107E 1 ShopManual PDF

SEN00161-12
ENGINE
107E-1 SERIES
SEN00163-12
Engine 1SHOP MANUAL
107E-1 Series
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 3
107E-1 Series 1
SEN00163-12 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00161-12
00 Index and foreword SEN00162-12

Index SEN00163-12 q
Foreword and general information SEN00164-05 q
01 Specification SEN00165-09
Specification and technical data SEN00166-09 q
10 Structure, function and maintenance standard SEN00167-00

Structure, function and maintenance standard SEN00168-00
20 Standard value table SEN00247-09

Standard service value table SEN00248-09 q
30 Testing and adjusting SEN00249-02

Testing and adjusting SEN00250-02
40 Troubleshooting SEN00251-02
General information on troubleshooting SEN00252-01
Troubleshooting of electrical system (E-mode), Part 1 SEN00254-02
Troubleshooting of mechanical system (S-mode) SEN00253-01
50 Disassembly and assembly SEN00256-02

General information on disassembly and assembly SEN00257-02
Disassembly and assembly, Part 1 SEN00258-01
2 107E-1 Series
Table of contents 1
00 Index and foreword
Index SEN00163-12
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00164-05

Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00166-09
General.................................................................................................................................... 2
Specifications........................................................................................................................... 3
General view............................................................................................................................ 16
Dimensions table ..................................................................................................................... 36
Engine performance curves..................................................................................................... 37
10 Structure, function and maintenance standard

Structure, function and maintenance standard SEN00168-00
Intake, exhaust system ............................................................................................................... 2
Intake system .......................................................................................................................... 2
Exhaust system ....................................................................................................................... 3
Lubricating oil system.................................................................................................................. 5
Cooling system............................................................................................................................ 9
Fuel system................................................................................................................................. 10
Maintenance standard................................................................................................................. 15
Turbocharger ........................................................................................................................... 15
Cylinder head .......................................................................................................................... 16
Cylinder block .......................................................................................................................... 18
Crankshaft ............................................................................................................................... 20
Piston, piston ring and piston pin............................................................................................. 22
Connecting rod ........................................................................................................................ 23
Vibration damper ..................................................................................................................... 24
Timing gear.............................................................................................................................. 25
Camshaft ................................................................................................................................. 26
Valve and valve guide.............................................................................................................. 28
Rocker arm, shaft and tappet .................................................................................................. 30
Flywheel and flywheel housing................................................................................................ 32
Oil pump .................................................................................................................................. 34
20 Standard value table

Standard service value table SEN00248-09
Standard value table for testing, adjusting and troubleshooting .............................................. 2
Run-in standard and performance test criteria ........................................................................ 14
107E-1 Series 3
30 Testing and adjusting

Testing and adjusting SEN00250-02
Testing and adjusting................................................................................................................... 2
Testing and adjusting tools list ................................................................................................. 2
Testing air boost pressure........................................................................................................ 4
Adjustment of valve clearance................................................................................................. 5
Testing compression pressure ................................................................................................. 7
Testing blow-by pressure ......................................................................................................... 10
Testing engine oil pressure ...................................................................................................... 11
Handling fuel system parts ...................................................................................................... 12
Releasing residual pressure in fuel system ............................................................................. 12
Testing fuel pressure................................................................................................................ 13
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector......................................... 17
Bleeding air from fuel circuit .................................................................................................... 24
Testing fuel system for leakage ............................................................................................... 25
Handling controller high-voltage circuit.................................................................................... 26
40 Troubleshooting
General information on troubleshooting SEN00252-01
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error and failure code table ..................................................................................................... 3

Troubleshooting of electrical system (E-mode), Part 1................................................................ 3
E-1 Code [111/CA111] Abnormality in engine controller .......................................................... 3
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor ................................... 3
E-3 Code [122/CA122] Abnormally high level in charge pressure sensor............................... 4
E-4 Code [123/CA123] Abnormally low level in charge pressure sensor ................................ 6
E-5 Code [131/CA131] Abnormally high level in throttle sensor power supply........................ 8
E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply ......................... 10
E-7 Code [144/CA144] Abnormally high level in coolant temperature sensor......................... 12
E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor .......................... 14
E-9 Code [153/CA153] Abnormally high level in charge temperature sensor ......................... 16
E-10 Code [154/CA154] Abnormally low level in charge temperature sensor......................... 18
E-11 Code [155/CA155] Derating of speed by abnormally high charge temperature .............. 20
E-12 Code [187/CA187] Abnormally low level in sensor power supply 2 ................................ 22
E-13 Code [221/CA221] Abnormally high level in atompspheric pressure sensor .................. 24
E-14 Code [222/CA222] Abnormally low level in atompspheric pressure sensor.................... 26
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2............................... 28
E-16 Code [234/CA234] Engine overspeed............................................................................. 29
E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply ......................... 30
E-18 Code [271/CA271] Short circuit in IMV/PCV1 ................................................................. 31
E-19 Code [272/CA272] Disconnection in IMV/PCV1 ............................................................. 32
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1..................................... 34
E-26 Code [342/CA342] Matching error in engine controller data ........................................... 46

Troubleshooting of electrical system (E-mode), Part 2................................................................ 4
E-27 Code [351/CA351] Abnormality in injector drive circuit ................................................... 4
4 107E-1 Series
E-28 Code [352/CA352] Abnormally low level in sensor power supply 1................................ 6
E-29 Code [386/CA386] Abnormally high level in sensor power supply 1 .............................. 8
E-30 Code [428/CA428] Abnormally high level in water sensor.............................................. 10
E-31 Code [429/CA429] Abnormally low level in water sensor ............................................... 12
E-32 Code [431/CA431] Abnormality in idle validation switch................................................. 14
E-33 Code [432/CA432] Abnormality in idle validation processing ......................................... 16
E-34 Code [435/CA435] Abnormality in engine oil pressure switch ........................................ 18
E-35 Code [441/CA441] Abnormally low power supply voltage .............................................. 20
E-36 Code [442/CA442] Abnormally high power supply voltage ............................................. 22
E-37 Code [449/CA449] Abnormally high common rail pressure 2 ......................................... 24
E-38 Code [451/CA451] Abnormally high level in common rail pressure sensor .................... 26
E-39 Code [452/CA452] Abnormally low level in common rail pressure sensor ..................... 28
E-40 Code [488/CA488] Derating of torque by abnormally high charge temperature ............. 30
E-41 Code [553/CA553] Abnormally high level in common rail pressure sensor 1 ................. 31
E-42 Code [559/CA559] No-pressure feed by supply pump 1 ................................................ 32
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor........................................... 34
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase ............................ 36
E-45 Code [757/CA757] Loss of all data in engine controller .................................................. 38
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor ....................................... 40
E-47 Code [1633/CA1633] Abnormality in KOMNET .............................................................. 42
E-48 Code [2185/CA2185] Abnormally high level in throttle sensor power supply ................. 44
E-49 Code [2186/CA2186] Abnormally low level in throttle sensor power supply................... 45
E-50 Code [2249/CA2249] No-pressure feed by supply pump 2 ............................................ 46
E-51 Code [2311/CA2311] Abnormality in IMV solenoid ......................................................... 48
E-52 Code [2555/CA2555] Disconnection in intake air heater relay ....................................... 50
E-53 Code [2556/CA2556] Short circuit in intake air heater relay ........................................... 52
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction....................... 54
E-55 Code [---/B@BAZG] Derating of torque by engine oil pressure reduction ...................... 54
E-56 Code [---/B@BCNS] Engine overheat............................................................................. 55
Troubleshooting of mechanical system (S-mode) SEN00253-01

Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 9
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations ........................................................................................ 13
S-5 Engine does not rotate smoothly ...................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 17
S-9 Oil becomes contaminated quickly ................................................................................... 18
S-10 Fuel consumption is excessive ....................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 20
S-12 Oil pressure drops........................................................................................................... 21
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 22
S-14 Coolant temperature becomes too high (overheating).................................................... 23
S-15 Abnormal noise is made ................................................................................................. 24
S-16 Vibration is excessive ..................................................................................................... 25
107E-1 Series 5
50 Disassembly and assembly

General information on disassembly and assembly SEN00257-02
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7

Disassembly and assembly......................................................................................................... 2
General disassembly of engine ............................................................................................... 2

Disassembly and assembly, Part 2 ............................................................................................. 2
General assembly of engine .................................................................................................... 2
6 107E-1 Series
107E-1 Series 7
KOMATSU 107E-1 Series Diesel engine
Form No. SEN00163-12
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
8
SEN00164-05
Engine 1SHOP MANUAL
107E-1 Series
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
107E-1 Series 1
Safety notice (Rev. 2008/06)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety plates stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety plates and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 107E-1 Series
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
107E-1 Series 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 107E-1 Series
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
107E-1 Series 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 107E-1 Series
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
107E-1 Series 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 107E-1 Series
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
107E-1 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 107E-1 Series
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
107E-1 Series 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 107E-1 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
107E-1 Series 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 107E-1 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
107E-1 Series 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 107E-1 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
107E-1 Series 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 107E-1 Series
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
107E-1 Series 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engine
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 107E-1 Series
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
107E-1 Series 21
q 95, 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 107E-1 Series
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
107E-1 Series 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (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 –
Cov-
AV Standard – – – – – – – 4.6
er D
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
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 107E-1 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: 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” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
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
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
107E-1 Series 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 107E-1 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
107E-1 Series 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 107E-1 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
107E-1 Series 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 107E-1 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
107E-1 Series 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 107E-1 Series
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
107E-1 Series 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
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 — —
34 107E-1 Series
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
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
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
107E-1 Series 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (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 2.047 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 2.874 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
36 107E-1 Series
Millimeters to inches
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
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 2.874 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
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 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
Liters to U.S. Gallons

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
107E-1 Series 37
Liters to U.K. Gallons

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
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
kgm to ft.lb
1 kgm = 7.233 ft.lb
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
38 107E-1 Series
kg/cm2 to lb/in2
1 kg/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
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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
107E-1 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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
–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
40 107E-1 Series
107E-1 Series 41
SEN00164-05
© 2008 KOMATSU
All Rights Reserved
42
SEN00166-09
Engine 1SHOP MANUAL
107E-1 Series
01 Specification 1
Specification and technical data
General ........................................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
General view ................................................................................................................................................. 16
Dimensions table .......................................................................................................................................... 36
Engine performance curves .......................................................................................................................... 37
107E-1 Series 1
SEN00166-09 01 Specification
General 1
1. Applicable machine
Engine Serial No. Applicable machine

PC200-8, PC200LC-8 Hydraulic excavator
PC220-8, PC220LC-8 Hydraulic excavator
PC270-8 Hydraulic excavator
PC228US-3E0, PC228USLC-3E0 Hydraulic excavator
PC308USLC-3E0 Hydraulic excavator
SAA6D107E-1
WA250-6, WA250PZ-6 Wheel loader
WA320-6, WA320PZ-6 Wheel loader
WA380-6 Wheel loader
BR380JG-1E0 Mobile crusher
PC160LC-7E0, PC160LC-8 Hydraulic excavator
SAA4D107E-1 WA200-6, WA200PZ-6 Wheel loader
D39EX-22, D39PX-22 Bulldozer
2 107E-1 Series
Specifications 1
Engine SAA6D107E-1
Applicable model PC200-8, PC200LC-8

No. of cylinders – Bore × Stroke mm 6 – 107 × 124
Total piston displacement l {cc} 6.69 {6,690}
Firing order — 1–5–3–6–2–4
Overall length mm 1,355
Dimensions
Overall width mm 790

Overall height (excluding exhaust pipe) mm —
Overall height (including exhaust pipe) mm 1,409
116 {155}/2,000
Flywheel horsepower kW{HP}/rpm
(Gross)
Performance
624 {63.6}/1,500
Max. torque Nm{kgm}/rpm
(Gross)
High idle speed rpm 2,060 ± 50
Low idle speed rpm 1,050 ± 25
g/kWh
Min. fuel consumption ratio 223 {166}
{g/HPh}
Dry weight kg 553
Fuel injection system HPCR
—
Fuel injection system control Electronic control type
Lubricating oil amount (refill capacity) l 25.4 (23.1)
Coolant amount l 8.4
Alternator — 24V, 35A
Starting motor — 24V, 4.5kW
Battery — 12V, 110Ah × 2
Turbocharger — HOLSET HX35W
Air compressor — —
Others — —
107E-1 Series 3
Engine SAA6D107E-1
Applicable model PC220-8, PC220LC-8

Dimensions

134 {179}/2,000
(Gross)
Performance
710 {72.4}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
4 107E-1 Series
Engine SAA6D107E-1
Applicable model PC270-8

Dimensions

149 {200}/2,050
(Gross)
Performance
771 {78.6}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
107E-1 Series 5
Engine SAA6D107E-1
Applicable model PC228US-3E0, PC228USLC-3E0

Dimensions

116 {155}/2,000
(Gross)
Performance
624 {63.6}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 553
—
Starting motor — 24V, 4.5kW, 5.5kW
Others — —
6 107E-1 Series
Engine SAA6D107E-1
Applicable model PC308USLC-3E0

Dimensions

149 {200}/2,050
(Gross)
Performance
771 {78.6}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
107E-1 Series 7
Engine SAA6D107E-1
Applicable model WA250-6, WA250PZ-6

Dimensions

104.1 {140}/2,000
(Gross)
Performance
627 {64}/1,400
(Gross)
Low idle speed rpm 825 ± 25
g/kWh
{g/HPh}
Dry weight kg 590
—
Others — —
8 107E-1 Series
Engine SAA6D107E-1

Dimensions

127.3 {171}/2,000
(Gross)
Performance
672 {68.5}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 650
—
Others — —
107E-1 Series 9
Engine SAA6D107E-1
Applicable model WA380-6

Dimensions

143.4 {192}/2,100
(Gross)
Performance
941 {96.0}/1,450
(Gross)
g/kWh
{g/HPh}
Dry weight kg 570
—
Others — —
10 107E-1 Series
Engine SAA6D107E-1
Applicable model BR380JG-1E0

Dimensions

149 {200}/2,050
(Gross)
Performance
771 {78.6}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
107E-1 Series 11
Engine SAA4D107E-1
Applicable model PC160LC-7E0, PC160LC-8

Firing order — 1–3–4–2
Dimensions

90.0 {121}/2,200
(Gross)
Performance
471 {48.0}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 430
—
Lubricating oil amount (refill capacity) l 18 (16)
Coolant amount l 7
Turbocharger — HOLSET HE221W
Others — —
12 107E-1 Series
Engine SAA4D107E-1

Overall length mm 853
Dimensions

95.2 {128}/2,000
(Gross)
Performance
586 {59.8}/1,400
(Gross)
g/kWh
{g/HPh}
Dry weight kg 465
—
Coolant amount l 7
Others — —
107E-1 Series 13
Engine SAA4D107E-1
Applicable model D39EX-22, D39PX-22

Overall length mm 924
Dimensions

Overall height (excluding exhaust pipe) mm 1,233
Overall height (including exhaust pipe) mm —
80.0 {108.7}/2,000
(Gross)
Performance
476 {48.5}/1,500
(Gross)
g/kWh
{g/HPh}
Dry weight kg 455
—
Lubricating oil amount (refill capacity) l 15 (13)
Coolant amount l 7
Alternator — 24V, 35A, 60A (option)
Others — —
14 107E-1 Series
107E-1 Series 15
General view 1
SAA6D107E-1 (Left side view of engine)
Machine model: PC200-8, PC200LC-8
a The shape may differ according to the machine model.
1. Crankshaft center
2. Flywheel housing rear surface
16 107E-1 Series
1
SAA6D107E-1 (Right side view of engine)
107E-1 Series 17
SAA6D107E-1 (Front view of engine)

2. Cylinder center
18 107E-1 Series
SAA6D107E-1 (Rear view of engine)

2. Cylinder center
107E-1 Series 19

Machine model: WA380-6
20 107E-1 Series

107E-1 Series 21

2. Cylinder center
22 107E-1 Series

2. Cylinder center
107E-1 Series 23

Machine model: PC160LC-7E0, PC160LC-8
24 107E-1 Series

107E-1 Series 25

2. Cylinder center
26 107E-1 Series

2. Cylinder center
107E-1 Series 27

28 107E-1 Series

107E-1 Series 29

2. Cylinder center
30 107E-1 Series

2. Cylinder center
107E-1 Series 31

Machine model: D39EX-22, D39PX-22
32 107E-1 Series

107E-1 Series 33

2. Cylinder center
34 107E-1 Series

2. Cylinder center
107E-1 Series 35
Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D
PC200-8 1,355 1,409 427 790
PC220-8 1,355 1,409 427 790
PC270-8 1,355 1,409 427 790
PC228US-3E0 1,355 1,409 427 790
SAA6D107E-1 PC308USLC-3E0 1,355 1,409 427 790
WA250-6, WA250PZ-6 1,067 1,612 427 819
WA320-6, WA320PZ-6 1,044 1,475 479 817
WA380-6 1,101 1,592 407 882
BR380JG-1E0 1,355 1,409 427 790
PC160LC-7E0,
1,104 1,333 382 717
PC160LC-8
SAA4D107E-1
WA200-6, WA200PZ-6 853 1,612 427 819
D39EX-22, D39PX-22 885 1,220 295 619
a These dimensions are given for reference when the engine is set on a test bench.
36 107E-1 Series
Engine performance curves 1

Engine Engine serial No. Machine model Page
PC200-8, PC200LC-8
38
PC228US-3E0, PC228USLC-3E0
PC220-8, PC220LC-8 39
PC270-8
40
SAA6D107E-1 PC308USLC-3E0
WA250-6, WA250PZ-6 41
WA320-6, WA320PZ-6 42
WA380-6 43
BR380JG-1E0 44
PC160LC-7E0, PC160LC-8 45
SAA4D107E-1 WA200-6, WA200PZ-6 46
D39EX-22, D39PX-22 47
107E-1 Series 37
SAA6D107E-1
(Machine model: PC200-8, PC200LC-8, PC228US-3E0, PC228USLC-3E0) 1
Rated output: 116 kW {155 HP}/2,000 rpm (Gross)
Max. torque: 624 Nm {63.6 kgm}/1,500 rpm (Gross)
38 107E-1 Series
SAA6D107E-1 (Machine model: PC220-8, PC220LC-8) 1

107E-1 Series 39
SAA6D107E-1 (Machine model: PC270-8, PC308USLC-3E0) 1

40 107E-1 Series
SAA6D107E-1 (Machine model: WA250-6, WA250PZ-6) 1
Rated output: 104.1 kW {140 HP}/2,000 rpm (Gross)

107E-1 Series 41

42 107E-1 Series
SAA6D107E-1 (Machine model: WA380-6) 1

107E-1 Series 43
SAA6D107E-1 (Machine model: BR380JG-1E0) 1

44 107E-1 Series
SAA4D107E-1 (Machine model: PC160LC-7E0, PC160LC-8) 1

107E-1 Series 45

46 107E-1 Series
SAA4D107E-1 (Machine model: D39EX-22, D39PX-22) 1
Rated output: 79.9 kW {108.7 HP}/2,200 rpm (Gross)

107E-1 Series 47
© 2008 KOMATSU
All Rights Reserved
48
SEN00168-00
Engine 1SHOP MANUAL
107E-1 Series
10 Structure, function and

maintenance standard
Intake, exhaust system ................................................................................................................................... 2
Intake system........................................................................................................................................ 2
Exhaust system .................................................................................................................................... 3
Lubricating oil system ..................................................................................................................................... 5
Cooling system ............................................................................................................................................... 9
Fuel system................................................................................................................................................... 10
Maintenance standard .................................................................................................................................. 15
Turbocharger ...................................................................................................................................... 15
Cylinder head...................................................................................................................................... 16
Cylinder block ..................................................................................................................................... 18
Crankshaft .......................................................................................................................................... 20
Piston, piston ring and piston pin........................................................................................................ 22
Connecting rod ................................................................................................................................... 23
Vibration damper ................................................................................................................................ 24
Timing gear ......................................................................................................................................... 25
Camshaft ............................................................................................................................................ 26
Valve and valve guide ......................................................................................................................... 28
Rocker arm, shaft and tappet.............................................................................................................. 30
Flywheel and flywheel housing ........................................................................................................... 32
Oil pump ............................................................................................................................................. 34
107E-1 Series
SEN00168-00 10 Structure, function and maintenance standard
Intake, exhaust system 1

Intake system 1
General Information
1. Intake air inlet to turbocharger Air is drawn through the air cleaner into the com-
2. Turbocharger air to charge air cooler pressor side of the turbocharger. It is then forced
3. Charge air cooler through the charge air cooler piping to the charge
4. Intake manifold air cooler, the intake air heater (if applicable), and
(integral part of the cylinder head) into the intake manifold. From the intake manifold,
5. Intake valve. air is forced into the cylinders and used for combus-
tion.
2 107E-1 Series
Exhaust system 1
General Information
1. Exhaust valve
2. Exhaust manifold
3. Turbocharger
4. Turbocharger exhaust outlet
The turbocharger uses exhaust gas energy to turn

the turbine wheel. The turbine wheel drives the
compressor impeller, which provides pressurized
air to the engine for combustion. The additional air
provided by the turbocharger allows more fuel to be
injected to increase the power output from the
engine.
The turbine and compressor wheels share a com-

mon shaft (referred to as a rotor assembly), which
is supported by two rotating bearings in the bearing
housing.
Passages in the bearing housing direct filtered,
pressurized engine oil to the shaft bearings and
thrust bearings. The oil is used to lubricate and cool
the rotating components. Oil then drains from the
bearing housing to the engine sump through the oil
drain line.
107E-1 Series 3
Lubricating Oil Consumption and Leaks

Engine lubricating oil is used to lubricate the bear-
ings and provide some cooling for the turbocharger.
The lubricating oil supplied to the turbocharger
through the supply line is at engine operating pres-
sure. A return line connected to the bottom of the
turbocharger routes the lubricating oil back to the
engine lubricating oil pan.
Seal rings are used on each end of the rotor

assembly. The primary function of the seals is to
prevent exhaust gases and compressed air from
entering the turbocharger housing. Lubricating oil
leakage from the seals is rare, but it can occur.
NOTE:
Excessive crankcase pressure will not allow the
oil to drain from the turbocharger. This will load
the bearing housing and allow lubricating oil to
leak past the seal rings and into the engine and
exhaust.
If turbine seal leakage into the exhaust occurs on

engines with a catalyst, check the exhaust restric-
tion during the repair.
4 107E-1 Series
Lubricating oil system 1

