oil seal (3).
3) Turn the handle clockwise, and remove engine rear oil
seal (3).
REMARK
Remove it while being careful not to damage the
crankshaft.

METHOD FOR INSTALLING ENGINE REAR OIL SEAL (6D107E-3)

Engine rear oil seal

107E-3 SERIES 50-185

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3) BLY

NOTICE
• Do not remove pilot [3] attached to engine rear oil seal
(3) until it is inserted into the crankshaft.
• Before installing the engine rear oil seal, degrease,
clean and dry the crankshaft sealing face and the seal
lip face to prevent oil leakage.

1. Install pilot [3] to crankshaft (4), and insert engine rear oil
seal (3) into flywheel housing (5).
2. Push in engine rear oil seal (3) further, and remove pilot
[3].

3. Install rear oil seal (3) to the proper depth in flywheel hous-
ing (5) by using tool G.
REMARK
• Insert rear oil seal (3) with careful attention that there
are no bend etc. on it.
• Measure the protrusion of rear oil seal (3) from flywheel
housing (5).
X: Max. 0.38 mm

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50 DISASSEMBLY AND ASSEM-
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Flywheel
4. Install guide bolt [1], and flywheel (2).
2 Flywheel mounting bolt:
Engine oil (EO15W-40)

4 Flywheel:
35 kg

5. Tighten mounting bolts (1) in the order shown in the figure.

3 Mounting bolt:
137±7 Nm {14.0±0.71 kgfm}
REMARK
Tighten the bolts by using plate [4] for preventing rotation
of the flywheel (2).

Measurement of radial runout

6. After installing flywheel (2), measure the radial runout by
using tool L.
Radial runout: Max. 0.13 mm
7. Set tool L to the flywheel housing.
8. Set the probe of the dial gauge perpendicularly to the spi-
got joint part (a) or outside perimeter of the flywheel.
9. Rotate the flywheel 1 turn, and measure the difference be-
tween the lowest and the highest values of the pointer of
dial gauge points.
REMARK
When the flywheel rotated 1 turn, check that the dial gauge
indicates the same value as it of the starting rotation.
Measurement of facial runout
10. Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end
face (b) near the outside perimeter of the flywheel.

107E-3 SERIES 50-187

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3) BLY

Facial runout: Max. 0.20 mm

REMARK
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the end
play.
11. Rotate the flywheel 1 turn, and measure the difference between the lowest and the highest values of the
pointer of dial gauge points.

50-188 107E-3 SERIES

 60 MAINTENANCE STANDARD

107E-3 SERIES 60-1

CONTENTS 60 MAINTENANCE STANDARD

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 60-3
ENGINE SYSTEM ......................................................................................................................................... 60-9
INTAKE AND EXHAUST SYSTEM PARTS ............................................................................................. 60-9
MAINTENANCE STANDARD OF VGT............................................................................................. 60-9
MAINTENANCE STANDARD OF VGT........................................................................................... 60-10
ENGINE MAIN BODY PARTS................................................................................................................60-11
MAINTENANCE STANDARD OF CYLINDER HEAD ......................................................................60-11
MAINTENANCE STANDARD OF CYLINDER BLOCK ................................................................... 60-13
MAINTENANCE STANDARD OF CRANKSHAFT .......................................................................... 60-16
MAINTENANCE STANDARD OF PISTON..................................................................................... 60-18
MAINTENANCE STANDARD OF CONROD .................................................................................. 60-19
MAINTENANCE STANDARD OF VIBRATION DAMPER ............................................................... 60-21
MAINTENANCE STANDARD OF TIMING GEAR........................................................................... 60-22
MAINTENANCE STANDARD OF CAMSHAFT .............................................................................. 60-23
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE....................................................... 60-25
MAINTENANCE STANDARD OF ROCKER ARM .......................................................................... 60-27
MAINTENANCE STANDARD OF TAPPET .................................................................................... 60-28
MAINTENANCE STANDARD OF FLYWHEEL ............................................................................... 60-29
LUBRICATION SYSTEM....................................................................................................................... 60-31
MAINTENANCE STANDARD OF ENGINE OIL PUMP .................................................................. 60-31

60-2 107E-3 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

107E-3 SERIES 60-3

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

60-4 107E-3 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

107E-3 SERIES 60-5

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

60-6 107E-3 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

107E-3 SERIES 60-7

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

60-8 107E-3 SERIES

60 MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM PARTS

ENGINE SYSTEM
INTAKE AND EXHAUST SYSTEM PARTS
MAINTENANCE STANDARD OF VGT
REMARK
Six cylinder engine is shown in this item.

Unit: mm
No. Item Criteria Remedy
When compressor wheel and turbine wheel are moved lightly
1 Radial play with the fingers toward the housing, both of them must not touch
the housing.
Replace VGT
2 End play (axial play) 0.025 to 0.127 assembly (in-
cluding hy-
Perform active regeneration for service. At this time, if KDOC in-
draulic actuator
let temperature remains at approximately 250 °C or below and
Operation check of VGT and VGT posi-
VGT solenoid current remains at approximately 1000 mA or be-
3 (operation check of nozzle tion sensor)
low, VGT is defective. (Approximate time taken for manual sta-
ring)
tionary regeneration depends on accumulation of soot. See fail-
ure code CA2639.)