General Information
1. Gerotor lubricating oil pump 8. Filter bypass valve

2. From lubricating oil pump 9. Filter bypass valve closed
3. Pressure regulating valve closed 10. Filter bypass valve open
4. Pressure regulating valve open 11. To lubricating oil filter
5. To lubricating oil cooler 12. Full-flow lubricating oil filter
6. To oil pan 13. From lubricating oil filter
7. Lubricating oil cooler 14. Main lubricating oil rifle
Lubrication for the turbocharger
1. Turbocharger lubricating oil supply

2. Turbocharger lubricating oil drain
107E-1 Series 5
Lubrication for the power components
1. From lubricating oil cooler

2. Main lubricating oil rifle
3. To valve train
4. From main lubricating oil rifle
5. To piston-cooling nozzle
6. To camshaft
7. Crankshaft main journal
8. Oil supply to rod bearings
9. Directed piston-cooling nozzle
10. To internal lubrication of air compressor
6 107E-1 Series
Lubrication for the overhead components
1. Main lubricating oil rifle

2. Rocker lever support
3. Transfer slot
4. Rocker lever shaft
5. Rocker lever bore
6. Rocker lever
107E-1 Series 7
Lubrication for the accessory drive
1. Oil feed from block

2. Oil supply to accessory drive
NOTE:
Oil returns to pan through the gear housing.
8 107E-1 Series
Cooling system 1
Flow Diagram
1. Coolant inlet
2. Pump impeller
3. Coolant flow past lubricating oil cooler
4. Coolant flow past cylinders
5. Coolant flow from cylinder block to cylinder
head
6. Coolant flow between cylinders
7. Coolant flow to thermostat housing
8. Coolant bypass passage
9. Coolant flow back to radiator
10. Bypass open
11. Coolant bypass in cylinder head
12. Coolant flow to water pump inlet
107E-1 Series 9
Fuel system 1
General Information
Without electric lift pump
1. From fuel supply tank 11. Fuel rail

2. Water/fuel separator (not mounted on engine) 12. To injectors
3. ECM cooling plate 13. High-pressure connector
4. To fuel gear pump 14. Injector
5. To fuel filter 15. Fuel return from injectors and fuel rail to fuel
6. Fuel filter head filter head
7. Fuel filter 16. Fuel return from high-pressure pump to fuel
8. To high-pressure pump filter head
9. High-pressure pump 17. Fuel return manifold
10. To fuel rail 18. To fuel supply tank.
10 107E-1 Series
Injectors and fuel lines - overview

General Information
q The fuel system is a high-pressure common q The fuel that enters the high-pressure fuel
rail electronically controlled fuel system. The pump is pressurized between 25 and 180 MPa
high-pressure common rail system consists of [255 to 1,837 kg/cm2] by three radial pumping
four main components: Fuel pump gear pump, chambers. An M-Prop valve, or EFC valve, at
high-pressure pump, fuel rail, and injectors. the inlet to the three radial pumping chambers
The high-pressure pump supplies high-pres- regulates the volume of fuel that is allowed to
sure fuel to the fuel rail independent of engine enter the pumping chambers. By regulating the
speed. The high-pressure fuel is then accumu- volume of fuel that is pressurized, the M-Prop
lated in the fuel rail. High-pressure fuel is con- valve uses signals from the ECM to maintain
stantly supplied to the injectors by the fuel rail. the pressure in the fuel rail at a desired level.
The electronic control module (ECM) controls Fuel that is not allowed to enter the three radial
the fueling and timing of the engine by actuat- pumping chambers is directed through the
ing the injectors. Cascade Overflow Valve. The Cascade Over-
q A suction side fuel/water separating filter is flow Valve directs a certain amount of pressure
required. This filter is located off of the engine to the lube channels of the high pressure pump
and contains a hand priming pump. Fuel and then returns the fuel to the fuel tank.
enters the engine at the ECM cooling plate, if q The fuel rail acts as a fuel manifold accumulat-
equipped, and then flows to the fuel pump gear ing and distributing fuel to each of the injector
pump. Using fuel pump gear pump pressure supply lines. Within the fuel rail, there is a fuel
(approximately 0.3 – 1.3 MPa {3.0 – 13.3 kg/ rail pressure sensor that monitors the pressure
cm 2 }), fuel is filtered using an on-engine or provided to the fuel rail from the high-pressure
remotely mounted fuel filter prior to entering fuel pump.
the high-pressure fuel pump. Pressure measured by the fuel rail pressure
sensor is used by the ECM to adjust the fuel
output of the high-pressure pump. The fuel rail
also contains a fuel rail pressure relief valve.
The fuel rail pressure relief valve is a safety
valve used to bleed off excess pressure if the
rail pressure exceeds a preset threshold. Fuel
bled off by the fuel rail pressure relief valve is
returned to the fuel tank through a fuel drain
line connected to the fuel rail.
107E-1 Series 11
q High-pressure common rail fuel systems use

solenoid-actuated injectors. High-pressure fuel
flows into the side of the injector. When the
solenoid is activated, an internal needle lifts
and fuel is injected. The clearances in the noz-
zle bore are extremely small and any dirt or
contaminants will cause the injector to stick.
This is why it is important to clean around all
fuel connections before servicing the fuel sys-
tem. Also, cap or cover any open fuel connec-
tions before a fuel system repair is performed.
q High-pressure fuel is supplied to the injector

from the fuel rail by an injector supply line and
a fuel connector. The fuel connector pushes
against the injector body when the fuel con-
nector nut is tightened. The injector supply line
is then connected to the fuel connector.
q The torque on this fuel connector and the injec-
tor supply lines is critical. If the nut or line is
undertightened, the surfaces will not seal and
a high-pressure fuel leak will result. If the nut is
overtightened, the connector and injector will
deform and cause a high-pressure fuel leak.
This leak will be inside the head and will not be
visible. The result will be a fault code, low
power, or no-start.
12 107E-1 Series
q The fuel connector contains an edge filter that

breaks up small contaminants that enter the
fuel system. The edge filter uses the pulsating
high pressure to break up any particles so that
they are small enough to pass through the
injector.
NOTE:
The edge filters are not a substitute for
cleaning and covering all fuel system con-
nections during repair. Edge filters are not
a substitute for maintaining the recom-
mended engine mounted fuel filter.
q All injectors feed into a common return circuit

contained within the cylinder head. Any excess
fuel is returned to the tank via this drilling in the
cylinder head and return line attached to the
rear of the cylinder head. A back-pressure
valve is located on the back of the cylinder
head where the drain line attaches. The fuel
drain lines may have either a quick-disconnect
fitting or a banjo fitting at ends of the fuel drain
lines.
Each of the fuel drain lines combine together at
the fuel return manifold.
q The electronic control module (ECM) controls
the fueling and timing of the engine by actuat-
ing the solenoids on the injector. An electronic
pulse is sent to the solenoids to lift the needle
and start the injection event. By electronically
controlling the injectors, there is a more pre-
cise and accurate control of fueling quantity
and timing. Also, multiple injection events can
be achieved by electronically controlling the
injectors.
107E-1 Series 13
Maintenance standard 1
Turbocharger 1
Unit: mm
No. Check item Criteria Remedy

Replace bearing
1 Radial play (Play in radial direction) 0.329 – 0.501
parts
Replace thrust
2 End play (Play in axial direction) 0.038 – 0.093
parts
Tightening torque of turbine housing Target (Nm {kgm})

3 Tighten
bolt 26 {2.6}
107E-1 Series 15
Cylinder head 1
16 107E-1 Series
Unit: mm

End-to-End Max. 0.305 Correct by grind-
1 Strain of cylinder head mounting face
Side-to-Side Max. 0.076 ing or replace
Procedure Target (Nm {kgm})

Tightening torque for cylinder head
mounting bolt 1st stage 90 {9.2} Tighten and
2
(Apply molybdenum disulfide or engine 2nd stage 90 {9.2} retighten
oil to threaded part)
3rd stage Retighten 90°
Replace nozzle
3 Projection of nozzle 2.45 – 3.15
or gasket
Tightening torque for injector holder Target (Nm {kgm})

4
mounting bolt 8 {0.8}
Tighten
Tightening torque for head cover mount-
5 24 {2.4}
ing bolt
107E-1 Series 17
Cylinder block 1
18 107E-1 Series
Unit: mm

End-to-End Max. 0.075 Correct by grind-
1 Strain of cylinder head mounting face
Side-to-Side Max. 0.075 ing or replace
Diameter of main bearing metal mount- Replace main

2 87.982 – 88.008
ing hole bearing metal cap
3 Inside diameter of main bearing metal 83.041 – 83.109 Replace bearing
4 Thickness of main bearing metal 2.456 – 2.464 metal
Diameter of cam bushing mounting Correct or replace

5 Max.: 59.248
hole block
Replace cam
6 Inside diameter of cam bushing Max.: 54.164
bushing
Tightening torque for main cap mount- 1st stage 60 {6.1} Tighten and
7 ing bolt
2nd stage 80 {8.2} retighten
(Apply engine oil to threads)
3rd stage Retighten 90°
Tightening torque for oil pan mounting Target (Nm {kgm})

8
bolt 28 {2.8}
Tighten
Tightening torque for crankshaft pulley
9 125 {12.7}
mounting bolt
Inside diameter of cylinder 106.990 – 107.010 Correct by over-
10 Roundness of inside of cylinder Repair limit: 0.038 size or replace
cylinder block
Taper of inside of cylinder Repair limit: 0.076
107E-1 Series 19
Crankshaft 1
20 107E-1 Series
Unit: mm

Replace thrust
1 End play (A) 0.065 – 0.415 bearing metal or
use oversize metal
Outside diameter of main journal 82.962 – 83.013
Use undersize
Roundness of main journal Repair limit: 0.050
journal or replace
2 Taper of main journal Repair limit: 0.013
Replace main
Clearance of main journal 0.04 – 0.12
bearing metal
Outside diameter of crank pin journal 68.962 – 69.013 Use undersize
Roundness of crank pin journal Repair limit: 0.050 journal or replace
3
Replace connect-
Clearance of crank pin journal 0.04 – 0.12 ing rod bearing
metal
Outside diameter of crankshaft gear
4 70.59 – 70.61 Use undersize
journal
crankshaft or
Inside diameter of crankshaft gear jour- replace
5 70.51 – 70.55
nal
107E-1 Series 21
Piston, piston ring and piston pin 1
Unit: mm

Outside diameter of piston
1 107.255 – 107.273 Replace piston
(at right angles to boss)
Top ring 0.33 – 0.43
2 Clearance at piston ring end gap 2nd ring 0.55 – 0.85
Replace piston
Oil ring 0.25 – 0.50
ring or piston
2nd ring 0.040 – 0.110
3 Clearance of piston ring
Oil ring 0.040 – 0.085
4 Outside diameter of piston pin 39.997 – 40.003 Peplace piston or
5 Inside diameter of piston pin bore 40.006 – 40.012 piston pin
22 107E-1 Series
Connecting rod 1
Unit: mm
Replace bushing
Inside diameter of connecting rod
1 40.019 – 40.042 (spare part is
bushing (when bushing is installed)
semi-finished part)
Inside diameter of connecting rod
2 69.05 – 69.10 Replace connect-
bearing
ing rod bearing
3 Thickness of connecting rod bearing 1.955 – 1.968
Inside diameter of connecting rod Replace connect-
4 72.99 – 73.01
bearing mounting hole ing rod
Tightening torque for connecting rod Procedure Target (Nm {kgm})

Tighten and
5 cap mounting bolt 1st stage 60 {6.1}
retighten
(Coat thread of bolt nut with engine oil) 2nd stage Retighten 60°
Replace connect-
6 Side clearance of connecting rod 0.125 – 0.275
ing rod
107E-1 Series 23
Vibration damper 1
Unit: mm

Tighten and
1 Tightening torque of vibration damper 1st stage 50 {5.1}
retighten
2nd stage Retighten 90°
24 107E-1 Series
Timing gear 1
Unit: mm

Backlash of oil pump
A 0.170 – 0.300
gear
Backlash of camshaft
B 0.076 – 0.280
gear
– Backlash of each gear Replace
Backlash of oil pump idler
C 0.170 – 0.300
gear
Backlash of fuel injection
D 0.146 – 0.222
pump gear
107E-1 Series 25
Camshaft 1
Unit: mm

Replace thrust
1 End play 0.100 – 0.360
plate
Outside diameter of camshaft bearing
2 53.095 – 54.045 Correct or replace
journal
Intake 47.175 – 47.855
3 Height of cam
Exhaust 45.632 – 46.312 Replace
4 Thickness of camshaft thrust plate 9.40 – 9.60
Tightening torque of camshaft thrust Target (Nm {kgm})

5
plate mounting bolt 24 {2.4}
Tighten
Tightening torque of camshaft gear
6 36 {3.7}
mounting bolt
26 107E-1 Series
Valve and valve guide 1
28 107E-1 Series
Unit: mm

Intake 0.584 – 1.092 Replace valve or
1 Sunk depth (A) of valve
Exhaust 0.965 – 1.473 valve seat
2 Thickness (B) of valve head Min. 0.79 Replace

Valve Angle Repair limit
Correct or replace
3 Angle of valve seat Intake 30° Judge condition of contact valve, valve seat
Exhaust 45° surface with vacuum test
4 Outside diameter of valve stem 6.96 – 7.01

Replace
5 Diameter of valve guide bore 7.027 – 7.077
Clearance between valve guide and Replace valve or
6 0.017 – 0.117
valve stem valve guide
Depth of valve insert bore
7 34.847 – 34.863 Replace
(standard insert)
107E-1 Series 29
Rocker arm, shaft and tappet 1
30 107E-1 Series
Unit: mm

Replace rocker
1 Outside diameter of rocker arm shaft Min. 21.965
arm shaft
Replace rocker
2 Inner diameter of rocker arm shaft hole Max. 22.027
arm
Clearance between rocker arm shaft Replace rocker
3 Max. 0.062
and rocker arm arm or shaft
Tightening torque of locknut for rocker Target (Nm {kgm})

4 Tighten
arm adjustment screw 24 {2.4}
Valve Repair limit
5 Valve clearance (cold) Intake 0.25 Adjust
Exhaust 0.51
6 Outside diameter of tappet 15.936 – 15.977 Replace tappet
Replace cylinder
7 Inside diameter of tappet hole 16.000 – 16.055
block
Clearance between tappet and tappet Replace tappet or
8 0.023 – 0.119
hole cylinder block
Tightening torque of rocker arm Target (Nm {kgm})

9 Tighten
mounting bolt 36 {3.7}
107E-1 Series 31
Flywheel and flywheel housing 1
32 107E-1 Series
Unit: mm

1 Face runout of flywheel housing Repair limit: 0.20 Reassemble,
2 Radial runout of flywheel housing Repair limit: 0.20 correct
Target (Nm {kgm})

Tightening torque of flywheel housing
3 M10: 49 {5.0} Tighten
mounting bolt
M12: 85 {8.7}
Flywheel Repair limit
For clutch 0.013 / ø25.4
4 Face runout of flywheel Reassemble,
For torque correct
Diameter (actual measurement) × 0.0005
converter
5 Radial runout of flywheel Repair limit: 0.13
Tightening torque of flywheel mounting
Tigthen and
6 bolt 1st stage 30 {3.0}
retighten
(Coat bolt thread with engine oil)
2nd stage Retighten: 60°
107E-1 Series 33
Oil pump 1
Unit: mm

1 Clearance of rotor in axial direction Max. 0.127
Clearance between outer rotor and Replace oil pump
2 Max. 0.178
inner rotor
Tightening torque of oil pump mounting Tigthen and
3 1st stage 8 {0.8}
bolt retighten
2nd stage 24 {2.4}
34 107E-1 Series
© 2005 KOMATSU
All Rights Reserved
36
SEN00248-09
Engine 1SHOP MANUAL
107E-1 Series
20 Standard value table

Standard service value table
Standard value table for testing, adjusting and troubleshooting ..................................................................... 2
Run-in standard and performance test criteria.............................................................................................. 14
107E-1 Series 1
SEN00248-09 20 Standard value table
Standard value table for testing, adjusting and troubleshooting 1

Engine SAA6D107E-1
Applicable machine PC200-8, PC200LC-8

Cate-
Standard value for

gory
Item Measurement conditions Unit Permissible value

new machine
High idle speed rpm 2,060 ± 50 2,060 ± 50
Performance
Engine speed
Low idle speed rpm 1,050 ± 25 1,050 ± 25
Necessary starting At 0°C rpm — —

speed At –20°C rpm — —
kPa Max. 3.73 7.45
Intake resistance At all speed
{mmH2O} {Max. 380} {760}
Intake pressure kPa Min. 140 113
Air intake and exhaust system
At rated horsepower
(Aftercooler inlet) {mmHg} {Min. 1,050} {850}
Exhaust pressure kPa
At rated horsepower — —
(Turbine inlet press.) {mmHg}
Exhaust temperature
At all speed (at 20°C) °C Max. 650 700
(Turbine outlet temp.)
At rated horsepower % Max. 12 22
Exhaust gas color Quick acceleration
% Max. 25 35
(Low idle o high idle)
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
Exhaust valve mm 0.51 0.381 – 0.762
Oil temperature: 40 – 60°C MPa Min. 2.41 1.69
Compression pressure
Engine speed: 250 – 280 rpm {kg/cm } {Min. 24.6} {17.2}
2
Body
kPa Max. 0.98 1.96

Blow-by pressure At rated horsepower
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
(Oil temperature: Min. 80°C)
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
Oil temperature °C 80 – 110 120
(Oil in oil pan)
At continuous rated
Oil consumption ratio % Max. 0.15 0.3
(Ratio to fuel consumption)
Radiator pressure Opening pressure kPa
— —
Cooling system
valve (Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm 1,740 1,740
Fan and alternator belt Deflects when pushed with a

mm Auto-tensioner Auto-tensioner
tension force of 98 N {10 kg}
2 107E-1 Series
Engine SAA6D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

107E-1 Series 3
Engine SAA6D107E-1
Applicable machine PC270-8

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

4 107E-1 Series
Engine SAA6D107E-1
Applicable machine PC228US-3E0, PC228USLC-3E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

107E-1 Series 5
Engine SAA6D107E-1
Applicable machine PC308USLC-3E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

6 107E-1 Series
Engine SAA6D107E-1
Applicable machine WA250-6, WA250PZ-6

Cate-
Standard value for

gory

new machine
Performance
Engine speed
Low idle speed rpm 825 ± 25 825 ± 25

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
(Aftercooler inlet) {mmHg} {Min. 900} {700}
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system
Fan speed At rated engine speed rpm Hydraulically driven on machine side

107E-1 Series 7
Engine SAA6D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

8 107E-1 Series
Engine SAA6D107E-1
Applicable machine WA380-6

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

107E-1 Series 9
Engine SAA6D107E-1
Applicable machine BR380JG-1E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

10 107E-1 Series
Engine SAA4D107E-1
Applicable machine PC160LC-7E0, PC160LC-8

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.381
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

107E-1 Series 11
Engine SAA4D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.382
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

12 107E-1 Series
Engine SAA4D107E-1
Applicable machine D39EX-22, D39PX-22

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
Exhaust temperature
% Max. 25 35
Intake valve mm 0.25 0.152 – 0.382
Valve clearance
2
Body
kPa Max. 0.98 1.96

{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated
— —
Cooling system

107E-1 Series 13
Run-in standard and performance test criteria 1

Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Dynamometer load N {kg} 0 {0} 98 {10} 245 {25} 440 {45} 771 {78.6}
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 116 {155}
a The table gives the standard values for machines without fan.
a The loads for the dynamometer are at an arm’s length of 716 mm.
Performance test criteria

Engine SAA6D107E-1
High idle Low idle
Test item Rated horsepower Max. torque
speed speed
116 ± 5.81 kW/ 624+19.6/–39.2 Nm/
Specification value 2,000 rpm 1,500 ± 100 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {155 ± 8 HP/ {63.6+2/–4 kgm/
2,000 rpm} 1,500 ± 100 rpm}
Speed rpm 2,000 1,500 ± 100 2,060 ± 50 1,050 ± 25
N 771 871
Dynamometer load — —
{kg} {78.6} {88.8}
kW 116
Output (Gross) — — —
{HP} {155}
Nm 624
Torque (Gross) — — —
{kgm} {63.6}
sec/
Fuel consumption 35 — — —
300cc
Coolant temperature °C 75 – 94 75 – 94 75 – 94 75 – 94
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values using the JIS correction factor.
a The output and torque values in the table are the standard values with the fan removed, so they are dif-
ferent from the specification values.
a This table shows the standard values with an air cleaner installed, muffler installed, alternator under no
load.
a The dynamometer load shows the value for an arm length of 716 mm.
a Use ASTM D975 diesel oil as the fuel.
a Use SAE15W-40 as the lubricating oil.
14 107E-1 Series
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Dynamometer load N {kg} 0 {0} 98 {10} 245 {25} 440 {45} 892 {91}
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 134 {179}

Engine SAA6D107E-1
High idle Low idle
speed speed
Specification value 134±6.69 kW/2,000 rpm 710±34.3 Nm/1,500±100 rpm
— 2,160 ± 50 rpm 1,050 ± 25 rpm
(Gross) {179±9 HP/2,000 rpm} {72.4±3.5 kgm/1,500±100 rpm}
Speed rpm 2,000 1,500 ± 100 2,160 ± 50 1,050 ± 25
N 892 991
{kg} {91} {101.0}
kW 134
{HP} {179}
Nm 710
{kgm} {72.4}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
load.
107E-1 Series 15
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
High idle Low idle
speed speed
— 2,180 ± 50 rpm 1,050 ± 25 rpm
Speed rpm 2,050 1,500 ± 100 2,180 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
load.
16 107E-1 Series
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 116 {155}

Engine SAA6D107E-1
High idle Low idle
speed speed
116 ± 5.81 kW/ 624+19.6/–39.2 Nm/
Specification value 2,000 rpm 1,500 ± 100 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {155 ± 8 HP/ {63.6+2/–4 kgm/
2,000 rpm} 1,500 ± 100 rpm}
Speed rpm 2,000 1,500 ± 100 2,060 ± 50 1,050 ± 25
N 771 871
{kg} {78.6} {88.8}
kW 116
{HP} {155}
Nm 624
{kgm} {63.6}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
load.
107E-1 Series 17
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
High idle Low idle
speed speed
— 2,180 ± 50 rpm 1,050 ± 25 rpm
Speed rpm 2,050 1,500 ± 100 2,180 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
load.
18 107E-1 Series
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 104.1 {140}

Engine SAA6D107E-1
High idle Low idle
speed speed
Specification value 104.1 ± 5.2 kW/2,000 rpm 627 ± 31 Nm/1,400 ± 100 rpm
— 2,250 ± 50 rpm 825 ± 25 rpm
(Gross) {140 ± 7.1 HP/2,000 rpm} {64 ± 3.2 kgm/1,400 ± 100rpm}
Speed rpm 2,000 1,400 ± 100 2,250 ± 50 825 ± 25
N 694 875
{kg} {71} {89.4}
kW 104.1
{HP} {140}
Nm 627
{kgm} {64.0}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 294 Min. 98
load.
107E-1 Series 19
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,100
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 127.3 {171}

Engine SAA6D107E-1
High idle Low idle
speed speed
Specification value 127.3 ± 6.4kW/2,000 rpm 672 ± 34 Nm/1,500 rpm
— 2,250 ± 50 rpm 825 ± 25 rpm
(Gross) {171 ± 8.6 HP/2,000 rpm} {68.5 ± 3.5 kgm/1,500 rpm}
Speed rpm 2,000 1,500 2,250 ± 50 825 ± 25
N 853 938
{kg} {87} {95.7}
kW 127.3
{HP} {171}
Nm 672
{kgm} {68.5}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 294 Min. 98
load.
20 107E-1 Series
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,100
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 143.4 {192}

Engine SAA6D107E-1
High idle Low idle
speed speed
Specification value 143.4 ± 7.21kW/2,100rpm 941 ± 47 Nm/1,450 ± 100 rpm
— 2,250 ± 50 rpm 850 ± 25 rpm
(Gross) {192 ± 9.7 HP/2,100 rpm} {96.0± 4.8kgm/1,450 ± 100rpm}
Speed rpm 2,100 1,450 ± 100 2,250 ± 50 850 ± 25
N 911 1,315
{kg} {93} {134.1}
kW 143.4
{HP} {192}
Nm 941
{kgm} {96.0}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
Lubricating oil kPa Min. 294 Min. 193.2 Min. 294 Min. 98
load.
107E-1 Series 21
Run-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
High idle Low idle
speed speed
— 2,330 ± 50 rpm 1,050 ± 25 rpm
Speed rpm 2,050 1,500 ± 100 2,330 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 –110 80 – 110 80 – 110 80 – 110
temperature
load.
22 107E-1 Series
Run-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 90 {121}

Engine SAA4D107E-1
High idle Low idle
speed speed
Specification value 90.0 ± 4.5 kW/2,200 rpm 471 ± 235 Nm/1,500 rpm
— 2,320 ± 30 rpm 1,050 ± 25 rpm
(Gross) {121 ± 6 HP/2,200 rpm} {48.0 ± 24 kgm/1,500 rpm}
Speed rpm 2,200 1,500 2,320 ± 30 1,050 ± 25
N 545 657
{kg} {55.6} {67.0}
kW 90
{HP} {121}
Nm 471
{kgm} {48.0}
sec/
300cc
Lubricating oil
°C 80 – 120 80 – 110 80 – 110 80 – 110
temperature
load.
107E-1 Series 23
Run-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 95.2 {128}

Engine SAA4D107E-1
High idle Low idle
speed speed
Specification value 95.2 ± 4.78 kW/2,000 rpm 586 ± 29 Nm/1,400 rpm
— 2,250 ± 50 rpm 825 ± 25 rpm
(Gross) {128 ± 6.4 HP/2,000 rpm} {59.8 ± 3.0 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,250 ± 50 825 ± 25
N 635 819
{kg} {64.8} {83.5}
kW 95.2
{HP} {129.5}
Nm 586
{kgm} {59.8}
sec/
300cc
Lubricating oil
°C 80 – 120 80 – 110 80 – 110 80 – 110
temperature
load.
24 107E-1 Series
Run-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,200
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 80 {108.7}

Engine SAA4D107E-1
High idle Low idle
speed speed
Specification value 800 ± 4.0 kW/2,200 rpm 476 ± 23.5 Nm/1,500 rpm
— 2,400 ± 50 rpm 975 ± 25 rpm
(Gross) {108.7 ± 5.3 HP/2,200 rpm} {48.5 ± 2.4 kgm/1,500 rpm}
Speed rpm 2,200 1,500 2,400 ± 50 975 ± 25
N 484 664
{kg} {49.4} {67.7}
kW 80.0
{HP} {107}
Nm 476
{kgm} {48.5}
sec/
300cc
Lubricating oil
°C 80 – 120 80 – 110 80 – 110 80 – 110
temperature
load.
107E-1 Series 25
© 2008 KOMATSU
All Rights Reserved
26
SEN00250-02
Engine 1SHOP MANUAL
107E-1 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting ...................................................................................................................................... 2
Testing and adjusting tools list ............................................................................................................. 2
Testing air boost pressure .................................................................................................................... 4
Adjustment of valve clearance ............................................................................................................. 5
Testing compression pressure ............................................................................................................. 7
Testing blow-by pressure ................................................................................................................... 10
Testing engine oil pressure .................................................................................................................11
Handling fuel system parts ................................................................................................................. 12
Releasing residual pressure in fuel system........................................................................................ 12
Testing fuel pressure .......................................................................................................................... 13
Reduced cylinder mode operation ..................................................................................................... 16
No-injection cranking.......................................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector ................................................... 17
Bleeding air from fuel circuit............................................................................................................... 24
Testing fuel system for leakage.......................................................................................................... 25
Handling controller high-voltage circuit .............................................................................................. 26
Replacing the fan belt ........................................................................................................................ 26
107E-1 Series 1
SEN00250-02 30 Testing and adjusting
Testing and adjusting 1

Testing and adjusting tools list 1
Testing and Sym-
Part No. Part name Q'ty Remarks
adjusting item bol
Testing air boost 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
1 795-799-1131 Gear 1
Adjusting valve
C Commercially
clearance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1
Testing compression 2 795-502-1590 Gauge assembly 1
D
pressure 3 795-790-4410 Adapter 1
4 6754-11-3130 Gasket 1
Testing blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
1 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing oil pressure F 2 790-301-1230 Nipple 1
3 799-101-5160 Nipple 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
6732-81-3170 Adapter 1 10 × 1.0 mm o PT1/8
Testing fuel pressure G 2
6215-81-9710 O-ring 1
3 799-401-2320 Hydraulic tester 1
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
Testing leakage from 4 Measuring cylinder 1
available
pressure limiter and
H Commercially
return rate from 5 Stopwatch 1
injector available
Commercially Hose
6 1
available (Inside diameter: ø14 mm)
Commercially Hose
7 1
available (Inside diameter: ø8 mm)
Measuring voltage Commercially
— Circuit tester 1
and resistance available
Removal and installa-
tion of booster pres- Commercially 3.26 mm Hexlobe (TORX) wrench
— Hexlobe (TORX) wrench 1
sure and temperature available (KTC Q4T15 or equivalent)
sensors
Commercially
tion of engine oil — Deep socket 1 27 mm deep socket
available
pressure sensor
tion of engine cool- Commercially 21 mm deep socket
— Deep socket 1
ant temperature available (MITOLOY 4ML-21 or equivalent)
sensor
2 107E-1 Series
Testing and Sym-

Part No. Part name Q'ty Remarks
adjusting item bol
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-7310 T-adapter 1 AWP (12 poles)
799-601-7070 T-adapter 1 AWP (16 poles)
799-601-4100 T-adapter assembly 1 Connected with engine
Diagnosis sensor and 799-799-5530 T-adapter 1 Engine coolant temperature
—
harness 799-601-4230 T-adapter 1 Boost temperature/pressure sensor
799-601-4130 T-adapter 1 Ne sensor, CAM sensor
799-601-4160 T-adapter 1 Hydraulic pressure sensor
799-601-4211 T-adapter 1 Controller (50 poles)
799-601-4140 T-adapter 1 Atmosperic pressure sensor
799-601-4340 T-adapter 1 Pump actuator
799-601-4190 T-adapter 1 Common rail pressure sensor
107E-1 Series 3
Testing air boost pressure 1

a Testing tools for air boost pressure 2. Install nipple [1] of boost gauge kit A and con-
nect it to gauge [2].
Symbol Part No. Part name <4D107E-1> (Aftercooler inlet side)
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
a The test point is subject to machine models.
1. Remove air boost pressure pickup plug (1).

<4D107E-1>
<6D107E-1> (Aftercooler outlet side)
<6D107E-1>
3. Run the engine at the rated output and test the

air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.
4. After finishing testing, remove the measuring

tools and return the removed parts.
4 107E-1 Series
Adjustment of valve clearance 1

a Valve clearance adjusting tools <The following photo shows WA380-6>
Symbol Part No. Part name

1 795-799-1131 Gear
C Commercially
2 Clearance gauge
available
1. Remove cylinder head cover (1).

<The following photo shows 6D107E-1>
3. Rotate the crankshaft forward with tool C1 and

set wide slit (b) on the disc having the revolu-
tion sensor slits at the rear of the crankshaft
pulley to projection top (a) of the front cover.
a Seeing from the air intake manifold side,
set projection top (a) into wide slit (b).
<The following photo shows 4D107E-1>
2. Remove plug (2) from the starting motor top

and install tool C1.
<The following photo shows PC200-8>
k After this positioning, each cylinder is not

set to the top dead center. Take care.
(Each cylinder is set 76 – 88° before the top
dead center.)
q 4D107E-1: No. 1 cylinder or No. 4 cylinder
107E-1 Series 5
4. Adjust the valve clearance according to the fol-

lowing procedure.
a If you cannot move the rocker arms of the
exhaust valves (on the EX side) with the
hand, adjust the valves marked with Q in
the valve arrangement drawing.
a If you can move the rocker arms of the
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
<4D107E-1>
5. Rotate the crankshaft forward by 1 turn with

tool C1 and set wide slit (b) to projection top
(a) according to step 3.
6. Adjust the other valve clearances according to

step 4.
a If the valves marked with Q in the valve
arrangement drawing were adjusted in
step 4, adjust the valves marked with q.
<6D107E-1>
7. After finishing adjustment, remove the adjust-
ing tools and return the removed parts.
k Remove tool C1 without fail.
3 Cylinder head cover mounting nut:
20 – 28 Nm {2.04 – 2.86 kgm}
1) Insert clearance gauge C2 in the clear-

ance between rocker arm (3) and cross-
head (4).
2) Loosen locknut (5) and adjust the valve
clearance with adjustment screw (6).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
gauge lightly.
3) While fixing adjustment screw (6), tighten
locknut (5).
3 Locknut:
20 – 28 Nm {2.04 – 2.86 kgm}
a After tightening the locknut, check the
valve clearance again.
6 107E-1 Series
Testing compression pressure 1

a Testing tools for compression pressure 4. Loosen injector terminal nut (4) and remove
the terminal from the injector.
1 795-799-6700 Puller 5. Move the cylinder to be tested to the compres-
sion top dead center.
2 795-502-1590 Gauge assembly
D a See “Adjusting valve clearance”.
3 795-790-4410 Adapter
4 6754-11-3130 Gasket 6. Remove rocker arm assembly (5).
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C).
a The photos and illustrations show 6D107E-1.
1. Remove cylinder head cover (1).
2. Disconnect injector harness connectors (2) (at

6 places) and move the harnesses.
7. Remove retainer (6) and disconnect fuel inlet
connector (7).
8. Remove holder (8).
9. Remove injector (9).

a Remove the injector using puller D1 and
the impact of slide hammer.
a Do not unclench the upper part of the
injector.
3. Disconnect fuel high-pressure tube (3).
107E-1 Series 7
15. Disconnect all the injector wiring harness con-

nectors.
k If the connectors are not disconnected,
the engine will start during measure-
m ent and tha t w ill be danger o us .
Accordingly, be sure to disconnect
them.
k If the crankshaft is rotated without turn-
ing on the controller, the common rail
is damaged. Accordingly, be sure to
check that the controller is turned ON.
k Cover the disconnected connectors
with a vinyl sheet etc. to prevent elec-
tric leakage and grounding fault.
10. Install gasket D4 to the tip of adapter D3 and
16. Rotate the engine with the starting motor and
connect it to the injector mount.
measure the compression pressure.
a Read the pressure gauge pointer when it
11. Fix adapter D3 with the injector holder.
is stabilized.
a Tighten the holder mounting bolts alter-
nately.
3 Holder mounting bolt:
17. After finishing testing, remove the testing tools
and return the removed parts.
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
a Install the injector and fuel high-pressure
tube according to the following procedure.
12. Connect gauge assembly D2 to adaptor D3.
1) Mate protrusion (a) of the injector with
a Apply a little amount of engine oil to the
notch (b) of the holder, and set the injector
connecting parts of the adapter and gauge
to the cylinder head.
so that air will not leak easily.
a Set the injector with the above mating
position toward the fuel inlet connec-
13. Install rocker arm assembly (5).
3 Rocker arm assembly mounting bolt:
tor insertion side.
36 ± 5 Nm {3.67 ± 0.51 kgm}
14. Adjust valve clearance.

a See “Adjusting valve clearance”.
2) Tighten injector holder mounting bolt (10)

3 to 4 threads.
3) Set fuel inlet connector (7).
a Press it in until you feel the O-ring
clicks in.
4) Install inlet connector (7) with retainer (6)
temporarily.
5) Alternately tighten injector holder mount-
ing bolt (10).
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
8 107E-1 Series
6) Tighten retainer (6) of the fuel inlet con-

nector.
3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}
7) Tighten the sleeve nut of the fuel high-

pressure tube (3) in order of the head side
and common rail side.
3 Sleeve nut:
35 ± 3.9 Nm {3.6 ± 0.4 kgm}
18. After installing the rocker arm assembly, adjust

the valve clearance. For details, see “Adjusting
valve clearance”.
3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
19. Tighten the injector terminal nut with the follow-

ing torque.
3 Terminal nut:
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
Check that the injector wiring harness does not
interfere with the rocker arm.
20. Tighten the head cover mounting nuts to the

following torque.
3 Head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
107E-1 Series 9
Testing blow-by pressure 1

a Testing tool for blow-by pressure

E 799-201-1504 Blow-by checker

a The photo below shows 6D107E-1 as an
example.
1. Install adaptor [1] of blow-by checker E to the

tip of blow-by hose (1).
2. Connect hose [2], and then connect it to adap-

tor [1] and gauge [3].
3. Run the engine at the rated output and test the

blow-by pressure.
machine.

10 107E-1 Series
Testing engine oil pressure 1

a Testing tools for engine oil pressure <4D107E-1 (PC160LC-7) as an example>

1 799-101-5002 Hydraulic tester
2 790-301-1230 Nipple
F
3 799-101-5160 Nipple
4 799-401-2320 Gauge
1. Remove oil pressure pickup plug (1).

<4D107E-1 (PC160LC-7) as an example>
3. Install the nipples to the plug mount in order of

F2 and F3, and connect it to gauge F4.
<6D107E-1 (WA380-6) as an example>
<6D107E-1 (WA380-6) as an example>
4. Run the engine at the rated output and low idle

and test the oil pressure.
machine.
2. Install nipple [1] of hydraulic tester F1 and con-

nect it to gauge F4. (4D107E-1)

107E-1 Series 11
Handling fuel system parts Releasing residual pressure in

1 fuel system 1
a Precautions for testing and maintaining fuel a Pressure is generated in the low-pressure cir-
system cuit and high-pressure circuit of the fuel sys-
The common rail fuel injection system (CRI) tem while the engine is running.
consists of more precise parts than the con- Low-pressure circuit:
ventional fuel injection pump and nozzle. If for- Feed pump – Fuel filter – Fuel supply
eign matter enters this system, it can cause a pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Fuel supply pump – Common rail –
take care more than the past. If dust, etc. Fuel injector
sticks to any part, wash that part thoroughly a The pressure in both low-pressure circuit and
with clean fuel. high-pressure circuit lowers to a safety level
a Precautions for replacing fuel filter cartridge automatically 30 seconds after the engine is
Be sure to use the Komatsu genuine fuel filter stopped.
cartridge. a Before the fuel circuit is tested and its parts are
Since the common rail fuel injection system removed, the residual pressure in the fuel cir-
(CRI) consists of more precise parts than the cuit must be released completely. Accordingly,
conventional fuel injection pump and nozzle, it observe the following.
employs a high-efficiency special filter to pre- k Before testing the fuel system or removing
vent foreign matter from entering it. If a filter its parts, wait at least 30 seconds after stop-
other than the genuine one is used, the fuel ping the engine until the residual pressure
system may have a trouble. Accordingly, never in the fuel circuit is released. (Do not start
use such a filter. the work just after stopping the engine
since there is residual pressure.)
12 107E-1 Series
Testing fuel pressure 1

a Testing tools for fuel pressure <6D107E-1 (PC200-8) as an example>

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
2 (10 × 1.0 mm o PT1/8)
G
6215-81-9710 O-ring
3 799-401-2320 Hydraulic tester
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel 2) Install adapter G2 and nipple [1] of
main filter to the supply pump and in the return hydraulic tester G1 and connect it to oil
circuit from the supply pump through the com- pressure gauge [2].
mon rail and the injector to the fuel tank. a Use an oil pressure gauge of 2.5 MPa
k Since the pressure in the high-pressure cir- {25 kg/cm2}.
cuit from the fuel supply pump through the <4D107E-1 (PC160LC-7) as an example>
common rail to the injector is very high, it
cannot be measured.
1. Testing fuel low-pressure circuit pressure

1) Remove fuel pressure pickup plug (1)
from the fuel main filter fuel inlet.
<4D107E-1 (PC160-7) as an example>
<6D107E-1 (PC200-8) as an example>
107E-1 Series 13
3) Run the engine at low idle and test the fuel 2) Install adapter [4] of hydraulic tester G1
low-pressure circuit pressure. between return manifold (3) and quick
a If the fuel low-pressure circuit pres- coupler (4) and install hydraulic tester G1
sure is in the following range, it is nor- to the center with nipple [1].
mal. a Adapter [4]: 795-790-5200
0.5 – 1.3 MPa
Low idle
{5.1 – 13.3 kg/cm2}
0.3 – 1.1 MPa
Cranking
{3.1 – 11.3 kg/cm2}
k When the engine cannot run, you

may test it by cranking the engine
with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine 20 seconds
or more.
3) While running the engine at low idle, mea-

sure the fuel return circuit pressure.
a If the fuel return circuit pressure is in
the following standard range, it is nor-
mal.
Low idle and Max. 0.02 MPa
cranking {Max. 0.19 kg/cm2}
k If the engine cannot be started, you

may measure while cranking the
engine with the starting motor. Do
not crank the engine for more than
4) After finishing testing, remove the testing continuous 20 seconds to protect
tools and return the removed parts. it, however.
3 Fuel pressure pickup plug:
10 ± 2 Nm {1 ± 0.2 kgm} 4) After finishing measurement, remove the
measuring instruments and return the
2. Checking fuel return circuit pressure removed parts.
(4D107E-1)
1) Disconnect quick coupler (4) of the return
hose connected to the fuel filter of fuel
return manifold (3).
14 107E-1 Series
3. Check of fuel return circuit pressure 4. Measuring fuel negative-pressure circuit

(6D107E-1) pressure
1) Remove fuel pressure pickup plug (2) a The figure below shows 6D107E-1 as an
from the fuel return block. example.
1) Remove joint bolt (2) of fuel hose (1)
between the prefilter and supply pump.
2) Connect nipples [3] and [1] of hydraulic

tester G1 there and connect hydraulic
tester G3. 2) Connect fuel hose (1) to supply pump (3)
a Nipple [3]: 790-301-1181, 07002-11223 by tool J1 instead of joint bolt (2).
a When installing tool J1, fit the gaskets to
both sides of the fuel hose joint.
3 Tool J1:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool J2 to tool J1.
3) Run the engine at low idle and test the fuel

return circuit pressure.
a If the fuel return circuit pressure is in
the following range, it is normal.
Low idle Max. 0.02 MPa 4) Run the engine and measure the circuit
Cranking {Max. 0.19 kg/cm2}
negative pressure at high idle.
Circuit standard negative pressure:
k When the engine cannot run, you Max. –50.7 kPa {–380 mmHg}
may test it by cranking the engine 5) If the negative pressure is higher than the
with the starting motor. To protect standard pressure, the fuel prefilter may
the starting motor, do not continu- be clogged. In this case, replace the fuel
ously crank the engine 20 seconds prefilter and measure again.
or more. 6) After finishing measurement, remove the
4) After finishing testing, remove the testing removed parts.
tools and return the removed parts. 3 Joint bolt (2):
3 Fuel pressure pickup plug: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 15
Reduced cylinder mode operation No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced a Perform the no-injection cranking mode opera-
cylinder mode operation, if the engine speed tion with the engine mounted on the machine
and output do not change from the normal or connected to INSITE (troubleshooting kit).
operation (all-cylinder operation), that cylinder Before performing, see Testing method in the
has 1 or more defects. shop manual for the machine or INSITE (trou-
The possible defects are as follows. bleshooting kit).
q Leakage through cylinder head gasket
q Defective injection
q Defective piston or piston ring
q Defective valve mechanism
(Moving valve system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (trouble-
shooting kit).
Before performing, see Testing method in
the shop manual for the machine or
INSITE (troubleshooting kit).
16 107E-1 Series
Testing leakage from pressure limiter and return rate from injector 1
a Testing tools for leakage from pressure limiter
and return rate from injector