107E-3 SERIES 60-9

INTAKE AND EXHAUST SYSTEM PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF VGT

REMARK
Four cylinder engine is shown in this item.

Unit: mm
No. Item Criteria Remedy
When compressor wheel and turbine wheel are moved lightly
1 Radial play with the fingers toward the housing, both of them must not touch Replace turbo-
the housing. charger assem-
bly
2 End play (axial play) 0.045 to 0.093

60-10 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CYLINDER HEAD

Unit: mm
No
Item Criteria Remedy
.
Lengthwise direction Maximum 0.305 Repair by
Strain of cylinder
1 grinding or
head mounting face Lateral direction Maximum 0.076 replace

107E-3 SERIES 60-11

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No
Item Criteria Remedy
.
Tightening torque of Procedure Target
cylinder head
1st stage 90±3 Nm {9.2±0.3 kgfm}
mounting bolt Tighten and
2 (Apply molybdenum 2nd stage 90±3 Nm {9.2±0.3 kgfm} retighten
disulfide or engine (*)
oil to underside of 3rd stage Retighten 90±5 °
bolt head.)
Repair limit Replace
Protrusion of injec-
3 nozzle or
tor nozzle 1.63 to 1.98 gasket
Tightening torque of Target
4 injector holder
mounting bolt 8 Nm {0.8 kgfm}
Retighten
Tightening torque of
5 head cover mount- 24 Nm {2.4 kgfm}
ing bolt:

*: Tighten in order of numbers shown in the figure.

60-12 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CYLINDER BLOCK

107E-3 SERIES 60-13

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Lengthwise direction Maximum 0.075 Repair by
Strain of cylinder head
1 grinding or re-
mounting face Lateral direction Maximum 0.051 place
Inside diameter of main Replace main
2 87.983 to 88.019
bearing mounting hole bearing cap
Inside diameter of main
3 83.041 to 83.109 Replace main
bearing
bearing
4 Main bearing thickness 2.456 to 2.464
Inside diameter of cam- Repair or re-
5 shaft bushing mounting Maximum 59.248 place cylinder
hole block
Machine the
cylinder block,
Inside diameter of cam-
6 Maximum 54.164 and insert the
shaft hole
camshaft bush-
ing
Procedure Target
Tightening torque of main 1st stage 60 Nm {6.1 kgfm} Tighten and re-
bearing cap (apply engine tighten
oil to threaded part) 2nd stage 80 Nm {8.2 kgfm} (*)
7
3rd stage Retighten 90 °
Replace main
Bolt stem length allowable
Maximum 120 bearing cap
limit of main bearing cap
bolt

Tightening torque of en- Target Tighten

8
gine oil pan mounting bolt 28 Nm, 2.8 kgfm (*)
Procedure Target
Tightening torque of crank-
9 1st stage 50 Nm {5.1 kgfm} Retighten
shaft pulley mounting bolt
2nd stage Retighten 90 °

60-14 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No. Item Criteria Remedy
Cylinder bore 106.990 to 107.030 Replace cylin-
10 Roundness of cylinder der liner or
Repair limit: 0.038 block
bore

*: Tighten in order of numbers in [ ] in the figure.

107E-3 SERIES 60-15

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CRANKSHAFT

Unit: mm
No
Item Criteria Remedy
.
Replace thrust
1 End play (A) 0.065 to 0.432 bearing or over
size repair

60-16 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No
Item Criteria Remedy
.
Outside diameter of crankshaft
82.962 to 83.013
main journal
Roundness of crankshaft main Undersize repair or
Repair limit: 0.050
journal replace
2
Taper of crankshaft main jour-
Repair limit: 0.013
nal
Clearance of crankshaft main Replace main
0.04 to 0.12
journal bearing
Outside diameter of crankshaft
82.962 to 83.013
pin journal Undersize repair or
Roundness of crankshaft pin replace
3 Repair limit: 0.050
journal
Clearance of crankshaft pin Replace connect-
0.04 to 0.12
journal ing rod bearing
Outside diameter of front
4 70.59 to 70.61
crankshaft gear journal Undersize repair or
Inside diameter of front crank- replace
5 70.51 to 70.55
shaft gear

107E-3 SERIES 60-17

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF PISTON

Unit: mm
No
Item Criteria Remedy
.
Outside diameter of Replace
1 106.878 to 106.892
piston skirt piston
Top ring 0.36 to 0.46
Closed gap of top
2 Second ring 0.52 to 0.88
ring Replace
Oil ring 0.22 to 0.58 piston ring
or piston
Clearance of piston Second ring 0.040 to 0.110
3
ring Oil ring 0.040 to 0.085
Outside diameter of Replace
4 39.997 to 40.003
piston pin piston pin
Inside diameter of Replace
5 40.006 to 40.012
piston pin bore piston

60-18 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CONROD

Unit: mm
No
Item Criteria Remedy
.
Inside diameter of con-
Inside diameter of con- necting rod small end
1 necting rod bushing 40.019 to 40.042 bushing
(When installing bushing) (Spare part is half fin-
ished.)
Inside diameter of con-
2 69.05 to 69.10
necting rod bearing Replace connecting
Thickness of connecting rod bearing
3 1.955 to 1.968
rod bearing