1 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
H Commercially
5 Stopwatch
available
Commercially Hose
6
available (Inside diameter: 14 mm)
Commercially Hose
7 3) Crank the engine for 30 seconds and
available (Inside diameter: 8 mm)
measure the delivery with measuring cyl-
inder H4.
a Prepare a receiver of 20 l for fuel leakage dur- a Adjust the route of the test hose so
ing testing. that it will not slacken and put its end
in an oil receiving pan.
1. Measuring supply pump delivery a Do not crank the engine for more than
(4D107E-1) 30 seconds to protect the starting
1) Loosen clamp (2) of discharge tube (1) of motor in any case other than this
the supply pump and disconnect tube (1). measurement.
a If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)
2) Install test hose H6 to the nipple on the

discharge side of the supply pump.
a Fix the hose with a wire etc.
a Adjust the route of the test hose so
that it will not slacken and put its end
4) After finishing measurement, remove the

removed parts.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
24 ± 4 Nm {2.5 ± 0.4 kgm}
107E-1 Series 17
2. Measuring supply pump return rate

(4D107E-1)
1) Disconnect quick coupler (2) of the return
hose of supply pump (1).

removed parts.
a When measuring the leakage from
2) Install connector H3 and cap nut [1] of the pressure limiter after the supply
tester kit H1 to quick coupler (2) of the pump return rate, return the engine to
return hose to stop the fuel from flowing the normal condition.
out. a When measuring the injector return
a Install the seal washer between con- rate after the supply pump return rate,
nector H3 and cap nut [1]. leave the engine as it is and keep the
3) Install connector H3 to the supply pump hose end in the oil receiving pan.
and connect test hose [2] of tester kit H1.
a Adjust the route of the test hose so 3. Measuring leakage from pressure limiter
that it will not slacken and put its end (4D107E-1)
in an oil receiving pan. 1) Disconnect quick coupler (4) of the return
hose of the pressure limiter from connec-
tor (5) of the pump side.

sure the returning fuel with measuring cyl-
inder H4 for 25 seconds.
a If the leakage from the supply pump
is in the following standard range, it is
normal.
At low idle
Max. 400 cc
(750 rpm)
18 107E-1 Series
2) Install connector H3 and cap nut [1] of 4. Measuring injector return rate (4D107E-1)
tester kit H1 to the return hose to stop the a The injector return rate must be measured
fuel from flowing out. with the pressure limiter return hose con-
3) Connect test hose [2] of tester kit H1 to nected. Accordingly, check that no fuel
the common rail side. leaks from the pressure limiter in advance.
a Adjust the route of the test hose so 1) Referring to "Measuring supply pump
that it will not slacken and put its end return rate", set the supply pump under
in an oil receiving pan. the condition for measurement.
a While the injector return rate is mea-
sured, the fuel flows out of the supply
pump. Accordingly, put the test hose
end on the supply pump in an oil
receiving pan.
2) Disconnect return hose (6) from the mani-
fold.
a Fit the seal washer to the return hose.

sure the leakage from the pressure limiter
with measuring cylinder H4 for 1 minute.
a If the leakage from the pressure lim-
iter is in the following standard range,
it is normal.
Low idle 0 cc (No leakage)
3) Install removed joint bolt (7) and cap nut
[1] of tester kit H1 to the return hose to
prevent the fuel from flowing out.
4) Install connector H3 to the manifold and
connect test hose [3] of tester kit H1.
a Set the test hose so that it will not
slack and put its end in the receiving
pan.

removed parts.
107E-1 Series 19
5) Run the engine at low idle and measure 5. Measuring supply pump delivery
the return rate from the injector in 1 minute (6D107E-1)
with measuring cylinder H4. 1) Loosen clamp (2) of discharge tube (1) of
a If the return rate from the injector is in the supply pump and disconnect tube (1).
Low idle Max. 120 cc/min.
Cranking Max. 90 cc/min.
a The fuel returning from the supply

pump flows out during measurement
of the return rate from the injector.
Accordingly, keep the test hose end
on the supply pump side in the receiv-
ing pan.
k If the engine cannot be started, you
may measure the return rate while
rotating the engine with the start-
ing motor. Do not rotate for more
than 20 seconds continuously, 2) Install test hose H6 to the nipple on the
however, for protection of the start- discharge side of the supply pump.
ing motor. a Fix the hose with a wire etc.

measuring tools and return the removed
parts.
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Crank the engine for 30 seconds and
measure the delivery with measuring cyl-
inder H4.
a Do not crank the engine for more than
30 seconds to protect the starting
motor in any case other than this
measurement.
a If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)
20 107E-1 Series
2) Install connector H3 and cap nut [1] of

tester kit H1 to the return hose to stop the
fuel from flowing out.
3) Connect test hose [2] of tester kit H1 to
the supply pump.

removed parts.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
6. Testing supply pump return rate (6D107E-1) 4) Run the engine at low idle and measure
1) Disconnect return hose (1) of the supply the return rate from the supply pump with
pump. measuring cylinder H4.
a If the return rate from the supply
pump is in the following range, it is
normal.
Low idle Max. 1,000 cc/min.
Cranking Min. 140 cc/min.

or more.
5) After finishing testing, remove the testing

107E-1 Series 21
7. Measuring leakage from pressure limiter

(6D107E-1)
1) Disconnect return hose (2) of the pressure
limiter.
a Keep the seal washer installed to the
connector bolt.

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
8. Testing return rate from injector (6D107E-1)

1) Disconnect return hose (4) from the cylin-
2) Install removed joint bolt (3) and cap nut
der head.
[1] of tester kit H1 to the return hose to
a Fit the seal washer to the connector
prevent the fuel from flowing out.
bolt.
3) Install connector H3 to the common rail
and connect test hose [2] of tester kit H1.
a Set the test hose so that it will not
slack and put its end in the receiving
pan.
2) Install connector H3 to the cylinder head

and connect test hose [2] of tester kit H1
and put its end in an oil receiving pan.
3) Install removed connector bolt (5) and cap
nut [1] of tester kit H1 to the return hose to
4) Run the engine at low idle and measure
prevent fuel leakage.
the leakage in 1 minute with measuring
4) Run the engine at low idle and test the
cylinder H4.
return rate from the injector with measur-
a If the leakage from the pressure lim-
ing cylinder H4.
iter is in the following range, it is nor-
a If the return rate from the injector is in
mal.
0 cc
Low idle Low idle Max. 180 cc/min.
(No leakage)
Cranking Max. 90 cc/min.
22 107E-1 Series

or more.

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 23
Bleeding air from fuel circuit 1

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
a When the priming pump and fuel filter is
remote mounted, bleed air by operating the
priming pump at the remote side.
1. Loosen the knob of the priming pump (1)

(remote mount side) and move it back and
forth.
<The photo shows PC160LC-7 as an example>
a Continue moving the knob until it becomes

hard to move.
(If the main filter is empty, move the knob
60 – 70 times, and the air is bled.)
2. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, air may not be
bled from the low-pressure circuit. In this
case, repeat the above work.
24 107E-1 Series
Testing fuel system for leakage 1

k Very high pressure is generated in the high- 9. Inspect the fuel piping and devices for fuel
pressure circuit of the fuel system. If fuel leakage.
leaks while the engine is running, it is dan- a Check mainly around the high-pressure
gerous since it can catch fire. circuit parts coated with the color checker
After testing the fuel system or removing for fuel leakage.
its parts, test it for fuel leakage according a If any fuel leakage is detected, repair it
to the following procedure. and inspect again from step 2.
a Clean and degrease the engine and the parts a If no fuel leakage is detected, check is
around it in advance so that you can test it eas- completed.
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
107E-1 Series 25
Handling controller high-voltage Replacing the fan belt 1

circuit 1 a The auto-tensioner is provided for the fan belt.
Thus, testing and adjustment of the belt is usu-
ally no necessary.
a Disconnect air conditioner compressor belt
before replacing the fan belt.
1. Insert a wrench to the portion (A) (width across

flats T 12.7 mm) of the tensioner assembly (3),
and rotate it to the opposite to the winding-up
direction to decrease the fan belt (2) tension.
k Make sure that the wrench is secured
at the portion (A) before rotating it.
(The spring of the tensioner assembly
(3) is strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
k The engine controller uses a high-voltage extremely dangerous.)
k After removing the fan belt (2), return
circuit to drive the fuel injector.
Accordingly, the high-voltage circuit is con- the tensioner assembly (3) slowly with
nected to the wiring harnesses and connec- care.
k Be careful not to get your fingers
tors between the engine controller and
injector. caught between the pulley and fan belt
a Normally, the engine controller keeps output- (2) during work.
ting the high voltage to the injector only while
the engine is running and stops outputting
when the engine stops.
k If you touch the high-voltage circuit
directly, you may get an electric shock. To
avoid this, observe the following precau-
tions when testing.
1. The following connectors are used in the high-

voltage circuit.
q Engine controller connector: J1
q Injector intermediate connector:
INJ CYL 1&2, INJ CYL 3&4,
INJ CYL 5&6 (for 6D107E-1
only)
q Injector head terminal (in head cover) 2. Replace the fan belt (2).
q Check each pulley for breakage and crack.
2. When disconnecting or connecting a connector
related to the high-voltage circuit, be sure to
turn the starting switch OFF.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
26 107E-1 Series
107E-1 Series 27
© 2008 KOMATSU
All Rights Reserved
28
SEN00252-01
Engine 1SHOP MANUAL
107E-1 Series
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error and failure code table .................................................................................................................. 3
107E-1 Series 1
SEN00252-01 40 Troubleshooting
General information on troubleshooting 1

Points on troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. Do not rush at disassembling the machine even if a failure occurs.

Otherwise,
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose
the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is nec-
essary to carry out thorough prior investigation and to carry out troubleshooting in accordance with
the fixed procedure.
2. Questions to users and operators
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Inspections before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirmation of failure
Confirm the degree of failure on your own to verify if it is a real failure and the machine is handled or
operated improperly.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Pinpoint high possibility causes according to the results of examinations and inspections of items 2 to 4,
and find the failure location based on the troubleshooting table or troubleshooting flow (chart).
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Radical countermeasures against failure cause
Even if the immediate problem is removed, a similar failure will reoccur unless its root cause is removed.
To prevent reoccurence, examine the reason of the failure cause occurrence and remove the root
cause.
2 107E-1 Series
Error and failure code table 1
Failure code of
Error code of Reference
applicable Trouble
INSITE document No.
machine
111 CA111 Abnormality in engine controller
115 CA115 Abnormality in engine NE and Bkup speed sensors
122 CA122 Abnormally high level in charge pressure sensor
123 CA123 Abnormally low level in charge pressure sensor
131 CA131 Abnormally high level in throttle sensor
132 CA132 Abnormally low level in throttle sensor
144 CA144 Abnormally high level in coolant temperature sensor
145 CA145 Abnormally low level in coolant temperature sensor
153 CA153 Abnormally high level in charge temperature sensor
154 CA154 Abnormally low level in charge temperature sensor
155 CA155 Derating of speed by abnormally high charge temperature
187 CA187 Abnormally low level in sensor power supply 2 circuit
Troubleshooting of
221 CA221 Abnormally high level in atmospheric pressure sensor electrical system
222 CA222 Abnormally low level in atmospheric pressure sensor (E-mode), Part 1
SEN00254-02
227 CA227 Abnormally high level in sensor power supply 2 circuit
234 CA234 Engine overspeed
238 CA238 Abnormality in Ne speed sensor power supply
271 CA271 Short circuit in PCV1
272 CA272 Disconnection in PCV1
322 CA322 Disconnection or short circuit in injector #1 (L/B #1) system
342 CA342 Matching error in engine controller data
351 CA351 Abnormality in injector drive circuit
352 CA352 Abnormally low level in sensor power supply 1 circuit
386 CA386 Abnormally high level in sensor power supply 1 circuit
428 CA428 Abnormally high level in water sensor
429 CA429 Abnormally low level in water sensor
431 CA431 Abnormality in idle validation switch
432 CA432 Abnormality in processing of idle validation
Troubleshooting of
435 CA435 Abnormality in engine oil pressure switch electrical system
441 CA441 Abnormally low power supply voltage (E-mode), Part 2
SEN00255-01
442 CA442 Abnormally high power supply voltage
449 CA449 Abnormally high common rail pressure 2
451 CA451 Abnormally high level in common rail pressure sensor
452 CA452 Abnormally low level in common rail pressure sensor
488 CA488 Derating of torque by abnormally high charge temperature
553 CA553 Abnormally high common rail pressure 1
559 CA559 No-pressure feed by supply pump 1
107E-1 Series 3
Failure code of
Error code of Reference
applicable Trouble
INSITE document No.
machine
689 CA689 Abnormality in engine Ne speed sensor
731 CA731 Abnormality in engine Bkup speed sensor phase
757 CA757 Loss of all data in engine controller
778 CA778 Abnormality in engine Bkup speed sensor
1117 CA1117 Loss of partial data in engine controller
1633 CA1633 Abnormality in KOMNET
2185 CA2185 Abnormally high level in throttle sensor power supply Troubleshooting of
electrical system
2186 CA2186 Abnormally low level in throttle sensor power supply
(E-mode), Part 2
2249 CA2249 No-pressure feed by supply pump 2 SEN00255-01
2311 CA2311 Abnormality in IMV solenoid
2555 CA2555 Abnormally low level intake air heater relay power supply voltage
2556 CA2556 Abnormally high level intake air heater relay power supply voltage
— B@BAZG Derating of speed by engine oil pressure reduction
— B@BAZG Derating of torque by engine oil pressure reduction
— B@BCNS Engine overheat
a Error code of INSITE:

3- or 4-digit error code displayed on INSITE when a failure occurrence condition is confirmed using
INSITE.
a Failure code of applicable machine:
5- or 6-digit failure code displayed on the machine monitor when a failure occurrence condition is con-
firmed using the machine monitor at the applicable machine side.
4 107E-1 Series
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code Failure code

Display on Trouble Problem that appears on engine
Display on
applicable
INSITE
machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of Action taken by engine controller to protect system or devices when engine controller detects
controller trouble
Problem that
appears Problem that appears on engine as result of action taken by engine controller (shown above)
on machine
Related
Information related to detected trouble or troubleshooting
information
Causes Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other
Possible abnormally.
causes and Possible causes of trouble
standard value (Given numbers are refer-
in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
3 bleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female“,
disconnect connector and insert T-adapters in both
male side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
107E-1 Series 5
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
6 107E-1 Series
© 2005 KOMATSU
All Rights Reserved
8
SEN00254-02
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3
E-1 Code [111/CA111] Abnormality in engine controller....................................................................... 3
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor................................................ 3
E-3 Code [122/CA122] Abnormally high level in charge pressure sensor ........................................... 4
E-4 Code [123/CA123] Abnormally low level in charge pressure sensor............................................. 6
E-5 Code [131/CA131] Abnormally high level in throttle sensor power supply .................................... 8
E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply ................................... 10
E-7 Code [144/CA144] Abnormally high level in coolant temperature sensor ................................... 12
E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor..................................... 14
E-9 Code [153/CA153] Abnormally high level in charge temperature sensor .................................... 16
E-10 Code [154/CA154] Abnormally low level in charge temperature sensor ................................... 18
E-11 Code [155/CA155] Derating of speed by abnormally high charge temperature ........................ 20
E-12 Code [187/CA187] Abnormally low level in sensor power supply 2 .......................................... 22
E-13 Code [221/CA221] Abnormally high level in atompspheric pressure sensor............................. 24
107E-1 Series 1
E-14 Code [222/CA222] Abnormally low level in atompspheric pressure sensor .............................. 26
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 ......................................... 28
E-16 Code [234/CA234] Engine overspeed ....................................................................................... 29
E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply.................................... 30
E-18 Code [271/CA271] Short circuit in IMV/PCV1............................................................................ 31
E-19 Code [272/CA272] Disconnection in IMV/PCV1 ........................................................................ 32
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 ............................................... 34
E-26 Code [342/CA342] Matching error in engine controller data...................................................... 46
2 107E-1 Series
Troubleshooting of electrical system (E-mode), Part 1 1

1
E-1 Code [111/CA111] Abnormality in engine controller 1

Trouble Abnormality in engine controller
111 CA111
Contents of
• Abnormality occurred in memory of engine controller or power supply circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears • Engine may stop suddenly or may not be able to start.
on machine
Related
—
information
Possible Causes Standard value in normal state/Remarks on troubleshooting

causes and
standard value Carry out troubleshooting of failure code [CA757].
in normal state
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor 1

Trouble Abnormality in engine Ne, Bkup speed sensor
115 CA115
Contents of
• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears
• Engine does not start
on machine
Related
• Method of reproducing failure code: Start engine.
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed
2 Carry out troubleshooting for failure code [CA778].
sensor system
Possible Defective installation of Ne Ne speed sensor may be installed defectively. Check it directly.
3
causes and speed sensor (Defective installation of sensor, internal defect of flywheel, etc.)
standard value Bkup speed sensor may be installed defectively. Check it directly.
in normal state Defective installation of Bkup
4 (Defective installation of sensor, internal defect of supply pump,
speed sensor
etc.)
Defective connection of Ne speed sensor and Bkup speed sensor may be connected defec-
5
sensor (Wrong connection) tively (wrongly). Check them directly.
If causes 1 - 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
107E-1 Series 3
E-3 Code [122/CA122] Abnormally high level in charge pressure sensor1

Trouble Abnormally high level in charge pressure sensor
122 CA122
Contents of
• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of
• Fixes charge pressure and continues operation.
controller
Problem that
appears • Engine output drops.
on machine
Related
• Method of reproducing failure code: Starting switch ON.
information

Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out trou-
1
ply 2 circuit bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective [pressure signal BOOST PRESS & IMT Voltage
2 circuit] of boost pressure Between (2) – (4) Power supply 4.75 – 5.25 V
sensor, temperature sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V, 24 V circuit) in wiring har-
ness Wiring harness between J1 (female) (44) –
Possible Voltage Max. 1 V
BOOST PRESS & IMT (female) (1)
causes and
a Prepare with starting switch OFF, then carry out troubleshooting
standard value
without turning starting switch ON.
in normal state
Short circuit in wiring harness Wiring harness between J1 (female) (44) –
4
(with another wiring harness) BOOST PRESS & IMT (female) (1) and J1 Resis- Min.
(female) (37) – BOOST PRESS & IMT tance 100 kz
(female) (2)
Connecting parts among boost pressure sensor, temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
5
connector • Loose connector, broken lock, broken seal
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
J1 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
4 107E-1 Series
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
107E-1 Series 5
E-4 Code [123/CA123] Abnormally low level in charge pressure sensor 1

Trouble Abnormally low level in charge pressure sensor
123 CA123
Contents of
• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of
• Fixes charge pressure and continues operation.
controller
Problem that
on machine
Related
information

Defective sensor power If failure code [CA187] is indicated simultaneously, carry out trou-
1
supply 2 circuit bleshooting for it first.
Defective [pressure signal BOOST PRESS & IMT Voltage
2 circuit] of boost pressure Between (2) – (4) Power supply 4.75 – 5.25 V
Ground fault in wiring harness without turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between J1 (female) (44) – Resis- Min.
Possible BOOST PRESS & IMT (female) (1) tance 100 kz
causes and
standard value
in normal state
Short circuit in wiring harness Wiring harness between J1 (female) (44)
4
(with another wiring harness) and BOOST PRESS & IMT (female) (1) and Resis- Min.
J1 (female) (47) and BOOST PRESS & IMT tance 100 kz
(female) (4)
5
J1 Voltage
6 107E-1 Series
107E-1 Series 7
E-5 Code [131/CA131] Abnormally high level in throttle sensor power

supply 1

Trouble Abnormally high level in throttle sensor
131 CA131
Contents of
• High voltage is detected in fuel control dial signal circuit.
trouble
Action of
• Depends on machine model.
controller
Problem that
appears • Depends on machine model.
on machine
Related
information

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
3 V, 24 V circuit) in wiring har-
Possible Wiring harness between J2 (female) (9) –
ness Voltage Max. 1 V
causes and P20 (female) (2)
standard value
in normal state
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between J2 (female) (9) – Resis- Min.
P20 (female) (2) and J2 (female) (22) – P20
tance 100 kz
(female) (1)
Connecting parts among fuel control dial, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 • Loose connector, broken lock, broken seal
connector
J2 Voltage
* The terminal names and Nos. of PC200-8 are shown as examples.
8 107E-1 Series
Circuit diagram related to fuel control dial (PC200-8 as an example)
107E-1 Series 9
E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply1

Trouble Abnormally low level in throttle sensor
132 CA132
Contents of
• Low voltage is detected in fuel control dial signal circuit.
trouble
Action of
controller
Problem that
on machine
Related
information

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
3
Possible (Short circuit with GND circuit) Wiring harness between J2 (female) (9) – Resis- Min.
causes and P20 (female) (2) tance 100 kz
standard value
in normal state
4
(with another wiring harness) Wiring harness between J2 (female) (9) – Resis- Min.
P20 (female) (2) and J2 (female) (23) – P20
tance 100 kz
(female) (3)
connector
J2 Voltage
10 107E-1 Series
Circuit diagram related to fuel control dial (PC200-8 as an example)
107E-1 Series 11
E-7 Code [144/CA144] Abnormally high level in coolant temperature

sensor 1

Trouble Abnormally high level in coolant temperature sensor
144 CA144
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that • Engine does not start easily at low temperature.
appears • Exhaust smoke is white.
on machine • Overheat prevention function does not function.
Related
information

Defective coolant tempera- without turning starting switch ON.
1
ture sensor COOLANT TEMP (Male) Resistance
Between (A) – (B) 0.18 – 160 kz
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between J1 (female) (15) – Resis-
2 (Disconnection in wiring or Max. 10 z
COOLANT TEMP (female) (B) tance
defective contact in connec-
tor) Wiring harness between J1 (female) (38) – Resis-
Max. 10 z
COOLANT TEMP (female) (A) tance
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value
Short circuit in wiring harness Wiring harness among all pins between J1
in normal state 3
(with another wiring harness) (female) (15) – J1 (female) Resis- Min.
(With all connectors of wiring harness dis- tance 100 kz
connected)
Connecting parts among coolant temperature, engine wiring har-
connector
J1 (Female) Resistance
Between (15) – (38) 0.18 – 160 kz
12 107E-1 Series
Circuit diagram related to coolant temperature sensor
107E-1 Series 13
E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor1

Trouble Abnormally low level in coolant temperature sensor
145 CA145
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that • Engine does not start easily at low temperature.
appears • Exhaust smoke is white.
on machine • Overheat prevention function does not function.
Related
information

Defective coolant tempera- COOLANT TEMP (Male) Resistance
1
ture sensor
Between (A) – (B) 0.18 – 160 kz
Between (B) – chassis ground Min. 100 kz
2
COOLANT TEMP (female) (B) tance 100 kz
Possible without turning starting switch ON.
causes and Short circuit in wiring harness Wiring harness among all pins between J1
standard value 3
in normal state
connected)
Connecting parts among coolant temperature, engine wiring har-
connector
5 Defective engine controller J1 (Female) Resistance
Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
14 107E-1 Series
Circuit diagram related to coolant temperature sensor
107E-1 Series 15
E-9 Code [153/CA153] Abnormally high level in charge temperature sensor1

Trouble Abnormally high level in charge temperature sensor
153 CA153
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature
trouble sensor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke is white
appears
• Boost temperature-based engine protection function does not function.
on machine
Related
information

Defective [temperature sig- without turning starting switch ON.
1 nal circuit] of boost pressure
BOOST PRESS & IMT (Male) Resistance
Between (3) – (4) 0.18 – 160 kz
ness
BOOST PRESS & IMT (female) (3) tance
Max. 10 z
BOOST PRESS & IMT (female) (4) tance
standard value Short circuit in wiring harness Wiring harness among all pins between J1
3
in normal state (with another wiring harness) (female) (23) – J1 (female) Resis- Min.
connected)
4
Between (23) – (47) 0.18 – 160 kz
16 107E-1 Series
107E-1 Series 17
E-10 Code [154/CA154] Abnormally low level in charge temperature sensor1

Trouble Abnormally low level in charge temperature sensor
154 CA154
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke is white
appears
• Boost temperature-based engine protection function does not function.
on machine
Related
information

Defective [temperature sig-
1 nal circuit] of boost pressure BOOST PRESS & IMT (Male) Resistance
sensor, temperature sensor Between (3) – (4) 0.18 – 160 kz
2
(Short circuit with GND circuit) Wiring harness between J1 (female) (23) Resis- Min.
and BOOT PRESS & IMT (female) (3) tance 100 kz
3
standard value (with another wiring harness) (female) (23) – J1 (female) Resis- Min.
in normal state (With all connectors of wiring harness dis- tance 100 kz
connected)
4
Between (23) – (47) 0.18 – 160 kz
18 107E-1 Series
107E-1 Series 19
E-11 Code [155/CA155] Derating of speed by abnormally high charge

temperature 1

Trouble Derating of speed by abnormally high charge temperature
155 CA155
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine stops
appears
• Output drops.
on machine
Related
—
information

Inspect following directly.
Drop in cooling performance • Loose, broken fan belt
1
Possible of aftercooler. • Lack of cooling air
causes and • Clogged aftercooler fin
standard value Abnormally high temperature
in normal state 2 Inspect related parts directly.
at turbocharger outlet
If causes 1 – 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
20 107E-1 Series
E-12 Code [187/CA187] Abnormally low level in sensor power supply 21

Trouble Abnormally low level in sensor power supply 2 circuit
187 CA187
Contents of
• Low voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes boost pressure and charge temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
on machine
Related
information

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Disconnect devices Boost pressure,
BOOST PRESS &
at right in order. temperature
IMT
Defective sensor or wiring If mark E of failure sensor
1 code disappears after
harness Common rail
reproduction opera- FUEL RAIL PRESS
pressure sensor
Possible tion is conducted,
causes and that device or Bkup sensor CAM SENSOR
standard value wiring harness has a Engine wiring
J1
in normal state defect in it. harness
Connecting parts among each sensor, engine wiring harness, and
engine controller are suspected. Inspect them directly.
connector
If causes 1 and 2 are not detected, engine controller may be defec-
out.)
22 107E-1 Series
Circuit diagram related to sensor power supply 2
107E-1 Series 23
E-13 Code [221/CA221] Abnormally high level in atompspheric pressure

sensor 1

Trouble Abnormally high level in atmospheric pressure sensor
221 CA221
Contents of
• High voltage is detected in atmospheric pressure sensor
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that
• Engine output drops.
appears
• Starting performance is poor.
on machine
Related
information

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sure sensor
Hot short (Short circuit with and carry out troubleshooting.
3 5 V, 24 V circuit) in wiring
harness Wiring harness between J1 (female) (3) –
Possible Voltage Max. 1 V
AMBAIR PRESSURE (female) (3)
causes and
standard value
in normal state
4
(with another wiring harness) AMBAIR PRESSURE (female) (3) and J1 Resis- Min.
(female) (33) – AMBAIR PRESSURE tance 100 kz
(female) (1)
Connecting parts among atmospheric pressure sensor, engine wir-
ing harness, and engine controller are suspected. Inspect them
Defective wiring harness directly.
5
J1 Voltage
24 107E-1 Series
Circuit diagram related to atmospheric pressure sensor
107E-1 Series 25
E-14 Code [222/CA222] Abnormally low level in atompspheric pressure

sensor 1

Trouble Abnormally low level in atmospheric pressure sensor
222 CA222
Contents of
• Low voltage is detected in atmospheric pressure sensor
trouble
Action of
controller
Problem that
appears
on machine
Related
information

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
sure sensor
3
Possible AMBAIR PRESSURE (female) (3) tance 100 kz
causes and
standard value
in normal state
4
(with another wiring harness) AMBAIR PRESSURE (female) (3) and J1 Resis- Min.
(female) (38) – AMBAIR PRESSURE tance 100 kz
(female) (2)
5
J1 Voltage
26 107E-1 Series
Circuit diagram related to atmospheric pressure sensor
107E-1 Series 27
E-15 Code [227/CA227] Abnormally high level in sensor power supply 21

Trouble Abnormally high level in sensor power supply 2 circuit
227 CA227
Contents of
• High voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes boost pressure and charge temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
on machine
Related
information

Possible engine controller are suspected. Inspect them directly.
causes and 1 • Loose connector, broken lock, broken seal
connector
standard value • Corrosive, bent, broken, forced-in, or extended pin
in normal state • Humidity in connector, entry of dirt or dust, poor insulation
If cause 1 is not detected, engine controller may be defective.
28 107E-1 Series
E-16 Code [234/CA234] Engine overspeed 1

Trouble Engine overspeed
234 CA234
Contents of
• Engine speed is above upper control limit.
trouble
Action of
• Stops injection of injector until engine speed drops to normal level.
controller
Problem that
appears • Engine speed fluctuates.
on machine
Related
• Method of reproducing failure code: Start engine and run it at high idle.
information

Possible 1 Use of improper fuel Check fuel used directly (for high viscosity).
causes and 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
standard value
If causes 1 and 2 are not detected, engine controller may be defec-
in normal state
out.)
107E-1 Series 29
E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply1

Trouble Abnormality in Ne speed sensor power supply
238 CA238
Contents of
• Low voltage is detected in engine Ne speed sensor power supply circuit.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
• Starting performance is poor
appears
• There is hunting from engine.
on machine
Related
information

Disconnect devices
at right in order.
If mark E of failure Ne speed sensor CRANK SENSOR
Defective sensor or wiring
Possible harness
causes and reproduction opera-
standard value tion is conducted,
that device or Engine wiring
in normal state J1
wiring harness has a harness
defect in it.
connector
Circuit diagram related to engine Ne speed sensor
30 107E-1 Series
E-18 Code [271/CA271] Short circuit in IMV/PCV1 1

Trouble Short circuit in IMV/PCV1
271 CA271
Contents of
• There is short circuit in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that • Engine speed does not rise from low idle.
on machine • Common rail fuel pressure is above command value.
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (Male) Resistance
2
CP3 PUMP REGULATOR (female) (1) tance 100 kz
standard value 3
in normal state
connected)
Connecting parts among supply pump actuator, engine wiring har-
connector
Circuit diagram related to supply pump actuator (metering unit)
107E-1 Series 31
E-19 Code [272/CA272] Disconnection in IMV/PCV1 1

Trouble Disconnection in IMV/PCV1
272 CA272
Contents of
• There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that
• Engine speed runs, but in unstable condition.
appears
• Common rail fuel pressure is above command value.
on machine
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (Male) Resistance
Between (1) – (2) Max. 5 z
ness
CP3 PUMP REGULATOR (female) (1) tance
Max. 10 z
Possible 3
24V circuit) in wiring harness Wiring harness between J1 (female) (2) –
causes and Voltage Max. 3 V
CP3 PUMP REGULATOR (female) (1)
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
4
connected)
connector
32 107E-1 Series
107E-1 Series 33
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 1

Trouble Disconnection, short circuit in injector No. 1
322 CA322
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that
• There is irregular combustion or hunting.
appears
• Output drops.
on machine
Related
information

1 Defective injector No. 1 INJ CYL 1 (Male) Resistance
ness
INJ CYL 1 (female) (3) tance
Max. 2 z
3
(Short circuit with GND circuit) Wiring harness between J1 (female) (45) – Resis-
Max. 2 z
causes and
standard value Wiring harness among all pins between J1
in normal state (female) (45) – J1 (female) Resis- Min.
Short circuit in wiring harness (With all connectors of wiring harness dis- tance 100 kz
4
(with another wiring harness) connected)
Wiring harness among all pins between J1
(female) (53) – J1 (female) Resis- Min.
connected)
Connecting parts among injector No. 1, engine wiring harness, and
connector
Defective injector or wiring If failure codes for troubles in multiple injectors, carry out trouble-
6
harness of another cylinder shooting for those codes.
Between (45) – (53) Max. 2 z
34 107E-1 Series
Circuit diagram related to injector No. 1
107E-1 Series 35

323 CA323
Contents of
trouble
Action of
controller
Problem that
appears
• Output drops.
on machine
Related
information

ness
Max. 2 z
3
Max. 2 z
causes and
4
connected)
connector
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
6
injector or wiring harness out troubleshooting for them, too.
Between (46) – (60) Max. 2 z
* This code is not applicable to 4D107E-1.
36 107E-1 Series
107E-1 Series 37

324 CA324
Contents of
trouble
Action of
controller
Problem that
appears
• Output drops.
on machine
Related
information

ness
Max. 2 z
3
Max. 2z
causes and
4
connected)
connector
6
Between (55) – (52) Max. 2 z
38 107E-1 Series
107E-1 Series 39

325 CA325
Contents of
trouble
Action of
controller
Problem that
appears • There is irregular combustion or hunting.
on machine
Related
information

ness
Max. 2 z
3
Max. 2 z
causes and
4
connected)
connector
6
Between (57) – (59) Max. 2 z
* This code is not applicable to 4D107E-1.
40 107E-1 Series
107E-1 Series 41

331 CA331
Contents of
trouble
Action of
controller
Problem that
appears
• Output drops.
on machine
Related
information

ness
Max. 2 z
3
Max. 2 z
causes and
4
connected)
connector
6
Between (54) – (51) Max. 2 z
42 107E-1 Series
107E-1 Series 43

332 CA332
Contents of
trouble
Action of
controller
Problem that
appears
• Output drops.
on machine
Related
information

ness
Max. 2 z
3
Max. 2 z
causes and
4
connected)
connector
6
Between (56) – (58) Max. 2 z
44 107E-1 Series
107E-1 Series 45
E-26 Code [342/CA342] Matching error in engine controller data 1

Trouble Matching error in engine controller data
342 CA342
Contents of
• Matching error occurred in engine controller data.
trouble
Action of
controller
Problem that
appears • Normal operation or engine stops and engine cannot be started.
on machine
Related
information

causes and
standard value Carry out troubleshooting for failure code [CA757].
in normal state
46 107E-1 Series
© 2006 KOMATSU
All Rights Reserved
48
SEN00255-01
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 4
E-27 Code [351/CA351] Abnormality in injector drive circuit ............................................................... 4
E-28 Code [352/CA352] Abnormally low level in sensor power supply 1 ............................................ 6
E-29 Code [386/CA386] Abnormally high level in sensor power supply 1 ........................................... 8
E-30 Code [428/CA428] Abnormally high level in water sensor ........................................................ 10
E-31 Code [429/CA429] Abnormally low level in water sensor.......................................................... 12
E-32 Code [431/CA431] Abnormality in idle validation switch ........................................................... 14
E-33 Code [432/CA432] Abnormality in idle validation processing .................................................... 16
E-34 Code [435/CA435] Abnormality in engine oil pressure switch................................................... 18
E-35 Code [441/CA441] Abnormally low power supply voltage ......................................................... 20
E-36 Code [442/CA442] Abnormally high power supply voltage ....................................................... 22
E-37 Code [449/CA449] Abnormally high common rail pressure 2.................................................... 24
E-38 Code [451/CA451] Abnormally high level in common rail pressure sensor............................... 26
E-39 Code [452/CA452] Abnormally low level in common rail pressure sensor ................................ 28
107E-1 Series 1
E-40 Code [488/CA488] Derating of torque by abnormally high charge temperature........................ 30

E-41 Code [553/CA553] Abnormally high level in common rail pressure sensor 1............................ 31
E-42 Code [559/CA559] No-pressure feed by supply pump 1 ........................................................... 32
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor ..................................................... 34
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase ....................................... 36
E-45 Code [757/CA757] Loss of all data in engine controller............................................................. 38
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor.................................................. 40
E-47 Code [1633/CA1633] Abnormality in KOMNET ......................................................................... 42
E-48 Code [2185/CA2185] Abnormally high level in throttle sensor power supply ............................ 44
E-49 Code [2186/CA2186] Abnormally low level in throttle sensor power supply.............................. 45
E-50 Code [2249/CA2249] No-pressure feed by supply pump 2 ....................................................... 46
E-51 Code [2311/CA2311] Abnormality in IMV solenoid .................................................................... 48
E-52 Code [2555/CA2555] Disconnection in intake air heater relay .................................................. 50
E-53 Code [2556/CA2556] Short circuit in intake air heater relay ...................................................... 52
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction ................................. 54
E-55 Code [---/B@BAZG] Derating of torque by engine oil pressure reduction ................................. 54
E-56 Code [---/B@BCNS] Engine overheat ....................................................................................... 55
2 107E-1 Series
Troubleshooting of electrical system (E-mode), Part 2 1

E-27 Code [351/CA351] Abnormality in injector drive circuit 1

Trouble Abnormality in injector drive circuit
351 CA351
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
Action of
controller
• Exhaust smoke is black
Problem that
• There is irregular combustion.
appears
on machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is burnt out, circuit probably has ground fault.
Defective relay for engine
3 Replace relays for engine controller power supply (R23, R24) with
controller power supply
other relays. If mark E of failure code disappears after reproduction
Possible operation is conducted, that relay has a defect.
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis- Max.
ness (female) (3) tance 0.5 z
4 (Disconnection in wiring or
defective contact in connec- Wiring harness between R23, R24 (female) Resis- Max.
tor) (5) – J3 (female) (3) tance 0.5 z
Wiring harness between J3 (female) (1) – Resis- Max.
chassis ground (T12) tance 10 z
If causes 1 – 4 are not detected, engine controller may be defective.
4 107E-1 Series
Circuit diagram related to engine controller power supply (PC200-8, as an example)
107E-1 Series 5
E-28 Code [352/CA352] Abnormally low level in sensor power supply 11

Trouble Abnormally low level in sensor power supply 1 circuit
352 CA352
Contents of
• Low voltage is detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears
on machine
Related
information

Disconnect devices
at right in order. Atmospheric
If mark E of failure AMBAIR PRESSURE
Defective sensor or wiring pressure sensor
harness
reproduction opera-
Possible tion is conducted,
causes and that device or Engine wiring
J1
standard value wiring harness has a harness
in normal state defect in it.
2
If causes 1 and 2 are not detected, engine controller may be defective.
6 107E-1 Series
107E-1 Series 7
E-29 Code [386/CA386] Abnormally high level in sensor power supply

1 1

Trouble Abnormally high level in sensor power supply 1 circuit
386 CA386
Contents of
• High voltage is detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears
on machine
Related
information

Possible
causes and 1
standard value
in normal state
If cause 1 is not detected, engine controller may be defective.
8 107E-1 Series
E-30 Code [428/CA428] Abnormally high level in water sensor 1

Trouble Abnormally high level in water sensor
428 CA428
Contents of
• High voltage occurred in fuel water sensor
trouble
Action of
controller
Problem that
appears • Water separator monitor does not indicate normally.
on machine
Related
information

1 Defective fuel water sensor
E06 (male) Resistance
Between (1) – (2) 10 – 100 kz
ness
E06 (female) (1) tance
Max. 10 z
E06 (female) (2) tance
standard value
in normal state 3
(With another wiring harness) (female) (14) – J1 (female) Resis- Min.
connected)
Connecting parts among fuel water sensor, engine wiring harness,
and engine controller are suspected. Inspect them directly.
connector
Between (14) – (47) 10 – 100 kz
10 107E-1 Series
Circuit diagram related to fuel water sensor
107E-1 Series 11
E-31 Code [429/CA429] Abnormally low level in water sensor 1

Trouble Abnormally low level in water sensor
429 CA429
Contents of
• Low voltage occurred in fuel water sensor
trouble
Action of
controller
Problem that
appears • Water separator monitor does not indicate normally.
on machine
Related
information

1 Defective fuel water sensor E06 (male) Resistance
Between (1) – chassis ground 10 – 100 kz
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
2
(Short circuit with GND cir- Wiring harness between J1 (female) (14) – Resis- Min.
cuit) E06 (female) (1) and chassis ground tance 100 kz
standard value 3
(With another wiring harness) (female) (14) – J1 (female) Resis- Min.
in normal state
connected)
Connecting parts among fuel water sensor, engine wiring harness,
connector
Between (14) – (47) 10 – 100 kz
12 107E-1 Series
Circuit diagram related to fuel water sensor
107E-1 Series 13
E-32 Code [431/CA431] Abnormality in idle validation switch 1

Trouble Abnormality in idle validation switch
431 CA431
Contents of
• Abnormality occurred in idle validation switch circuit
trouble
Action of
• Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears • Engine speed may not rise from low idle.
on machine
Related
• Method of reproducing failure code: Starting switch ON, accelerator ON.
information

WAS1 (Male) Accelerator pedal Resistance
1 Defective accelerator pedal Release Max. 1 z
Between (5) – (4)
Press Min. 1 Mz
Release Min. 1 Mz
Between (6) – (4)
Press Max. 1 z
Disconnection in wiring har-
ness
WAS1 (female) (5) tance 10 z
defective contact in connec- Wiring harness between J2 (female) (1) – Resis- Max.
tor) WAS1 (female) (6) tance 10 z
Possible Resis- Min.
(female) (11) – J2 (female)
causes and tance 100 kz
(With also WAS1 disconnected)
in normal state Resis- Min.
Short circuit in wiring harness (female) (1) – J2 (female)
3 tance 100 kz
(With another wiring harness) (With also WAS1 disconnected)
Resis- Min.
(female) (11) – J3 (female) (3)
tance 100 kz
Resis- Min.
tance 100 kz
Connecting parts among accelerator pedal, engine unit wiring har-
connector
J2 (Female) Accelerator pedal Resistance
5 Defective engine controller Release Max. 1 z
Between (11) – (32)
Press Min. 1 Mz
Release Min. 1 Mz
Between (1) – (32)
Press Max. 1 z
14 107E-1 Series
Circuit diagram related to accelerator pedal (PC200-8, as an example)
107E-1 Series 15
E-33 Code [432/CA432] Abnormality in idle validation processing 1

Trouble Abnormality in processing of idle validation processing
432 CA432
Contents of
• Abnormality occurred in processing of idle validation switch circuit.
trouble
Action of
• Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears • Engine speed may not rise from low idle.
on machine
Related
• Method of reproducing failure code: Starting switch ON, accelerator ON.
information

1 Defective accelerator pedal WAS1 (Male) Accelerator pedal Resistance
Release 1.5 – 3.0 kz
Between (2) – (1)
Press 0.25 – 1.5 kz
ness
tor) Wiring harness between J2 (female) (9) – Resis- Max.
causes and
standard value Resis- Min.
in normal state 3 tance 100 kz
(With another wiring harness) (With also WAS1 disconnected)
Resis- Min.
tance 100 kz
Connecting parts among accelerator pedal, engine unit wiring har-
connector
5 Defective engine controller J2 (Female) Accelerator pedal Resistance
Release 1.5 – 3.0 kz
Between (22) – (9)
Press 0.25 – 1.5 kz
16 107E-1 Series
Circuit diagram related to accelerator pedal (PC200-8, as an example)
107E-1 Series 17
E-34 Code [435/CA435] Abnormality in engine oil pressure switch 1

Trouble Abnormality in engine oil pressure switch
435 CA435
Contents of
• Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
controller
Problem that
appears • Engine oil pressure switch-based engine protection function does not function.
on machine
Related
• Method of reproducing failure code: Starting switch ON or start engine
information

Defective engine oil pressure
1 OIL PRESSURE SWITCH
switch Resistance
(Male)
Between (1) – body Max. 10 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
defective contact in connec- Wiring harness between J1 (female) (17) – Resis-
Max. 10 z
tor) OIL PRESSURE SWITCH (female) (1) tance
a Troubleshoot with starting switch OFF, then carry out trouble-

Possible
shooting without turning starting switch ON.
causes and
standard value Short circuit in wiring harness Wiring harness among all pins between J1
3
in normal state (With another wiring harness) (female) (17) – J1 (female) Resis- Min.
connected)
Connecting parts among engine oil pressure switch, engine wiring
harness, and engine controller are suspected. Inspect them
4
Between (17) – chassis ground Max. 10 z
Circuit diagram related to engine oil switch
18 107E-1 Series
E-35 Code [441/CA441] Abnormally low power supply voltage 1

Trouble Abnormally low power supply voltage
441 CA441
Contents of
• Low voltage occurred in controller power supply circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears
• Starting performance is poor
on machine
Related
information