107E-3 SERIES 60-19

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No
Item Criteria Remedy
.
Inside diameter of con-
Replace connecting
4 necting rod bearing 72.99 to 73.11
rod
mounting hole
Tightening torque of con- 1st stage 30±3 Nm {3.06±0.1 kgfm}
necting rod cap mounting
2nd stage 60±5 Nm {6.12±0.51 kgfm}
bolt
5 Tighten and retighten
(Apply engine oil to nut
seat surface of thread 3rd stage Retighten 60±5 °
part of bolt)
Side clearance of con- Replace connecting
6 0.10 to 0.33
necting rod rod

60-20 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF VIBRATION DAMPER

REMARK
This item applies to six cylinder engine only.

No. Item Criteria Remedy

Procedure Target
Tightening torque of vibra- Tighten and re-
1 1st stage 50 Nm {5.1 kgfm}
tion damper mounting bolt tighten
2nd stage Retighten 90 °

107E-3 SERIES 60-21

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TIMING GEAR

Unit: mm
No. Item Criteria Remedy
A Backlash of engine oil pump gear 0.170 to 0.300
B Backlash of camshaft gear 0.076 to 0.280
- Backlash of each gear Replacement
C Backlash of idler gear 0.150 to 0.250
D Backlash of supply pump gear 0.022 to 0.146

60-22 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CAMSHAFT

Unit: mm
No. Item Criteria Remedy
Replace
1 End play 0.23±0.13
thrust plate
Outside diameter of
Repair or re-
2 camshaft bearing jour- 53.095 to 54.045
place
nal
Intake side 46.545 to 47.855
3 Camshaft lobe height
Exhaust side 45.002 to 46.312
Replacement
Thickness of camshaft
4 5.25 to 5.35
thrust plate

107E-3 SERIES 60-23

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Tightening torque of
5 camshaft thrust plate 24±4 Nm {2.45±0.41 kgfm}
mounting bolt
Tighten
Tightening torque of
6 camshaft gear mount- 36±4 Nm {3.67±0.41 kgfm}
ing bolt

60-24 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE

Unit: mm
No. Item Criteria Remedy
Intake side 0.584 to 1.092 Replace valve
1 Valve recess
Exhaust side 0.965 to 1.473 or valve seat

2 Valve rim thickness (B) Min. 0.79 Replace valve

Valve Angle Repair limit
Repair or re-
3 Valve seat angle Intake side 30 ° Judge contact surface state place valve or
by vacuum test valve seat
Exhaust side 45 °
Outside diameter of
4 6.69 to 7.01 Replace valve
valve stem
Valve guide bore diame- Replace valve
5 7.027 to 7.077
ter guide

107E-3 SERIES 60-25

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Inside diameter of valve
6 insert bore 34.847 to 34.863 -
(Standard insert)

60-26 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF ROCKER ARM

Unit: mm
No. Item Criteria Remedy
Replace
Outside diameter of
1 Min. 21.965 rocker arm
rocker arm shaft
shaft
Inside diameter of rock- Replace
2 Max. 22.027
er arm shaft hole rocker arm
Replace
Clearance between
rocker arm or
3 rocker arm shaft and Max. 0.062
rocker arm
rocker arm
shaft
Tightening torque of Target
4 rocker arm adjustment Tighten
screw lock nut 24 Nm {2.4 kgfm}

Valve Repair limit Adjustment value

Valve clearance (when
5 Intake side 0.152 to 0.381 0.25±0.05 Adjustment
cooled)
Exhaust side 0.381 to 0.762 0.51 0.05
Tightening torque of Target
6 rocker arm mounting Tighten
bolt 36 Nm {3.7 kgfm}

107E-3 SERIES 60-27

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TAPPET

Unit: mm
No. Item Criteria Remedy
1 Outside diameter of tappet 15.936 to 15.977 Replace tappet
Inside diameter of tappet Cylinder block re-
2 16.000 to 16.055
hole placement
Clearance between tappet Replace tappet or
3 0.023 to 0.119
and tappet hole cylinder block

60-28 107E-3 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF FLYWHEEL

Unit: mm
No. Item Criteria Remedy
Radial runout of flywheel
1 Repair limit: 0.20
housing Reassemble
Facial runout of flywheel and repair
2 Repair limit: 0.20
housing
Tightening torque of fly- M10 49±5 Nm {5±0.51 kgfm} Tighten
3 wheel housing mounting
bolt M12 85±10 Nm {8.67±1.38 kgfm} (*)

Allowable value
4 Facial runout of flywheel Reassemble
Diameter of measurement point x 0.0005
and repair
5 Radial runout of flywheel Repair limit: 0.13

107E-3 SERIES 60-29

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Tightening torque of fly-
wheel mounting bolt (apply Tighten
6 137±7 Nm {14±0.71 kgfm}
engine oil to threaded part (*)
or seat surface)

*: Tighten in order of numbers shown in the figure.

60-30 107E-3 SERIES

60 MAINTENANCE STANDARD LUBRICATION SYSTEM

LUBRICATION SYSTEM
MAINTENANCE STANDARD OF ENGINE OIL PUMP

Unit: mm
No. Item Criteria Remedy
Clearance in axial di-
1 Maximum 0.127
rection of rotor
Replace oil
Clearance between pump
2 outer rotor and inner Maximum 0.178
rotor
8±1 Nm {0.82±0.1 kgfm}
1st time
Tightening torque of oil (Tightening order: A) Tighten
3
pump mounting bolt 24±4 Nm {2.45±0.41 kgfm} (*)
2nd time
(Tightening order: B)

*: Tighten in order of numbers shown in the figure.

107E-3 SERIES 60-31

INDEX

INDEX
A C
Abbreviation List.......... 00-5,01-4,10-5,20-3,50-3,60-3 Camshaft - Maintenance standard......................60-23
Actions if fire occurs............................................00-23 CDR valve......................................................... 10-110
Actions taken to meet exhaust gas regulations.. 00-25 CDR valve - Operation...................................... 10-110
AdBlue/DEF - Store............................................ 00-27 Charge (boost) pressure and temperature sensor -
AdBlue/DEF hose............................................... 10-55 Function..................................................... 10-178
AdBlue/DEF hose - Function.............................. 10-55 Charge (boost) pressure and temperature sensor -
AdBlue/DEF hose - Structure..............................10-55 Structure.................................................... 10-178
AdBlue/DEF injector............................................10-54 Coating materials list...........................................50-11
AdBlue/DEF injector - Function...........................10-54 Common rail pressure sensor - Function..........10-182
AdBlue/DEF injector - Operation.........................10-54 Common rail pressure sensor - Structure......... 10-182
AdBlue/DEF injector - Structure..........................10-54 Component parts of electrical system...............10-146
AdBlue/DEF mixing tube.....................................10-45 Component parts of urea SCR system............... 10-45
AdBlue/DEF mixing tube - Function....................10-46 Connecting rod - Maintenance standard.............60-19
AdBlue/DEF mixing tube - Structure.........10-45,10-46 Connector - Precautions for disconnection and con-
AdBlue/DEF pump.............................................. 10-53 nection......................................................... 00-46
AdBlue/DEF pump - Structure............................ 10-53 Connector with housing to rotate - Disconnect/
AdBlue/DEF supply system - Function............... 10-23 Connect....................................................... 00-56
AdBlue/DEF tank................................................ 10-51 Connector with lock to push - Disconnect/Connect......
AdBlue/DEF tank - Structure...............................10-51 .....................................................................00-54
AdBlue/DEF tank heating valve.......................... 10-56 Conversion table................................................. 00-71
AdBlue/DEF tank heating valve - Function......... 10-56 Coolant temperature sensor - Function............ 10-179
AdBlue/DEF tank heating valve - Operation....... 10-56 Coolant temperature sensor - Structure............10-179
AdBlue/DEF tank heating valve - Structure........ 10-56 Cooling system................................................. 10-139
AdBlue/DEF tank sensor.....................................10-52 Cooling system - Circuit diagram..........10-140,10-141
AdBlue/DEF tank sensor - Function....................10-52 Cooling system parts - Layout drawing.............10-139
AdBlue/DEF tank sensor - Structure...................10-52 Crankcase pressure sensor - Function............. 10-188
Air cleaner...........................................................10-65 Crankcase pressure sensor - Structure............ 10-188
Air cleaner - Operation........................................10-65 Crankshaft - Maintenance standard....................60-16
Air cleaner - Specifications................................. 10-65 Cylinder block..................................................... 10-70
Air cleaner - Structure......................................... 10-65 Cylinder block - Maintenance standard...............60-13
Air cleaner clogging sensor - Function..............10-190 Cylinder block - Specifications............................ 10-70
Air cleaner clogging sensor - Structure.............10-190 Cylinder block - Structure....................................10-70
Alternator.......................................................... 10-146 Cylinder head......................................................10-68
Alternator with built-in regulator (open type, 140 A) - Cylinder head - Maintenance standard............... 60-11
Specifications.............................................10-151 Cylinder head - Specifications............................ 10-69
Alternator with built-in regulator (open type, 140 A) - Cylinder head - Structure.................................... 10-68
Structure.................................................... 10-150
Alternator with built-in regulator (open type, 85 A) - D
Specifications.............................................10-147
Alternator with built-in regulator (open type, 85 A) - Deutsch connector - Disconnect/Connect...........00-50
Structure.................................................... 10-146 Drive pulley....................................................... 10-142
Alternator with built-in regulator (open type, 90 A) - Drive pulley - Structure (Hydraulic excavator, Wheel
Structure.................................................... 10-148 loader, Motor grader)................................. 10-143
Alternator with built-in regulator (open type, 90A) - Drive pulley - Structure(Bulldozer) ................... 10-142
Specifications.............................................10-149
Ambient pressure sensor - Function................. 10-176 E
Ambient pressure sensor - Structure................ 10-176
Applicable machines list: 107E-3........................ 01-13 EGR cooler....................................................... 10-102
Assembly and disassembly - Related information 50-9 EGR cooler - Operation.................................... 10-103
EGR cooler - Structure......................... 10-102,10-103
EGR orifice temperature sensor - function........10-194
B EGR orifice temperature sensor - structure...... 10-194
Bkup (camshaft) speed sensor - Function........ 10-181 EGR system........................................................10-93
Bkup (camshaft) speed sensor - Structure....... 10-181 EGR system - Circuit diagram............................ 10-95