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is burnt out, circuit probably has ground fault. (See cause 6.)
operation is conducted, that relay has a defect.
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
ness Max. 10 z
Possible (female) (3) tance
causes and defective contact in connec- Wiring harness between R23, R24 (female) Resis-
Max. 10 z
standard value tor) (5) – J3 (female) (3) tance
in normal state Wiring harness between J3 (female) (1) – Resis-
Max. 10 z
chassis ground (T12) tance
Ground fault in wiring harness Wiring harness between F01-19 – R23, R24 Resis- Min.
6
(Short circuit with GND circuit) (female) (3) and chassis ground tance 100 kz
Wiring harness between R23, R24 (female) Resis-
Max. 10 z
(5) – J3 (female) (3) and chassis ground tance
Resis- Min.
tance 100 kz
(With battery terminal disconnected)
7
(With another wiring harness) Wiring harness among all pins between J3 Resis- Min.
tance 100 kz
Resis- Min.
tance 100 kz
20 107E-1 Series

Connecting parts among fuse No. 19, engine unit wiring harness,
connector
Possible • Corrosive, bent, broken, forced-in, or extended pin
causes and • Humidity in connector, entry of dirt or dust, poor insulation
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and START and carry out troubleshooting.
9 Defective engine controller J3 (Female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
107E-1 Series 21
E-36 Code [442/CA442] Abnormally high power supply voltage 1

(PC200-8, as an example)
Trouble Abnormally high power supply voltage
442 CA442
Contents of
• High voltage (min. 36V) occurred in controller power supply circuit.
trouble
Action of
controller
Problem that
appears • Engine may stop.
on machine
Related
information

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible a Prepare with starting switch OFF, then start the engine and carry
causes and out troubleshooting.
standard value 2 Defective alternator E12 (Male) Engine speed Voltage
in normal state
Between (1) – chas-
Min. medium speed 27.5 – 29.5 V
sis ground
J3 (Female) Voltage
Between (3) – (1) Max. 32 V
22 107E-1 Series
107E-1 Series 23
E-37 Code [449/CA449] Abnormally high common rail pressure 2 1

Trouble Abnormally high common rail pressure 2
449 CA449
Contents of
• Pressure (2) in common rail circuit is abnormally high.
trouble
Action of
controller
Problem that
• Engine sound becomes larger under no load or light load.
appears
on machine
Related
information

Inspect it for air entry directly according to the following procedure.
1) Remove pressure pickup plug (outlet side) from fuel main filter.
2 Air in low-pressure circuit
2) Operate feed pump of fuel pre-fuel filter.
3) Inspect fuel and air from pressure pickup plug for leakage level.
a For check of pressure in fuel return circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Defective fuel return circuit
3 At low idle
device Fuel return circuit Max. 0.02 MPa
or
pressure {Max. 0.19 kg/cm2}
Possible cranking
causes and
a Prepare with starting switch ON, then carry out troubleshooting
standard value
without turning starting switch OFF.
in normal state
Defective common rail Monitoring on
4 Monitoring information
pressure sensor INSITE
Common rail Condition when 0 ± 0.39 MPa
pressure engine stopped {0 ± 4 kg/cm2}
a For testing of leakage from pressure limiter, see TESTING AND
ADJUSTING, Testing leakage from pressure limiter and return
5 Defective pressure limiter rate from injector.
Leakage
At low idle 0 cc (No leakage)
from pressure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
24 107E-1 Series
E-38 Code [451/CA451] Abnormally high level in common rail pressure

sensor 1

Trouble Abnormally high level in common rail pressure sensor
451 CA451
Contents of
• High voltage occurred in common rail pressure sensor.
trouble
Action of
controller
Problem that
• Engine speed or output drops.
appears
• Engine does not start.
on machine
Related
information

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
3 5V, 24V circuit) in wiring har- Wiring harness between J1 (female) (25) –
ness FUEL RAIL PRESS (female) (2) and chassis Voltage Max. 1 V
Possible
causes and ground
standard value a Troubleshoot with starting switch OFF, then carry out trouble-
in normal state shooting without turning starting switch ON.
4
(With another wiring harness) FUEL RAIL PRESS (female) (2) and J1 Resis- Min.
(female) (37) – FUEL RAIL PRESS (female) tance 100 kz
(3)
Connecting parts among common rail pressure sensor, engine wir-
5
J1 Voltage
26 107E-1 Series
Circuit diagram related to common rail pressure sensor
107E-1 Series 27
E-39 Code [452/CA452] Abnormally low level in common rail pressure

sensor 1

Trouble Abnormally low level in common rail pressure sensor
452 CA452
Contents of
• Low voltage occurred in common rail pressure sensor.
trouble
Action of
controller
Problem that
• Engine speed or output drops.
appears
on machine
Related
information

Defective sensor power If failure code [CA187] is indicated simultaneously, carry out trou-
1
supply 2 circuit bleshooting for it first.
FUEL RAIL PRESS Voltage
Defective common rail
pressure sensor
Ground fault in wiring harness
3
Possible FUEL RAIL PRESS (female) (2) and chassis
tance 100 kz
causes and ground
standard value a Troubleshoot with starting switch OFF, then carry out trouble-
in normal state shooting without turning starting switch ON.
4
(With another wiring harness) FUEL RAIL PRESS (female) (2) and J1 Resis- Min.
(female) (47) – FUEL RAIL PRESS (female) tance 100 kz
(1)
Connecting parts among common rail pressure sensor, engine wir-
5
J1 Voltage
28 107E-1 Series
Circuit diagram related to common rail pressure sensor
107E-1 Series 29
E-40 Code [488/CA488] Derating of torque by abnormally high charge

temperature 1

Trouble Derating of torque by abnormally high charge temperature
488 CA488
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of
controller
Problem that
appears • Output drops.
on machine
Related
information

Inspect following directly.
Drop in cooling performance • Loose, broken fan belt
Possible 1
of aftercooler. • Lack of cooling air
causes and • Clogged aftercooler fin
standard value
in normal state Abnormally high temperature
2 Inspect related parts directly.
at turbocharger outlet
30 107E-1 Series
E-41 Code [553/CA553] Abnormally high level in common rail pressure

sensor 1 1

Trouble Abnormally high common rail pressure sensor 1
553 CA553
Contents of
• Voltage (1) in common rail circuit is abnormally high.
trouble
Action of
controller
Problem that
• Engine sound becomes larger under no load or light load.
appears
on machine
Related
information

Possible Inspect following directly for connection of ground terminal.

causes and • Ground terminal (battery (–)) of machine main unit.
Defective connection of
standard value 2 • Ground terminal of engine
ground terminal
in normal state • Ground terminal of engine controller
• Ground terminal of starting motor
Broken O-ring of supply
3 Inspect O-ring directly for breakage.
pump actuator
107E-1 Series 31
E-42 Code [559/CA559] No-pressure feed by supply pump 1 1

Trouble No-pressure feed by supply pump 1
559 CA559
Contents of
• No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or starting performance is poor
appears • Exhaust smoke is black
on machine • Engine output drops.
Related
information

1 Use of improper fuel Fuel used may be improper. Check it directly.
a For contents of troubleshooting, see “Note 1”. For measurement
of pressure in fuel low-pressure circuit, see TESTING AND
ADJUSTING, “Measurement of fuel pressure”.
Fuel supply pump
At high idle
inlet negative pres- Max. –50.7 kPa
(When engine can be
sure (Fuel prefilter {Max. –380 mmHg}
Defective fuel low-pressure started)
2 outlet side)
circuit parts
During cranking
0.3 – 1.1 MPa
(When engine can-
{3.1 – 11.3 kg/cm2}
Fuel main filter inlet not be started)
pressure At low idle
0.5 – 1.3 MPa
(When engine can be
{5.1 – 13.3 kg/cm2}
started)
a For testing of leakage from pressure limiter, see TESTING AND
Possible 3 Defective pressure limiter rate from injector.
causes and Leakage
standard value At low idle 0 cc (No leakage)
from pressure limiter
in normal state
a For testing of return rate from injector, see TESTING AND
rate from injector.
Defective injector At cranking
4 (High-pressure piping in (When engine Max. 90 cc/min.
head included) Return rate from cannot be started)
injector At low idle
(When engine Max. 180 cc/min.
can be started)
a For testing of return rate from supply pump, see TESTING AND
rate from injector.
At cranking
5 Defective supply pump (When engine Max. 140 cc/min.
Return rate from cannot be started)
supply pump At low idle
(When engine Max. 1,000 cc/min.
can be started)
32 107E-1 Series
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Leaking or clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
107E-1 Series 33
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor 1

Trouble Abnormality in engine Ne speed sensor
689 CA689
Contents of
• Abnormality occurred in signals from engine Ne speed sensor.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that • There is hunting from engine.
appears • Starting performance is poor.
on machine • Engine output drops.
Related
information

Defective Ne speed sensor If failure code [CA238] is indicated simultaneously, carry out trou-
1
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Broken engine Ne speed
3 sensor or defective clear- Inspect engine Ne speed sensor for breakage or clearance.
ance
Broken rotation sensing
4 Inspect it for breakage directly.
flywheel
Possible defective contact in connec- Wiring harness between J1 (female) (27) – Resis- Max.
causes and tor) CRANK SENSOR (female) (3) tance 10 z
standard value
in normal state
6
CRANK SENSOR (female) (3) and chassis
tance 100 kz
ground
7 V, 24 V circuit) in wiring har- Wiring harness between J1 (female) (27) –
ness CRANK SENSOR (female) (3) and chassis Voltage Max. 1 V
ground
Wiring harness between J1 (female) (27) –
CRANK SENSOR (female) (3) and J1 Resis- Min.
Short circuit in wiring harness (female) (16) – CRANK SENSOR (female) tance 100 kz
8
(With another wiring harness) (1)
CRANK SENSOR (female) (3) and J1 Resis- Min.
(female) (48) – CRANK SENSOR (female) tance 100 kz
(2)
34 107E-1 Series

Connecting parts among engine Ne speed sensor, engine wiring
Possible 9
causes and • Corrosive, bent, broken, forced-in, or extended pin
standard value • Humidity in connector, entry of dirt or dust, poor insulation
in normal state
J1 Voltage
Circuit diagram related to engine Ne speed sensor
107E-1 Series 35
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase 1

Trouble Abnormality in engine Bkup speed sensor phase
731 CA731
Contents of
• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that • Engine does not start or is difficult to start.
appears • Idle speed is unstable.
on machine • Exhaust smoke is black.
Related
information

Broken engine Ne speed
1 Inspect engine Ne speed sensor for breakage directly.
sensor
Broken engine Bkup speed
2 Inspect engine Bkup speed sensor for breakage directly.
sensor
Inspect it for defect or breakage according to the following proce-
dure.
Defective or broken mount of
1) Set No. 1 cylinder to compression top dead center (align stamp-
3 rotation sensing flywheel on
ing mark).
crankshaft side
2) If tip of Ne speed sensor is aligned with center of oblong hole of
rotation sensing flywheel, it is mounted normally.
Possible
causes and Inspect it for defect or breakage according to the following proce-
standard value dure.
in normal state Defective or broken mount of 1) Set No. 1 cylinder to compression top dead center (align stamp-
4 rotation sensing ring on cam- ing mark).
shaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 thread) of rotation sensing ring can be seen
through sensor mounting hole, it is mounted normally.
Defective timing between
5 Inspect crankshaft and camshaft for timing directly.
crankshaft and camshaft
Inspect following directly for connection of ground terminal.
• Ground terminal (battery (–)) of machine main unit.
Defective connection of
6 • Ground terminal of engine
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
36 107E-1 Series
E-45 Code [757/CA757] Loss of all data in engine controller 1

Trouble Loss of all data in engine controller
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears • Engine stops and sometimes cannot be started.
on machine
Related
information

Loose or corroded battery
2 Inspect battery terminal directly for loose and corrosion.
terminal
a Prepare with starting switch OFF, then turn starting switch OFF
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is burnt out, circuit probably has ground fault.
operation is conducted, that relay has a defect.
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
ness Max. 10 z
(female) (3) tance
defective contact in connec- Wiring harness between R23, R24 (female) Resis-
Max. 10 z
tor) (5) – J3 (female) (3) tance
Max. 10 z
chassis ground (T12) tance
Connecting parts among fuse No. 19, engine unit wiring harness,
connector
8 Defective engine controller J3 (Female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
38 107E-1 Series
107E-1 Series 39
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor 1

Trouble Abnormality in engine Bkup speed sensor
778 CA778
Contents of
• Abnormality is detected in signals of engine Bkup speed sensor.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Problem that
appears
• Output drops.
on machine
Related
information

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Broken engine Bkup speed
Inspect engine Bkup speed sensor directly for breakage or clear-
3 sensor or defective
ance.
clearance
4 Broken rotation sensing ring Inspect it for breakage directly.
Possible 5 (Disconnection in wiring or
causes and defective contact in connec- Wiring harness between J1 (female) (26) – Resis- Max.
tor) CAM SENSOR (female) (3) tance 10 z
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
6
CAM SENSOR (female) (3) and chassis
tance 100 kz
ground
7 V, 24 V circuit) in wiring har- Wiring harness between J1 (female) (26) –
ness CAM SENSOR (female) (3) and chassis Voltage Max. 1 V
ground
Resis- Min.
Short circuit in wiring harness CAM SENSOR (female) (3) and J1 (female)
8 tance 100 kz
(With another wiring harness) (37) – CAM SENSOR (female) (1)
Resis- Min.
CAM SENSOR (female) (3) and J1 (female)
tance 100 kz
(47) – CAM SENSOR (female) (2)
40 107E-1 Series

Connecting parts among engine Bkup speed sensor, engine wiring
Possible 9
causes and • Corrosive, bent, broken, forced-in, or extended pin
standard value • Humidity in connector, entry of dirt or dust, poor insulation
in normal state
J1 Voltage
Circuit diagram related to engine Bkup speed sensor
107E-1 Series 41
E-47 Code [1633/CA1633] Abnormality in KOMNET 1

Trouble Abnormality in KOMNET
1633 CA1633
Contents of • Engine controller detected abnormality in KOMNET communication circuit to controllers on applica-
trouble ble machine side.
Action of • Depends on machine model.
controller • If problem is removed, circuit is returned to normal operating state.
Problem that • KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears of machine.
on machine (Problem depends on failure occurrence location.)
Related
information

Wiring harness between CM02 (female) (8)
Disconnection in wiring har-
(9) – C01 (female) (45), CM02 (female) (8) Resis-
ness Max. 1 z
(9) – J2 (female) (46), CM02 (female) (8) (9) tance
– K02 (female) (A)
tor) Wiring harness between CM02 (female) (10)
– C01 (female) (64), CM02 (female) (10) – Resis-
Max. 1 z
J2 (female) (47), CM02 (female) (10) – K02 tance
(female) (B)
(9) – C01 (female) (45), CM02 (female) (8)
Resis-
(9) – J2 (female) (46), CM02 (female) (8) (9) Min. 1 Mz
tance
Ground fault in wiring harness – K02 (female) (A), CM02 (female) (8) (9) –
2
(Short circuit with GND circuit) N08 (male) (3)
Possible – C01 (female) (64), CM02 (female) (10) –
causes and Resis-
J2 (female) (47), CM02 (female) (10) – K02 Min. 1 Mz
standard value tance
(female) (B), CM02 (female) (10) – N08
in normal state (male) (10)
(9) – C01 (female) (45), CM02 (female) (8)
Max.
(9) – J2 (female) (46), CM02 (female) (8) (9) Voltage
Hot short (Short circuit with 5.5 V
– K02 (female) (A), CM02 (female) (8) (9) –
3 24 V circuit) in wiring har-
N08 (male) (3)
ness
– C01 (female) (64), CM02 (female) (10) –
Max.
J2 (female) (47), CM02 (female) (10) – K02 Voltage
5.5 V
(female) (B), CM02 (female) (10) – N08
(male) (10)
Defective terminal resistance without turning starting switch ON.
4 (Internal short circuit, discon-
K02 (Male) Resistance
nection)
Between (A) – (B) 47 – 67 z
5 Defective pump controller
42 107E-1 Series
Circuit diagram related to KOMNET communication (PC200-8, as an example)
107E-1 Series 43
E-48 Code [2185/CA2185] Abnormally high level in throttle sensor power

supply 1

Trouble Abnormally high level in throttle sensor power supply
2185 CA2185
Contents of
• High voltage (min. 5.25 V) occurred in throttle sensor power supply circuit.
trouble
Action of
controller
Problem that
on machine
Related
information

Resis- Min.
1 tance 100 kz
(With another wiring harness) (With also P20 disconnected)
Possible Wiring harness among all pins between J2
causes and Resis- Min.
standard value tance 100 kz
(With also P20 disconnected)
in normal state
connector
Circuit diagram related to fuel control dial (PC200-8, as an example)
44 107E-1 Series
E-49 Code [2186/CA2186] Abnormally low level in throttle sensor power

supply 1

Trouble Abnormally low level in throttle sensor power supply
2186 CA2186
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Action of
controller
Problem that
on machine
Related
information

Ground fault in wiring harness shooting without turning starting switch ON.
1
P20 (female) (1) tance 100 kz
Possible Short circuit in wiring harness
2
causes and (With another wiring harness) Wiring harness among all pins between J2 Resis- Min.
standard value (female) (9) – J2 (female)
tance 100 kz
in normal state (With also P20 disconnected)
connector
Circuit diagram related to fuel control dial (PC200-8, as an example)
107E-1 Series 45
E-50 Code [2249/CA2249] No-pressure feed by supply pump 2 1

Trouble No-pressure feed by supply pump 2
2249 CA2249
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Action of
controller
Problem that • Starting performance is poor
appears • Exhaust smoke is black
on machine • Output drops.
Related
information

causes and
standard value 1 Carry out troubleshooting for failure code [CA559].
in normal state
46 107E-1 Series
E-51 Code [2311/CA2311] Abnormality in IMV solenoid 1

Trouble Abnormality in IMV solenoid
2311 CA2311
Contents of
• Resistance in supply pump actuator is abnormally high or low.
trouble
Action of
controller
Problem that
on machine
Related
information

Defective supply pump CP3 PUMP REGULATOR (Male) Resistance
2
actuator
ness
Possible tor) Wiring harness between J1 (female) (32) – Resis-
Max. 5 z
causes and CP3 PUMP REGULATOR (female) (2) tance
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state Ground fault in wiring harness without turning starting switch ON.
4
CP3 PUMP REGULATOR (female) (1) tance 100 kz
connector
48 107E-1 Series
107E-1 Series 49
E-52 Code [2555/CA2555] Disconnection in intake air heater relay 1

Trouble Disconnection in intake air heater relay
2555 CA2555
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function (Poor starting performance, white exhaust smoke at low temper-
appears
ature)
on machine
Related
• Method of reproducing failure code: Starting switch ON when coolant temperature is –4°C or less.
information

without turning starting switch ON. (Test relay unit).
R18 (Male) Resistance
Between (1) – (2) 300 – 600 z
Defective auto preheat relay
1 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection)
and carry out troubleshooting. (Test by replacing relay unit.)
Replace auto preheat relay (R18) with other relay. If mark E of fail-
ure code disappears after reproduction operation is conducted, that
relay has a defect.
ness
Possible R18 (female) (1) tance 10 z
causes and Wiring harness between J2 (female) (42) – Resis- Max.
tor)
standard value R18 (female) (2) tance 10 z
in normal state
3
tance 100 kz
(With also R18 disconnected)
Connecting parts among auto preheat relay, engine unit wiring har-
connector
Between (40) – (42) 300 – 600 z
50 107E-1 Series
Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)
107E-1 Series 51
E-53 Code [2556/CA2556] Short circuit in intake air heater relay 1

Trouble Short circuit in intake air heater relay
2556 CA2556
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function.
appears
(Poor starting performance, white exhaust smoke at low temperature)
on machine
Related
• Method of reproducing failure code: Starting switch ON when coolant temperature is –4°C or less.
information

without turning starting switch ON. (Test relay unit).
R18 (Male) Resistance
Between (1) – (2) 300 – 600 z
Defective auto preheat relay
1 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection)
and carry out troubleshooting. (Test by replacing relay unit.)
Replace auto preheat relay (R18) with other relay. If mark E of fail-
ure code disappears after reproduction operation is conducted, that
relay has a defect.
2
Possible (Short circuit with GND circuit) Wiring harness between J2 (female) (40) – Resis- Min.
causes and R18 (female) (1) tance 100 kz
standard value
in normal state
3
tance 100 kz
(With also R18 disconnected)
Connecting parts among auto preheat relay, engine unit wiring har-
connector
Between (40) – (42) 300 – 600 z
52 107E-1 Series
Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)
107E-1 Series 53
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure

reduction 1

Trouble Derating of speed by engine oil pressure reduction
--- B@BAZG
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
on machine
Related
information

causes and This fault is indicated on only machine side when detected.
standard value Carry out troubleshooting on
1 Accordingly, contents of troubleshooting depend on machine
in normal state machine side
model. See Shop manual for machine.
E-55 Code [---/B@BAZG] Derating of torque by engine oil pressure

reduction 1

Trouble Derating of torque by engine oil pressure reduction
--- B@BAZG
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
on machine
Related
information

1 Accordingly, contents of troubleshooting depend on machine
model. See Shop manual for machine.
54 107E-1 Series
E-56 Code [---/B@BCNS] Engine overheat 1

Trouble Engine overheat
--- B@BCNS
Contents of
• Engine coolant temperature is above operating range.
trouble
Action of
controller
Problem that
on machine
Related
information

1 Accordingly, contents of troubleshooting depend on machine model.
See Shop manual for machine.
107E-1 Series 55
© 2005 KOMATSU
All Rights Reserved
56
SEN00253-01
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start..................................................................................................................... 9
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 17
S-9 Oil becomes contaminated quickly .............................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 20
S-12 Oil pressure drops ..................................................................................................................... 21
107E-1 Series 1
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 22

S-14 Coolant temperature becomes too high (overheating) .............................................................. 23
S-15 Abnormal noise is made ............................................................................................................ 24
S-16 Vibration is excessive ................................................................................................................ 25
2 107E-1 Series
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
4 107E-1 Series
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
107E-1 Series 5
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 107E-1 Series
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
107E-1 Series 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

Improper selection of fuel
Defective or deteriorated battery

q
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element
Clogged fuel filter, element

fuel injection timing electrically. Accordingly, even if the
Worn piston ring, cylinder

starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w Q Q
Oil must be added more frequently w

When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not w
While engine is cranked flow out
with starting motor,
Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w

some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
8 107E-1 Series
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Seized parts inside engine
o See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

Carry out troubleshooting

on applicable machine
There is not voltage (20 – 30 V) between battery relay terminal B q
and terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected, q

engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are
connect cord, and carry out q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start q
When terminal at safety switch and terminal B at starting motor are

connected, engine starts q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
107E-1 Series 9
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes
Defective operation of overflow valve (Does not close)

out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump MPROP
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Replacement of filters has not been carried out according to Operation and w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-
q q
mode
Carry out troubleshooting according to “Abnormality in supply pump PCV (*2)” in E-
q
mode
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
*1: Code [559/CA559] and code [2249/CA2249] in E mode

*2: Code [271/CA271] and code [272/CA272] in E mode
10 107E-1 Series
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

q Insufficient supply of fuel
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

w w
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
If air bleeding plug of fuel filter is removed, fuel does not Q w

While engine is cranked with flow out
starting motor,
If spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Inspect fuel filter directly q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is q
installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
107E-1 Series 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Improper selection of fuel
q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray


Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
w w
Manual
Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
12 107E-1 Series
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Problem in drive devices on applicable machine

side
o Carry out troubleshooting for devices on
Broken, seized piston, connecting rod

applicable machine
Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Condition when engine w Q Q Q Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation w w
and Maintenance Manual
Fuel level monitor indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply
pump (*1)” in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)

q
is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
—
107E-1 Series 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Degree of use of machine Operated for long period E
Occurs at a certain speed range Q Q
Questions
Occurs at low idle Q Q Q Q Q

Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in E-mode q
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in E-mode q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Code [689/CA689] in E-mode

*2: Code [778/CA778] in E-mode
14 107E-1 Series
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Insufficient supply of fuel
Defective installation of boost pressure sensor

q
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)“

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red (if indicator is installed) w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting engine, temperature of
w w
some cylinders is low
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-
q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)”
q
in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

107E-1 Series 15
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head



o See “S-14 Coolant temperature becomes too high
(Overheating)“

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler

electrical system)
Abnormally worn injector

Improper injection timing
Clogged, seized injector
Suddenly became black w w Q Q Q
Color of exhaust gas is Gradually became black w Q Q
Questions

Non-specified fuel is being used Q Q
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E- q
mode
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

16 107E-1 Series
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of pats in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased w Q

Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
107E-1 Series 17
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
18 107E-1 Series
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.

Defective fuel supply pump oil seal
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective spray by injector
Improper injection timing

Questions
More than for other machines of same model Q Q Q Q

Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Troubleshooting
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E-mode q
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

107E-1 Series 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
power train oil cooler on applicable

Broken cylinder head, head gasket
q Internal leakage in cooling system
Broken oil cooler core, O-ring
Broken hydraulic oil cooler or

Cracks inside cylinder block
Holes caused by pitting
machine side
Questions
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q Carry out

shooting
Trouble-
troubleshooting
Inspect cylinder block directly q q on applicable
Pressure-tightness test of oil cooler shows there is leakage q machine
Replace
Replace
Replace
Replace
Remedy —
20 107E-1 Series
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear or lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q

(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy —
107E-1 Series 21
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in clutch chamber or damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
22 107E-1 Series
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too Causes
high
Defective radiator cap (pressure valve)
Rise in power train oil temperature on

Defective coolant temperature gauge
q Lack of cooling air (deformation, damage of fan)
Defective operation of thermostat

Drop in heat dissipation efficiency
Slipping fan belt, worn fan pulley

q
Clogged, crushed radiator fins

q Problem in coolant circulation system
Clogged, broken oil cooler

Rise in oil temperature in power train
Broken fan pulley bearing

q
applicable machine side

o Carry out troubleshooting on applicable machine
Clogged radiator core

Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Coolant temperature gauge Rises quickly Q Q w

(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed) Q w
Engine oil level has risen, oil is milky w w Q

Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged

with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w

Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)

Inspect cylinder block directly q q
Carry out troubleshooting
Inspect oil cooler directly q

on applicable machine
Temperature difference between upper and lower tanks of radiator is large q

Troubleshooting
When operation of thermostat is carried out, it does not open at cracking q

temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
107E-1 Series 23
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
When exhaust manifold is touched immediately after starting engine, temperature of
Check items
some cylinders is low w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
24 107E-1 Series
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature

Abnormal combustion
Broken output shaft, parts in damper on applicable machine side

q
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for “S-15 Abnormal noise is made“, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
107E-1 Series 25
© 2005 KOMATSU
All Rights Reserved
26
SEN00257-02
Engine 1SHOP MANUAL
107E-1 Series
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 1
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tools list.................................................................................................................................... 7
107E-1 Series 1
SEN00257-02 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1 Removal
q The “Removal” section contains procedures,
1. Removal and installation of assemblies precautions and the amount of oil or coolant to
Special tools be drained.
q As to the special tools needed for removal q Various symbols used in the “Removal” section
and installation, symbols such A1···X1 are are explained and listed below.
k : Precautions related to safety in execution
attached in the table along with respective
part numbers, part names and quantity. of work.
q In addition to the above, the list of special a : This mark gives guidance or precautions
tools contains the following information. when doing the procedure.
1) Necessity [*1] : This mark shows that there are instructions
t: Special tools that cannot be substi- or precautions for installing parts.
tuted and should always be used
6 This mark shows oil or coolant to be drained.
(installed).
q: Special tools that will be useful if 4 : Weight of part or component
available and are substitutable with
commercially available tools. Installation
2) Distinction of new and existing special q Except where otherwise instructed, installation
tools of parts is done in the r evers e order of
N: Tools newly developed for this model. removal.
They respectively have a new part q Instructions and precautions for installing parts
number. are shown with [*1] mark in the “Removal” sec-
R: Tools with upgraded part numbers. tion, identifying which step the instructions are
They are remodeled from already intended for.
available tools for other models. q As to the multi purpose tools used in installa-
Blank: Tools already available for other tion, the numbers such [1], [2]··· are given.
models. They can be used without Their part numbers, part names and quantity
any modification. are not described.
3) Circle mark (Q) in sketch column: q Marks shown in the “Installation” section stand
q A circle mark means that a sketch of for the following.
the special tool is presented in the
section of Sketches of special tools. of work.
q Part No. of special tools starting with a : This mark gives guidance or precautions
79*T means that they are locally when doing the procedure.
2 : Type of coating material
made parts and as such not inter-
3 : Tightening torque
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
5 : Quantity of oil or coolant to be added
a As to the multi purpose tools used in
removal and installation, the numbers Sketches of special tools
such [1], [2]··· are given. Their part num- q Various special tools are illustrated for the con-
bers, part names and quantity are not venience of local manufacture.
described.
2 107E-1 Series
2. Disassembly and assembly of assem- Assembly

blies q In “Assembly” section, the work procedures,
Special tools precautions and know-how for carrying out
q As to the special tools needed for disas- those procedures, and quantity of the oil and
sembly and assembly, symbols such coolant added are described.
A1···X1 are attached along with respective q As to the multi purpose tools used in assembly,
part numbers, part names and quantity. the numbers such [1], [2]··· are given. Their
q In addition to the above, the list of special part numbers, part names and quantity are not
tools contains the following information. described.
1) Necessity q Various symbols used in “Assembly” section
t: Special tools that cannot be substi- are explained and listed below.
tuted and should always be used k : Precautions related to safety in execution
(installed). of work
q: Special tools that will be useful if a : This mark gives guidance or precautions
available and are substitutable with when doing the procedure.
commercially available tools. 2 : Type of coating material
2) Distinction of new and existing special 3 : Tightening torque
tools 5 : Quantity of oil or coolant to be added
N: Tools newly developed for this model.
They respectively have a new part
Sketches of special tools
number.
R: Tools with upgraded part numbers. q Various special tools are illustrated for the con-
They are remodeled from already venience of local manufacture.
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a sketch of
the special tool is presented in the
section of Sketches of special tools.
q Part No. of special tools starting with
79*T means that they are locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
a As to the multi purpose tools used in dis-

assembly and assembly, the numbers
such [1], [2]··· are given. Their part num-
bers, part names and quantity are not
described.
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q Various symbols used in the “Disassembly”
section are explained and listed below.
of work.
a : This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or coolant to be drained.
107E-1 Series 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent falling off of rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube
ber cushions, and cork plugs.
• Used for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene • Features: Resistant to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
Adhesive:
790-129-9060
1 kg
LT-3 Set of adhesive Can • Used to stick and seal metal, glass, and plastics.
Hardener:
and hardener
500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs for drilled holes.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant sealant used to repair engines.
• Quick-setting adhesive.
Three Bond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-hardening type. (max. strength is obtained
790-129-9130 2g
201 container after 30 minutes of application)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistant to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions of high temperatures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic pipes.
• Features: Silicon-based heat and cold-resistant
Gasket sealant
sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flanged surfaces and threaded por-
tions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-hardening sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat-resistant, vibration-
Three Bond
419-15-18131 100 g Tube resistant and impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
4 107E-1 Series
Cate- Komatsu
gory code
• Used to lubricate sliding portions (for preventing
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
squeaking)
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
G0-LI(*)
SYG2-160LI Various Various • General purpose type.
*: For cold
SYGA-160CNLI
districts
SYG0-400LI-A(*)
SYG0-16CNLI(*)
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
• Used for parts under heavy load.
Molybdenum Caution:
SYG2-400M 400 g × 10
disulfide lubri- Bellows-type • Do not use this grease for ball bearings such
Grease
SYG2-400M-A 400 g × 20
cant LM-G as swing circle bearing.
SYGA-16CNM 16 kg Can
(G2-M) • Apply this grease to work equipment pins only
when installing but do not use it after then.
SYG2-400T-A
Hyper white
SYG2-16CNT • Seizure resistance and heat resistance higher
grease
SYG0-400T-A 400 g Bellows-type than molybdenum disulfide grease.
G2-T, G0-T(*)
(*) 16 kg Can • Not conspicuous on machine since its color is
*: For cold
SYG0-16CNT white.
districts
(*)
Bio grease
SYG2-400B
G2-B, G2-
SYGA-16CNB
BT(*) • Since this grease is decomposed by natural bacte-
SYG2-400BT 400 g Bellows-type
*For use at ria in short period, its impacts on microorganisms,
(*) 16 kg Can
high tempera- animals, and plants are minimized.
SYGA-16CNBT
ture under
(*)
high load
SUNSTAR
• Used as primer for cab side.
PAINT Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
ture)
SUPER
417-926-3910
SUNSTAR
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
Adhesive for cab glass
ture)
SUPER
SUNSTAR • Used as primer for painted surface on cab
Primer
PAINT Glass side.

22M-54-27230 20 ml
PRIMER 435- container (Using limit: 4 months after date of manufac-
95 ture)
SUNSTAR • Used as primer for black ceramic-coated sur-
GLASS face on glass side and for hard polycarbon-
22M-54-27240 150 ml Steal can
PRIMER 435- ate-coated surface. (Using limit: 4 months
41 after date of manufacture)
SUNSTAR
• Used as primer for sash (processing of Alu-
SASH Glass
22M-54-27250 20 ml mite surface) (Using limit: 4 months after date
PRIMER GP- container
of manufacture)
402
107E-1 Series 5
Cate- Komatsu
gory code
SUNSTAR • “S” is used for high-temperature season (April
PENGUINE – October) and “W” for low-temperature sea-
Polyethylene
SEAL 580 417-926-3910 320 ml son (October – April) as adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manufac-
“W” ture)
Adhesive
Sika Ltd., • Used as adhesive for glass.

Polyethylene
Japan, Sikaf- 20Y-54-39850 310 ml (Using limit: 6 months after date of manufac-
container
lex 256HV ture)
Adhesive for cab glass

SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
SUPER 560 container) ture)
SUNSTAR
• Used to seal joint of glasses.
PENGUINE Polyethylene
417-926-3920 320 ml (Using limit: 4 months after date of manufac-
SEAL No. container
ture)
Caulking material
2505
SEKISUI SIL- • Used to seal front window.
Polyethylene
ICON SEAL- 20Y-54-55130 333 ml (Using limit: 6 months after date of manufac-
container
ANT ture)
GE TOSHIBA • Used to seal joint of glasses
SILICON Translucent white seal
22M-54-27220 333 ml Cartridge
TOSSEAL (Using limit: 12 months after date of manufac-
381 ture)
6 107E-1 Series
Special tools list 1

a Tools with part number 79QT - QQQ - QQQQ cannot be supplied (they must be locally manufactured)
a Necessity : t ------ Cannot be substituted, should always be installed (used)
: q ------ Extremely useful if available, can be substituted with commercially available part
a New / Remodel : N ------------Tools newly developed for this model and given new part Nos.
: R ------------Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank-------Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools
(See Sketches of special tools)
a Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are
CUMMINS part Nos.
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
790-501-2001
A Repair stand t 1
795-799-1150
Disassembly and assembly Specialized for Komatsu
of engine assembly — N
repair stand
B Adapter t 1
Specialized for CUMMINS
795-799-7210 N
repair stand
Removal and installation of 795-102-2103
C Spring pusher q 1
air intake and exhaust valves 795-799-8800 N
Removal and installation of
D 795-100-2800 Piston ring tool t 1
piston ring
Installation of piston E 795-921-1100 Piston holder t 1 φ75 – 175 mm
Removal of injector F 795-799-6700 Puller t 1 N
G 795-799-6500 Seal driver q 1 N
rear seal
H 795-799-6400 Seal driver q 1 N
front seal
790-331-1120 Wrench (angle)
Angle tightening of bolt J q 1
795-799-2240 Angle gauge
Commercially
Adjusting valve clearance K Clearance gauge q 1
available
Adjusting gear backlash and Commercially
L Dial gauge and stand q 1
end play available
Removal of fuel inlet
M 795-799-8150 Remover q 1 N
connector
U 795-799-2270 Remover and installer q 1
main bearing
Rotation of crankshaft V 795-799-1131 Barring tool q 1
Tightening of injector har-
W 795-799-7110 Torque wrench q 1 N
ness nut
Measurement of cylinder
X 795-790-4510 Gauge q 1 N
head bolt length
107E-1 Series 7
SEN00257-02
© 2006 KOMATSU
All Rights Reserved
8
SEN00258-01
Engine 1SHOP MANUAL
107E-1 Series

Disassembly and assembly, Part 1
Disassembly and assembly ............................................................................................................................ 2
General disassembly of engine............................................................................................................ 2
107E-1 Series 1
Disassembly and assembly 1

General disassembly of engine 1 2. Installation to engine repair stand
1) Install tool B to engine assembly (1).
a This disassembly manual is a general disas- q Mounting bolt on engine side M12 x
sembly manual for the SAA4D107E-1 and 1.75
3 Mounting bolt:
SAA6D107E-1 engines. Since the shapes,
numbers, locations, etc. of the parts depend on 77 ± 12 Nm {7.9 ± 1.2 kgm}
each applicable machine, check them before 2) Sling engine assembly (1) and install it to
starting the work. tool A.
4 Engine assembly:
a The photos and illustrations show the 6D107E-
1, unless otherwise specified. Approx. 430 kg (4D107E-1)
(Weight depends on each appli-
1. Preparation work cable machine)
4 Engine assembly:
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it Approx. 520 kg (6D107E-1)
generally and carefully for accurate inspection (Weight depends on each appli-
of its parts and quick disassembly and assem- cable machine)
bly. 3) Drain the engine coolant and engine oil.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts, 6 Engine oil:
and wiring connectors so that water will Approx. 16 l (4D107E-1)
6
not enter them. Engine oil:
1) Prepare stable 2 engine stands (Blocks Approx. 23 l (6D107E-1)
[1]) for the right and left and secure the
engine assembly on them so that it will not <4D107E-1>
tip over.
2) Remove oil gauge assembly (2).
<4D107E-1>
<6D107E-1>
<6D107E-1>
2 107E-1 Series
3. Starting motor assembly 5. Fan pulley

Remove mounting bolt (1) and then remove 1) Remove fan belt (1).
starting motor assembly (2). q Insert a wrench to the portion (A)
<4D107E-1> (width across flats T 12.7 mm) of the
tensioner assembly (2), and rotate it
to the opposite to the winding-up
direction to decrease the fan belt (1)
tension, then remove.
k Make sure that the wrench is
secured at the portion (A) before
rotating it. (The spring of the ten-
sioner assembly (2) is strong. If the
wrench is loosely inserted, the
wrench may accidentally come off
w h i l e b e i n g r o ta t e d a n d i t i s
extremely dangerous.)
k After removing the fan belt (1),
return the tensioner assembly (2)
<6D107E-1> slowly with care.
caught between the pulley and fan
belt (1) during work.
2) Remove bolt (3) and then remove fan pul-
ley (4).
4. Engine sling bracket on rear side

Remove rear engine sling bracket (1) from the
cylinder head.
6. Vibration damper and crankshaft pulley

q 4D107E-1 (Without damper)
Remove bolts (1) and crankshaft pulley
(2).
<4D107E-1>
107E-1 Series 3
q 6D107E-1 (With damper) 9. Alternator

Remove bolts (1) and vibration damper 1) Remove plate (1).
(2). 2) Remove bolt (2) and then remove alterna-
<6D107E-1> tor (3).
7. Belt tensioner 3) Remove alternator bracket (4) and front

Remove bolt (1) and then remove belt ten- side sling bracket (5).
sioner (2).
10. Thermostat
8. Fan hub 1) Remove coolant outlet connector (1).
Remove 4 bolts (1) and then remove fan hub <4D107E-1>
(2).
4 107E-1 Series
<6D107E-1> 12. Turbocharger and exhaust manifold

<4D107E-1>
1) Remove turbocharger heat insulation
cover (1) and lubricating oil inlet tube (2).
<4D107E-1>
2) Remove thermostat (2).
2) Remove head cover (5) and oil return tube

flange bolt (on the head cover side).
3) Remove turbocharger assembly mount-
ing nuts (3) and place turbocharger
assembly (4) on the stud bolts.
<4D107E-1>
11. Water pump

1) Remove coolant inlet connector (1).
2) Remove water pump (2).
107E-1 Series 5
4) Since there is not sufficient clearance on 2) Remove turbocharger assembly (3) and
the exhaust manifold side, move turbo- exhaust manifold (4).
charger assembly (4) to the right and <6D107E-1>
remove the flange bolts (6) of drain tube
(7) with hexagonal wrench [1].
<4D107E-1>
13. Fuel filter assembly

<4D107E-1>
Since the fuel prefilter and main filter are
5) Remove exhaust manifold (10). installed to the chassis, they do not need to be
<4D107E-1> removed for general disassembly of the
engine.
<6D107E-1>
1) Disconnect hoses (1) and (2) from the fil-
ter.
2) Disconnect drain hose (3) from filter
bracket (4).
3) Remove fuel filter assembly (5).
q Removal of hose
While pressing the adapter (by the
right and left sides) at the hose end,
pry off the hose end face with a
screwdriver.
k The internal parts of the adapter
may be damaged when the hose is
removed. Accordingly, do not
(6D107E-1) reuse the adapter but use new one
1) Remove turbocharger lubricating oil inlet when installing the hose again, as
tube (1) and drain tube (2). a rule.
<6D107E-1> <6D107E-1>
6 107E-1 Series
<6D107E-1> <4D107E-1>
<6D107E-1>
14. Harness assembly
Disconnect the harness from the sensor and
controller, and then remove the clamp to
remove harness assembly (1).
16. Air intake manifold cover

1) Remove tube (1) and electrical intake air
heater (2).
2) Remove manifold covers (3) and (4).
<4D107E-1>
15. Fuel high-pressure piping and common rail
1) Remove boots (9) of high-pressure pip-
ings (1) to (7) and then remove the high-
pressure pipings.
2) Remove fuel drain hose (8).
3) Remove common rail (10).
q Removal of hose
Remove the hose by prying the hose
end face with screwdriver while push-
ing the mouthpiece (on both sides) of
the hose termination.
k Do not use the hose again,
because inside of the mouthpiece
removed. Use a new hose when
assembling.
107E-1 Series 7
<6D107E-1> 4) Remove bolt (5) and then remove rocker

housing assembly (6).
17. Head cover and rocker housing

1) Remove duct (1). 18. Rocker arm assembly and crosshead
2) Remove nuts (2) and then remove head 1) Remove bolts (1) and rocker arm assem-
cover (3). bly (2).
a Loosen the locknut and then loosen
the adjustment screw fully so that the
tension of the valve spring will not be
applied to the rocker arm assembly
mounting bolts.
2) Remove crosshead (3).
3) Remove nuts (4) of the harness from

injector.
a Harness installation position

Color of cable Cylinder No.
White 1, 3, 5 a Record the position of the crosshead
Black 2, 4, 6 and the shapes of holes "a" and "b"
(to install the crosshead in the same
Note: No.5 and 6 cylinders are equipped direction again).
with 6D107E-1 only.
8 107E-1 Series
19. Push rod 21. Cylinder head assembly

Remove push rods (1). Remove bolts (1) and cylinder head assembly
(2).
4 Cylinder head assembly:
50 kg (4D107E-1)
4 Cylinder head assembly:
70 kg (6D107E-1)
20. Fuel injector assembly

1) Remove retainer (5) and then remove 6
inlet connectors (1).
q Use tool M when removing the inlet
connector.
2) Remove mounting bolts (3) of injector (2)
and then remove holder (4). q Disassemble the cylinder head assembly
3) Remove injector (2). according to the following procedure.
1) Using tool C, compress valve spring (3) to
remove valve cotter (4).
a Lift and remove the injector using tool

F. (Don't try to pry the top of the injec-
tor.) 2) Remove upper seat (5) and valve spring
(3).
107E-1 Series 9
3) Raise the cylinder head assembly, pull 2) Remove mounting bolts (6), cover (2) and
and remove valve (6) and then remove cover gasket (3).
valve seal (7). 3) Remove oil cooler (4) and cooler gasket
a Apply a marking to valve (6) to make (5).
it identifiable to which cylinder head it
should be combined.
23. Engine controller

1) Remove engine controller (1).
2) Disconnect ground cable (2).
22. Oil cooler
1) Remove oil filter (1). (When filter is
installed to engine)
a The oil filter of 4D107E-1 is installed
to the chassis.
3) Remove cooling plate (3).
10 107E-1 Series
24. Fuel supply pump 26. Rear oil seal

1) Remove hose (1). 1) Install tool G to the crankshaft.
2) Remove 3 nuts (2) and then remove sup- 2) Screw in tapping screw [1] of tool G to the
ply pump (3). seal carrier section of rear oil seal (1).
<4D107E-1> 3) Turn the handle counterclockwise to
remove rear oil seal (1).
<6D107E-1>
25. Flywheel 27. Flywheel housing

Install guide bolt [1] and then remove flywheel Remove bolts (1) and then remove flywheel
(1). housing (2).
4 Flywheel: 35 kg
k Take care in this operation so that your
fingers may not be damaged by the fly-
wheel that can fall off from the shallow
spigot joint.
107E-1 Series 11
28. Oil pan 30. Oil pump assembly

1) Remove bolts (1) and then remove oil pan Remove bolts (1) and then remove oil pump
(2). assembly (2).
2) Remove suction tube (3). 31. Camshaft

3) Remove plate (4) and 3 plates (5). a Rotate the crankshaft to align punch mark
a Plates (5) are not installed in 4D107E-1. A on camshaft gear (1) to the chamfered
tooth of crankshaft gear (4) (preventing of
interference with the connecting rod when
removing the camshaft).
29. Front cover

1) Remove bolts (1) and then remove front
cover (2).
1) Remove gear (1).
2) Remove front seal (3).
12 107E-1 Series
2) Remove thrust plate (2). 33. Piston and connecting rod assembly
1) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
2) Scrub the carbon off the top wall of the cyl-
inder liner with fine sandpaper.
3) Apply a marking to each of connecting rod
cap (1) assembly position on respective
cylinders.
a Before removing the piston and con-
necting rod assembly, measure the
side clearance between the connect-
ing rod and crankshaft using tool K.
3) Rotate camshaft (3) when removing the

plate.
4) Remove bolt (2).