1
 INDEX

EGR system - Function.......................................10-94 Engine oil pump - Function............................... 10-123

EGR system - Layout drawing............................ 10-93 Engine oil pump - Maintenance standard........... 60-31
EGR system - Operation.....................................10-97 Engine oil pump - Specifications.......................10-123
EGR valve...........................................................10-98 Engine oil pump - Structure.............................. 10-123
EGR valve - Operation......................................10-100 Engine oil regulator valve..................................10-127
EGR valve - Structure...............................10-98,10-99 Engine oil regulator valve - function..................10-127
EGR valve (with built-in position sensor) - Function.... Engine oil regulator valve - specafications........10-127
...................................................................10-192 Engine oil regulator valve - suructure............... 10-127
EGR valve (with built-in position sensor) - Structure.... Engine performance curve..................................01-85
...................................................................10-192 Engine rear oil seal (4D107E-3) - Install........... 50-182
EGR valve lift sensor - Function....................... 10-183 Engine rear oil seal (4D107E-3) - Remove....... 50-181
EGR valve lift sensor - Structure.......................10-183 Engine rear oil seal (4D107E-3) - Remove/Install........
Electrical system............................................... 10-146 ...................................................................50-181
Engine - General assembly (4D107E-3)............. 50-45 Engine rear oil seal (6D107E-3) - Install........... 50-185
Engine - General disassembly (4D107E-3)........ 50-18 Engine rear oil seal (6D107E-3) - Remove....... 50-185
Engine - Standard value table...............................20-9 Engine rear oil seal (6D107E-3) - Remove/Install........
Engine (4D107E-3) - General disassembly and as- ...................................................................50-185
sembly......................................................... 50-18 Engine sensors - Layout drawing......... 10-172,10-174
Engine (6D107E-3) - General assemble........... 50-118 Engine shop manual - How to read.....................00-11
Engine (6D107E-3) - General disassemble........ 50-93 Engine system.................................. 10-57,50-18,60-9
Engine (6D107E-3) - General disassembly and as- Engine wiring harness.......................................10-154
sembly......................................................... 50-92 Engine wiring harness - Structure.........10-154,10-155
Engine boost oil pump...................................... 10-124 Exhaust gas regulation - Outline.........................01-10
Engine boost oil pump - Function..................... 10-124 Exhaust manifold pressure sensor - function....10-193
Engine boost oil pump - Specifications............. 10-124 Exhaust manifold pressure sensor - structure.. 10-193
Engine boost oil pump - Structure.....................10-124
Engine components - Layout.............................. 10-57 F
Engine components - Layout drawing...... 10-57,10-60
Engine controller............................................... 10-158 Flywheel - Maintenance standard....................... 60-29
Engine controller - Function.............................. 10-158 Flywheel / Flywheel housing - Specifications......10-83
Engine controller - Input and output signals................. Flywheel and flywheel housing........................... 10-82
.......................................................10-160,10-166 Flywheel and flywheel housing - Structure......... 10-82
Engine controller - Structure............................. 10-158 Foreword, Safety, Basic information....................00-11
Engine controller - System diagram..................10-158 Front cover..........................................................10-78
Engine front oil seal (4D107E-3) - Install.......... 50-174 Front cover - Structure........................................ 10-78
Engine front oil seal (4D107E-3) - Remove...... 50-172 Fuel main filter.................................................. 10-138
Engine front oil seal (4D107E-3) - Remove/Install....... Fuel main filter - Function................................. 10-138
...................................................................50-172 Fuel main filter - Structure.................................10-138
Engine front oil seal (6D107E-3) - Install.......... 50-179 Fuel prefilter...................................................... 10-137
Engine front oil seal (6D107E-3) - Remove...... 50-177 Fuel prefilter - Function..................................... 10-137
Engine front oil seal (6D107E-3) - Remove/Install....... Fuel prefilter - Structure.................................... 10-137
...................................................................50-177 Fuel system.......................................................10-130
Engine general view............................................01-29 Fuel system - Circuit diagram........................... 10-133
Engine main body parts............................ 10-68,60-11 Fuel system - Function......................................10-134
Engine oil cooler............................................... 10-126 Fuel system equipment - Precautions for handling......
Engine oil cooler - Function.............................. 10-126 .....................................................................00-40
Engine oil cooler - Specifications...................... 10-126 Fuel system parts - Layout drawing.................. 10-130
Engine oil cooler - Structure..............................10-126
Engine oil filter.................................................. 10-125 G
Engine oil filter - Function................................. 10-125
Engine oil filter - Structure.................................10-125 General character and precautions for handling.00-26
Engine oil level sensor - Function..................... 10-189
Engine oil level sensor - Structure.................... 10-189 H
Engine oil pan................................................... 10-129
How to read electrical wire code......................... 00-57
Engine oil pan - Structure................................. 10-129
How to read this manual....................................... 50-9
Engine oil pressure switch - Function............... 10-177
Engine oil pressure switch - Structure.............. 10-177
Engine oil pump................................................ 10-123

2
INDEX

I KDOC................................................................10-115
KDOC - Function...............................................10-116
Improved points of engine conformed to Tier 4 regula- KDOC - Structure.............................................. 10-115
tion............................................................... 01-12 KDPF................................................................. 10-111
Inducement strategy........................................... 10-26 KDPF - Function................................................10-112
Inducement strategy for abnormality recurrence with- KDPF - Structure............................................... 10-111
in 40 hours (For European Union)............... 10-44 KDPF differential pressure and outlet pressure sen-
Inducement strategy for abnormality recurrence with- sor - Function.............................................10-187
in 40 hours (For North America).................. 10-34 KDPF differential pressure and outlet pressure sen-
Inducement strategy when abnormality is found in the sor - Structure............................................ 10-187
AdBlue/DEF quality or in the Urea SCR system
devices (For European Union).....................10-36 L
Inducement strategy when abnormality is found in the
EGR system by the Urea SCR system devices Lubrication system.................................. 10-118,60-31
(For European Union).................................. 10-41 Lubrication system - Circuit diagram.... 10-121,10-122
Inducement strategy when abnormality is found in the Lubrication system parts - Layout drawing...................
KDOC system by the Urea SCR system (For ....................................................... 10-118,10-120
North America).............................................10-29
Inducement strategy when abnormality is found in the M
KDOC system by the urea SCR system devices
(For European Union).................................. 10-37 Main drive parts - Specifications......................... 10-74
Inducement strategy when abnormality is found in the Main moving parts...............................................10-72
KDPF system by the Urea SCR system (For Main moving parts - Structure.............................10-72
North America).............................................10-32 Mass air flow and temperature sensor - Function........
Inducement strategy when abnormality is found in the ...................................................................10-186
KDPF system by the urea SCR system devices Mass air flow and temperature sensor - Structure.......
(For European Union).................................. 10-39 ...................................................................10-186
Inducement strategy when abnormality is found in the Method for disconnecting and connecting connector
urea SCR system devices (For North America).... with lock to pull............................................ 00-53
.....................................................................10-27
Inducement strategy when the AdBlue/DEF level in N
the tank becomes low (For European Union).......
NE (crankshaft) speed sensor - Function......... 10-180
.....................................................................10-35
NE (crankshaft) speed sensor - Structure.........10-180
Inducement strategy when the AdBlue/DEF level in
the tank becomes low (For North America). 10-26
Intake air heater.................................................. 10-67 P
Intake air heater - Specifications.........................10-67 Piping - Precautions for disconnection and connec-
Intake air heater - Structure................................ 10-67 tion............................................................... 00-31
Intake and exhaust system - Function................ 10-63 Piston - Maintenance standard........................... 60-18
Intake and exhaust systems - Circuit diagram.... 10-63 Piston ring........................................................... 10-74
Intake and exhaust systems - Layout drawing............. Piston ring - Structure......................................... 10-74
...........................................................10-61,10-62 Precautions for adding........................................ 00-26
Intake and exhaust systems parts.............. 10-61,60-9 Precautions for DEF............................................00-26
Intake system equipment - Precautions for handling... Precautions for disposing of waste materials......00-24
.....................................................................00-41 Precautions for fire hazard and leakage............. 00-26
Precautions for handling electrical equipment.... 00-38
K Precautions for handling hydraulic equipment.... 00-28
Precautions for storing........................................ 00-26
KCCV system....................................................10-105
Precautions to prevent fire.................................. 00-21
KCCV system - Forming of condensed water and
Push-pull type coupler - Disconnect/Connect..... 00-42
emulsion.................................................... 10-106
KCCV system - Function...................................10-106
KCCV system - Layout drawing........................ 10-105 R
KCCV system - Operation.................................10-108 Regeneration functions - Types........................ 10-116
KCCV ventilator................................................ 10-109 Rocker arm - Maintenance standard...................60-27
KCCV ventilator - Function............................... 10-109 Running-in standard and performance test standard...
KCCV ventilator - Operation..............................10-110 .....................................................................20-54
KCCV ventilator - Structure...............................10-109

3
 INDEX

S SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,

D61PX-24E0, D61PXI-24E0) - Engine
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, performance curve.......................................01-91
D51PXI-24) - Engine general view.............. 01-29 SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D61PX-24E0, D61PXI-24E0) - Running-in stand-
D51PXI-24) - Engine performance curve.....01-85 ard and performance................................... 20-66
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,
D51PXI-24) - Running-in standard and perform- D61PX-24E0, D61PXI-24E0) - Specifications......
ance............................................................. 20-54 .....................................................................01-20
SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, SAA6D107E-3 (D61EX-24E0, D61EXI-24E0,
D51PXI-24) - Specifications.........................01-14 D61PX-24E0, D61PXI-24E0) - Standard value
SAA4D107E-3 (HB215LC-3) - Engine general view.... table for engine............................................ 20-27
.....................................................................01-33 SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
SAA4D107E-3 (HB215LC-3) - Engine performance GD675-7E0) - Engine general view............. 01-57
curve............................................................ 01-86 SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
SAA4D107E-3 (HB215LC-3) - Running-in standard GD675-7E0) - Running-in standard and perform-
and performance..........................................20-56 ance............................................................. 20-68
SAA4D107E-3 (HB215LC-3) - Specifications..... 01-15 SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
SAA4D107E-3 (HB215LC-3) - Standard value table GD675-7E0) - Specifications....................... 01-21
for engine.....................................................20-12 SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
SAA4D107E-3 (PC170LC-11) - Engine general view.. GD675-7E0) - Standard value table for engine.....
.....................................................................01-37 .....................................................................20-30
SAA4D107E-3 (PC170LC-11) - Engine performance SAA6D107E-3 (GD655-6, GD655-7, GD675-6,
curve............................................................ 01-87 GD675-7E0) -Engine Performance curve....01-92
SAA4D107E-3 (PC170LC-11) - Running-in standard SAA6D107E-3 (PC210LC-11, PC210LCI-11) - Run-
and performance..........................................20-58 ning-in standard and performance...............20-70
SAA4D107E-3 (PC170LC-11) - Specifications... 01-16 SAA6D107E-3 (PC210LC-11, PC210LCI-11) - Stand-
SAA4D107E-3 (PC170LC-11) - Standard value table ard value table for engine............................ 20-33
for engine.....................................................20-15 SAA6D107E-3 (PC210LC-11, PC210LCI-11)) - Speci-
SAA4D107E-3 (WA200-8) - Engine general view........ fications........................................................01-22
.....................................................................01-41 SAA6D107E-3 (PC228USLC-11, PC238USLC-11) -
SAA4D107E-3 (WA200-8) - Engine performance Specifications...............................................01-23
curve............................................................ 01-88 SAA6D107E-3 (PC240LC-11, PC290LC-11,
SAA4D107E-3 (WA200-8) - Running-in standard and PC290LCI-11) - Engine general view...........01-69
performance.................................................20-60 SAA6D107E-3 (PC240LC-11) - Engine performance
SAA4D107E-3 (WA200-8) - Specifications......... 01-17 curve............................................................ 01-95
SAA4D107E-3(D51EX-24, D51EXI-24, D51PX-24, SAA6D107E-3 (PC240LC-11) - Running-in standard
D51PXI-24) - Standard value table for engine...... and performance..........................................20-74
.......................................................................20-9 SAA6D107E-3 (PC240LC-11) - Specifications... 01-24
SAA4D107E-3(WA200-8) - Standard value table for SAA6D107E-3 (PC240LC-11) - Standard value table
engine.......................................................... 20-18 for engine.....................................................20-39
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, SAA6D107E-3 (PC290LC-11, PC290LCI-11) - Engine
D61PXI-24) - Engine general view.............. 01-49 performance curve.......................................01-96
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, SAA6D107E-3 (PC290LC-11, PC290LCI-11) - Run-
D61PXI-24) - Engine performance curve.....01-90 ning-in standard and performance...............20-76
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, SAA6D107E-3 (PC290LC-11, PC290LCI-11) - Speci-
D61PXI-24) - Running-in standard and perform- fications........................................................01-25
ance............................................................. 20-64 SAA6D107E-3 (PC290LC-11, PC290LCI-11) - Stand-
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, ard value table for engine............................ 20-42
D61PXI-24) - Specifications.........................01-19 SAA6D107E-3 (WA270-8, WA270-8E0) - Engine gen-
SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, eral view.......................................................01-73
D61PXI-24) - Standard value table for engine...... SAA6D107E-3 (WA270-8, WA270-8E0) - Engine per-
.....................................................................20-24 formance curve............................................ 01-97
SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, SAA6D107E-3 (WA270-8, WA270-8E0) - Running-in
D61PX-24E0, D61PXI-24E0) - Engine general standard and performance test criteria........ 20-78
view..............................................................01-53 SAA6D107E-3 (WA270-8, WA270-8E0) - Specifica-
tions............................................................. 01-26

4
INDEX

SAA6D107E-3 (WA270-8, WA270-8E0) - Standard Starter (5.5 kw) with built-in safety relay - Structure....
value table for engine.................................. 20-45 ...................................................................10-153
SAA6D107E-3 (WA320-8, WA320-8E0) - Engine gen- Starter built in safety relay (5.5 kW) - Specifications....
eral view.......................................................01-77 ...................................................................10-153
SAA6D107E-3 (WA320-8, WA320-8E0) - Engine per- Starting motor................................................... 10-152
formance curve............................................ 01-98 Starting motor with built-in safety relay (11kW) -
SAA6D107E-3 (WA320-8, WA320-8E0) - Running-in Specifications.............................................10-152
standard and performance...........................20-80 Supply pump..................................................... 10-136
SAA6D107E-3 (WA320-8, WA320-8E0) - Specifica- Supply pump - Function.................................... 10-136
tions............................................................. 01-27 Supply pump - Specifications............................10-136
SAA6D107E-3 (WA320-8, WA320-8E0) - Standard Supply pump - Structure................................... 10-136
value table for engine.................................. 20-48 Supply pump assembly (4D107E-3) - Install.....50-164
SAA6D107E-3 (WA380-8) - Engine general view........ Supply pump assembly (4D107E-3) - Remove.50-161
.....................................................................01-81 Supply pump assembly (4D107E-3) - Remove/Install.
SAA6D107E-3 (WA380-8) - Engine performance .......................................................50-161,50-167
curve............................................................ 01-99 Supply pump assembly (6D107E-3) - Install.....50-169
SAA6D107E-3 (WA380-8) - Running-in standard and Supply pump assembly (6D107E-3) - Remove.50-167
performance.................................................20-82
SAA6D107E-3 (WA380-8) - Specifications......... 01-28 T
SAA6D107E-3 (WA380-8) - Standard value table for
engine.......................................................... 20-51 Tappet - Maintenance standard.......................... 60-28
SAA6D107E-3(BR380JG-3) - Engine general view..... Temporary restoration from Inducement (For Europe-
.....................................................................01-45 an Union) - Function.................................... 10-43
SAA6D107E-3(BR380JG-3) - Engine performance Temporary restoration from Inducement (For North
curve............................................................ 01-89 America) - Function..................................... 10-34
SAA6D107E-3(BR380JG-3) - Running-in standard Terms for maintenance standard - Explanation.. 00-61
and performance test criteria....................... 20-62 The other precautions......................................... 00-26
SAA6D107E-3(BR380JG-3) - Specifications...... 01-18 Thermostat........................................................10-145
SAA6D107E-3(BR380JG-3) - Standard value table Thermostat - Specifications.............................. 10-145
for engine.....................................................20-21 Thermostat - Structure...................................... 10-145
SAA6D107E-3(PC210LC-11, PC210LCI-11) - Engine Tier 4 engine - System diagram.......................... 01-11
general view.................................................01-61 Timing gear......................................................... 10-77
SAA6D107E-3(PC210LC-11, PC210LCI-11) - Engine Timing gear - Function........................................ 10-77
performance curve.......................................01-93 Timing gear - Maintenance standard.................. 60-22
SAA6D107E-3(PC228USLC-11, PC238USLC-11) - Timing gear - Structure....................................... 10-77
Engine general view.................................... 01-65 Turbocharger system.......................................... 10-84
SAA6D107E-3(PC228USLC-11, PC238USLC-11) - Type 1 push-pull type coupler - Disconnect/Connect...
Engine performance curve...........................01-94 .....................................................................00-42
SAA6D107E-3(PC228USLC-11, PC238USLC-11) - Type 2 push-pull type coupler - Disconnect/Connect...
Running-in standard and performance........ 20-72 .....................................................................00-43
SAA6D107E-3(PC228USLC-11, PC238USLC-11) - Type 3 push-pull type coupler - Disconnect/Connect...
Standard value table for engine...................20-36 .....................................................................00-44
Safety notice for operation.................................. 00-13 Types of regeneration - Function...................... 10-113
Safety valve of engine oil.................................. 10-128
Safety valve of engine oil - Function................. 10-128 U
Safety valve of engine oil - Specifications.........10-128
Safety valve of engine oil - Structure................ 10-128 Urea SCR system............................................... 10-11
SCR assembly.................................................... 10-47 Urea SCR system - Function.................... 10-22,10-23
SCR assembly - Structure........................ 10-47,10-49 Urea SCR system - Layout drawing....................10-11
Sensor...............................................................10-172 Urea SCR system - System diagram........10-19,10-21
Slide lock type connector - Disconnect/Connect.00-51
Special tools - List...............................................50-15 V
Special tools - Sketches......................................50-17
Valve and valve guide - Maintenance standard.. 60-25
Specification............................................. 01-10,01-14
Valve system.......................................................10-79
Standard tightening torque table.........................00-64
Valve system - Structure..................................... 10-79
Starter (4.5 kw) with built-in safety relay - Structure....
VGT.....................................................................10-87
...................................................................10-152
VGT - Function....................................................10-89
VGT - Maintenance standard......................60-9,60-10

5
 INDEX

VGT - Operation....................................... 10-89,10-91

VGT - Structure.........................................10-87,10-88
VGT actuator (with built-in position sensor) — func-
tion............................................................. 10-195
VGT actuator (with built-in position sensor) — struc-
ture.............................................................10-195
VGT position sensor - Function........................ 10-185
VGT position sensor - Structure........................10-185
VGT speed sensor - Function........................... 10-184
VGT speed sensor - Structure.......................... 10-184
VGT system - Circuit diagram.............................10-84
VGT system - Function....................................... 10-85
Vibration damper.................................................10-76
Vibration damper - Function................................10-76
Vibration damper - Maintenance standard..........60-21
Vibration damper - Structure...............................10-76

W
Water pump.......................................................10-144
Water pump - Function......................................10-144
Water pump - Specifications............................. 10-144
Water pump - Structure.....................................10-144
Water-in-fuel sensor - Function.........................10-191
Water-in-fuel sensor - Structure........................ 10-191

6
107E-3 SERIES ENGINE
Form No. SEN06502-17

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Printed in Japan 11-2019