5) Hit connecting rod cap (1) with a plastic
hammer lightly, and remove connecting
rod cap (1) and connecting rod bearing as
a unit.
a Keep the connecting rod and connecting
32. Gear housing rod cap so that their mating faces will not
Remove bolts (1) and then remove gear hous- be damaged.
ing (2). If their mating faces are damaged, replace
them.
107E-1 Series 13
6) Push in and remove the piston and con- 4] Using tool D, remove piston ring (7).
necting rod assembly with a wood bar, etc. a Keep the piston, connecting rod,
from the oil pan side, while supporting pis- connecting rod bearing, piston
ton (6) on the cylinder head side. rings, and piston pin by cylinder.
a Take care in the removal so that inner
surface of the cylinder liner may not
be damaged by corners of the con-
necting rod.
a Make a cylinder No. mark on the pis-
ton.
34. Crankshaft
a Before removing the crankshaft, measure
its end play X with dial gauge.
7) Remove the other piston and connecting

rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
q Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove snap ring (3).
2] Separate piston (6) from connecting
rod by pulling out piston pin (5) while
supporting connecting rod (4) with
1) Remove mounting bolts (2) of main cap
hand.
(1).
3] Remove the snap ring on the oppo-
2) Insert the bolts in the bolt holes of main
site side.
cap (1) and remove the cap, while shaking
it.
a Installation position numbers are
marked on the main cap. No. 1 starts
from the front side of the cylinder
block.
14 107E-1 Series
<4D107E-1> 3) Remove bottom lower bearing (3) from

main cap (1).
a Mark the installation position number
on claw (A) of the removed bearing.
(Don't apply the number on the sliding
surface of the bearing.)
<6D107E-1>
4) Lift off crankshaft (4) using the nylon sling.

a When lifting and removing the crank-
shaft, take care not to damage it by
bumping against the cylinder block.
a Keep the crankshaft in a safe place
so that its sliding portions will not be
damaged.
4 Crankshaft: 45 kg (4D107E-1)
a Check that the position No. of the
main cap (stamped at part A) is
directed toward the oil cooler.
107E-1 Series 15
5) Remove upper thrust bearing (5) and 36. Tappet

upper bearings (6). Remove tappets (1) and then mark the installa-
tion position on them.
a When reusing the camshafts and tappets,
be sure to install them in the original posi-
tion.
Mark the assembly position on the main

cap, upper bearing and upper thrust bear-
ing (in the claw of the bearing). It is
advised to maintain the bearings of a main
cap separately from that for another main 37. Cylinder block
cap. And take care not to damage these Remove cylinder block (1) from tool A.
parts. 4 Cylinder block: 100 kg (4D107E-1)
4 Cylinder block: 140 kg (6D107E-1)
35. Piston cooling nozzle
Remove bolt (1) and then remove piston cool-
ing nozzles (2).
16 107E-1 Series
SEN00258-01
© 2006 KOMATSU
All Rights Reserved
18
SEN00259-02
Engine 1SHOP MANUAL
107E-1 Series

Disassembly and assembly, Part 2
Disassembly and assembly, Part 2 ................................................................................................................. 2
General assembly of engine ................................................................................................................ 2
107E-1 Series 1
Disassembly and assembly, Part 2 1

General assembly of engine 1 a Don't invert the cylinder block by 90°
or more. Otherwise, the tappet may
a This document describes the general assem- fall off from the mounting hole during
bly procedure of SAA4D107E-1 and assembly.
SAA6D107E-1. The shapes, quantity, loca-
tions, etc. of the parts depend on each applica-
ble machine. Take care.
a When reusing a part, be sure to install it to its
original position.
a Unspecified photos and drawings show those
of 6D107E-1.
1. Preparation work
1) Install tool B.
2) Install cylinder block (1) to tool A.
3 Mounting bolt:
77 ± 12 Nm {7.9 ± 1.2 kgm}
3. Piston cooling nozzle

Set piston cooling nozzles (2) and then tighten
them using mounting bolt (1).
3 Mounting bolt:
15 ± 2 Nm {1.5 ± 0.2 kgm}
2. Tappet
1) Apply engine oil (EO15W-40) to tappets
(1).
2 Tappet: Engine oil (EO15W-40)
4. Crankshaft
1) Install upper bearings (6) and an upper
thrust bearing (5).
a Set the projection of each bearing to
the notch of the cylinder block.
a When installing the bearings, check
that their back sides are free from for-
eign matter.
a Apply engine oil to inner surface of
metal. Don't apply the oil to the back-
side.
2 Inside of bearing:
Engine oil (EO15W-40)
2) Install tappets (1). a When reusing the bearings, check the
a When reusing the camshafts and tap- marks made on them when removed
pets, be sure to install them in the and install them to their original posi-
original position. tions.
2 107E-1 Series
4) Apply engine oil (EO15W-40) to the jour-

nal surfaces of the crankshaft.
5) Before installation, check the No. stamped
on main cap (1).
q Installation shall start from the front
side of the cylinder block in a numeri-
cal order.
<4D107E-1)
2) Using a nylon sling, lift up and install

crankshaft (4).
a When installing, take care so that the
upper thrust bearing may not be dam-
aged.
<6D107E-1)
3) Fit lower bearing (3) to the main cap, q In the installation, make sure the
matching the projection of the former to stamped No. (section A) is faced to
the notch of the latter. the oil cooler.
a Make sure ring dowel (7) is installed q Push in each main cap by hitting it
on the main cap. lightly with a plastic hammer or rubber
hammer.
107E-1 Series 3
6) Before tightening the main cap mounting a Tighten the bolts of 6D170E-1 in the
bolt (2), check the following. order [1] o [14] shown in the figure.
1] Using tool X, measure stem length (a)
of every bolt and check that it is less
than the using limit.
q Using limit length of bolt stem:
Less than 120.0 mm
a If a bolt is longer than the using
limit, do not reuse it but replace
it.
3 Main cap mounting bolt

When current bolts are used again:
1] 60 ± 5 Nm {6.1 ± 0.5 kgm}
2] 80 ± 5 Nm {8.2 ± 0.5 kgm}
3] 90° ± 5° (When angle tighten-
ing tool J is used)
When new bolts are used:

7) Tightening procedure of main cap mount- 1] 120 ± 5 Nm {12.2 ± 0.5 kgm}
ing bolts (2). 2] Loosen by 360°
a Apply engine oil to the bolts. 3] 60 ± 5 Nm {6.1 ± 0.5 kgm}
2 Main cap mounting bolt: 4] 85 ± 5 Nm {8.7 ± 0.5 kgm}
Engine oil (EO15W-40) 5] 120° ± 5° (When angle tight-
a Tighten the bolts of 4D107E-1 in the ening tool J is used)
order [1] o [10] shown in the figure.
q When tool J is not used:

Mark the main cap and each bolt with paint
and then tighten the bolt by 90° ± 5° (when the
bolt is reused) or 120° ± 5° (when a new bolt
is used).
4 107E-1 Series
2) Installation of oil ring

Set the oil ring (9) so that its abutment
joint comes in a position at 180° to the end
of expander (8).
8) After tightening the bolts, make sure that

the crankshaft turns smoothly.
9) Measure the end play of the crankshaft
with a dial gauge.
a End play X: 0.24 ± 0.175 mm 3) Fit second ring (10) with the stamp of
“TOP” near the abutment joint up.
4) Fit top ring (11) with the “dot” mark near
the abutment joint up.
5) When fitting each ring, set the abutment
joint off the thrust, anti-thrust, and piston
axis directions.
5. Piston and connecting rod assembly

1) Using tool D, fit piston rings (7) to the pis-
ton.
6) Apply engine oil (EO15W-40) to piston

ring and piston skirt.
7) Set the piston and connecting rod.
q When “FRONT” mark of piston (6)
head is set at the top, connecting rod
(4) must be facing to the direction
shown in the figure.
107E-1 Series 5
8) Install the bearing to the connecting rod

and connecting rod cap.
q Check that the back side of the bear-
ing is free from foreign matter.
q Fit the bearing to the connecting rod
and cap, matching the projection of
the former to the notch of the con-
necting rod and cap.
1] Apply engine oil to the piston pin hole

and piston pin.
2 Piston pin and pin hole:
9) Set the crankshaft to the bottom dead

center of the cylinder to install the piston
and apply engine oil to the inside of the
cylinder.
2 Inside of cylinder:
10) Insert the piston and connecting rod
assembly setting “FRONT” mark of piston
(6) to the front side of the cylinder.
a Check the directions of the abutment
2] Insert piston pin (5) and then assem- joints of the piston rings again.
ble piston (6) to connecting rod (4). a When inserting the connecting rod,
3] Install snap ring (3) to both sides. take care not to damage the wall of
the cylinder.
a When installing the assembly, take
care so that it may hit the cooling noz-
zle.
6 107E-1 Series
q Using tool E, reduce the piston rings

and push in the piston head with a
wood bar, etc.
q When not using tool J

Make marks on the main cap and bolt with
paint and then tighten the bolt by 60° ± 5°.
11) Install connecting rod cap (2) by tightening
bolt (1) in the following procedure.
a Apply engine oil to the threaded por-
tions of the bolts and inside of the
connecting rod bearings.
2 Threaded portions of bolts:
2 Inside of connecting rod bear-
ings:
12) After installing the piston and connecting

rod assembly, rotate the crankshaft to
make sure that it turns smoothly without
getting hung up.
13) Measure the side clearance between the
connecting rod and crankshaft with tool K.
a Side clearance: 0.10 – 0.33 mm
a Tighten the bolts with angle tightening

tool J (wrench and angle gauge).
3 Mounting bolts (Tighten both bolts
alternately):
1] 30 ± 3 Nm {3.06 ± 0.31 kgm}
2] 60 ± 5 Nm {6.12 ± 0.51 kgm}
3] 60° ± 5° (When angle tighten-
ing tool J is used)
107E-1 Series 7
6. Gear housing
1) Apply gasket sealant to part A of the
mounting face of housing (2).
2 Housing: Gasket sealant (LG-7)
q Diameter of gasket sealant line shall
be 1 – 2 mm.
a If too much gasket sealant is applied
near blow-by oil groove B, the groove
may be clogged. Accordingly, keep
the gasket sealant line diameter
strictly.
2) Make sure that each of the dowel ring of
the gear housing is correctly inserted to
the dowel hole at both the top and bottom
(indicated with ∗ mark).
a Otherwise, they can be damaged
when bolt-tightened.
3) Press the gear housing against the cylin-
der block so that its entire mating surface
with the cylinder block is closely con-
tacted.
a Don't apply torque to the mounting
bolts until the entire mating surface is
closely contacted.
7. Camshaft
a Rotate the crankshaft to set the No. 1 cyl-
inder to the top dead center.
1) Apply engine oil (EO15W-40) to the cam-
shaft bore, camshaft journal and lobed
surface. Then lightly push in and rotate
camshaft (3) to install.
2 Sliding surfaces of camshaft:
4) Tighten the mounting bolts.
Bolts tightening procedure
Tighten the bolts according to the num-
bers [1] o [10] shown in the figure.
a 4 types of bolts are used. Make sure
when tightening that specified torque
is applied.
3 Mounting bolt:
1] M12:
77 ± 7 Nm {7.9 ± 0.7 kgm}
(No marking)
2] M10:
43 ± 5 Nm {4.4 ± 0.5 kgm}
(Q mark l = 30, T mark l = 50)
3] M8:
24 ± 4 Nm {2.5 ± 0.4 kgm}
(E mark)
8 107E-1 Series
2) Install thrust plate (2). 8. Flywheel housing

3 Mounting bolt: 1) Install flywheel housing (2) using bolt (1).
24 ± 4 Nm {2.4 ± 0.4 kgm} a Apply gasket sealant (LG-7) to the
flanged housing installation surface
as well as ci rc umfer enc e of th e
mounting bolt hole. Diameter of gas-
ket sealant line shall be 1 – 3 mm.
2 Flywheel housing:
Gasket sealant (LG-7)
3) When installing, fit in the thrust plate to

timing mark A on camshaft gear (1) as
well as to the chamfered tooth (a single
location) of crankshaft gear (4).
3 Mounting bolt:
36 ± 4 Nm {3.7 ± 0.4 kgm}
2) Tighten the mounting bolts in the numeric
order [1] o [20] shown in the figure.
a 2 types of bolts are used. Make sure
when tightening that the specified
torque is used.
1] M12:
85 ± 10 Nm {8.7 ± 1.0 kgm}
(E mark)
2] M10:
49 ± 5 Nm {5.0 ± 0.5 kgm}
(T mark)
4) Measure the end play and backlash of the

camshaft with a dial gauge.
a End play: 0.10 – 0.36 mm
q The end play is determined by thick-
ness of the thrust plate and groove of
the camshaft.
a Backlash: 0.076 – 0.280 mm
3) After installing the flywheel housing, mea-

sure the radial runout and facial runout
with tool L.
a Radial runout: Max. 0.20 mm
a Facial runout: Max. 0.20 mm
q Measurement of radial runout
1] Install tool L to the crankshaft end
face.
107E-1 Series 9
2] Contact the probe of the dial gauge at 9. Rear oil seal

right angle against part of the spigot 1) Insert pilot [2] to rear oil seal (4).
joint of the flywheel housing. a Before inserting the pilot, clean,
3] Set graduations of the dial gauge to degrease and dry the oil seal lip sur-
“0” and then rotate the crankshaft by face.
a turn to measure differences in the
maximum deflections of the gauge
pointer.
a Make sure after rotating the
crankshaft by a turn that the
gauge pointer is returned to the
position where it had situated
when the crankshaft was started
to turn.
2) Insert oil seal (4), together with pilot [2], to

the crankshaft and then push in the seal
carrier of oil seal (4) to the flywheel hous-
ing (1).
a Before inserting the oil seal, clean,
degrease and dry the surface where
the seal is contacted against the
crankshaft.
3) Pull out pilot [2] and then further push in
q Measurement of facial runout oil seal (4).
1] Like in measurement of the radial
runout, contact the probe of the dial
gauge at right angle against the end
face of the flywheel housing.
a Before conducting the measure-
ment, move the crankshaft either
in the front or rear side in order to
prevent errors due to the end
play.
2] Set graduations of the dial gauge to
“0” and then rotate the crankshaft by
a turn to measure the difference in the
maximum deflections of the gauge
pointer.
10 107E-1 Series
4) Using tool G, insert the oil seal until it is

flush with the flywheel housing end face.
2) Tighten the mounting bolts in the order

indicated in the figure.
3 Mounting bolt:
a When pushing in the oil seal, make
137 ± 7 Nm {14.0 ± 0.7 kgm}
sure that the seal carrier is free from
bending.
a Installed dimension
X = Max. 0.38 mm
3) After installing the flywheel, measure the

radial runout and facial runout with tool L.
a Radial runout: Max. 0.13 mm
10. Flywheel a Facial runout: Max. 0.20 mm
1) Install guide bolt [1] and flywheel (1). q Measurement of radial runout
q Apply gasket sealant to the circumfer- 1] Install tool L to the flywheel housing.
ence of the bolt hole (8 locations) on 2] Contact the probe of the dial gauge at
the mounting surface of the crank- right angle against section (a) of the
shaft. Diameter of gasket sealant line spigot joint or periphery of the fly-
shall be 1 – 3 mm. wheel housing.
2 Flywheel mounting surface: 3] Rotate the flywheel by a turn to mea-
Gasket sealant (LG-7) sure the differences in the maximum
4 Flywheel assembly: 35 kg deflections of the dial gauge pointer.
a Make sure after rotating the fly-
wheel by a turn that the dial
gauge pointer is returned to the
position where it had situated
when the flywheel was started to
turn.
107E-1 Series 11
q Measurement of facial runout 1) Install oil pump assembly (2) with bolts (1).
1] Like in measurement of the radial
runout, contact the probe of the dial
gauge at right angle against end face
(b) situated near the periphery of the
flywheel housing.
a Before conducting the measure-
ment, move the crankshaft either
in the front or rear side in order to
prevent errors due to the end
play.
2] Rotate the flywheel by a turn to mea-
sure the differences in the maximum
deflections of the dial gauge pointer.
2) Tighten the mounting bolts in the order

indicated in the figure.
3 Mounting bolt:
1st time:
8 ± 1 Nm {0.8 ± 0.1 kgm} (Fig.a)
2nd time:
24 ± 4 Nm {2.4 ± 0.4 kgm} (Fig.b)
3) Measurement of backlash
Stop move of a gear of either side and
then measure backlash (C) of the pump
and idler gear.
a Total amount of backlash (C):
0.2 ± 0.05 mm
11. Oil pump assembly
a Fill up the oil pump rotor space and the
idler shaft bore with engine oil (EO15W-
40) and then rotate the rotor by two turns.
12 107E-1 Series
12. Front cover 3) Using tool H, install front seal (3).

1) Apply gasket sealant to installation sur- a Before installing the seal, check that
face (A) of cover (2). the end corners and lip sliding sur-
2 Front cover: Gasket sealant (LG-7) faces of the crankshaft are free from
q Diameter of gasket sealant line shall flaw, burr, and rust of the housing.
be 1 – 2 mm. a When installing the seal, do not apply
oil or grease to the shaft and seal lip.
Wipe off the oil from the shaft.
a The deviation of seal (3) from cover

(2) must be as follows:
q Extrusion (x): Max. 0.38 mm
q Facial runout (TIR) (y): Max. 0.25 mm
2) Tighten the mounting bolts according to

the numbers [1] o [13] shown in the figure.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 13
13. Oil pan 5) Tighten the mounting bolts according to

1) Install plate (4) and 3 plates (5). the numbers shown in the figure.
3 Mounting bolt: 3 Mounting bolt:
43 ± 5 Nm {4.4 ± 0.5 kgm} 28 ± 2 Nm {2.9 ± 0.2 kgm}
q Plate (5) is not installed to 4D107E-1. <4D107E-1>
2) Install suction tube (3).
3 Flange mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
<6D107E-1>
3) Apply gasket sealant to installation sur-

face (A).
2 Oil pan: Gasket sealant (LG-7)
q Diameter of gasket sealant line:
Straight line: 3 mm, curved line: 1 mm
14. Crankshaft pulley and vibration damper

1) Install crankshaft pulley (4D107E-1) and
vibration damper (6D107E-1) by fitting in
their knock holes to dowel pin (a) of the
crankshaft.
2) Bolt (1) tightening procedure
1] Tighten the bolt's opposing corner
sequentially with 55 ± 5 Nm {5.6 ±
0.5 kgm}.
4) Install oil pan (2) with bolts (1).
2] Loosen the bolt by 180°.
3] Tighten the bolt's opposing corner
sequentially with 55 ± 5 Nm {5.6 ±
0.5 kgm}.
4] 90° ± 5° (When angle tightening
tool J is used)
14 107E-1 Series
3 Mounting nut:
q When not using angle tightening tool:
24 ± 4 Nm {2.4 ± 0.4 kgm}
Make marks on the crankshaft pulley
2) Install new hose (1).
k The internal parts of the adapter
or vibration damper and each bolt
with paint and then tighten the bolt by
90° ± 5°.
removed. Accordingly, do not
reuse the adapter but use new one
when installing the hose again, as
a rule.
<4D107E-1>
15. Fuel supply pump

1) Install supply pump (3) with 3 nuts (2).
k If grease is applied too much to the
O-ring when the supply pump is
<6D107E-1>
installed, it will ooze out during
operation. Accordingly, do not
apply grease too much. (Apply
grease to O-ring groove area A.)
k When removing and installing the
supply pump mounting stud bolts
of the gear housing, apply LOC-
TITE to the root side.
107E-1 Series 15
16. Engine controller a Tighten the bolts in the numeric order

1) Install cooling plate assembly (2) and shown in the figure.
tighten mounting bolts (4). 3 Mounting bolt:
3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) For a model such as WA380-6 which has

the oil filter on its engine, select oil filter
2) Install engine controller (1) and tighten
(1).
mounting bolts (5).
a Apply engine oil to the seal.
3 Mounting bolt:
2 Oil filter seal:
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Filter: 13 ± 2 Nm {1.3 ± 0.2 kgm}
3) Install ground wire (3).
Or tighten 3/4 turns after contacting
mating part.
<6D107E-1>
17. Oil cooler

1) Install gaskets (5) and (3), oil cooler (4)
and cover (2) with bolts (6).
16 107E-1 Series
18. Cylinder head assembly 4] Using tool C, compress valve spring

1) Assemble the cylinder head assembly (3) to install valve cotter (4).
according to the following procedure.
1] Install valve seal (7).
2] Apply engine oil to the valve stem and
inside of valve guide and install valve
(6).
2 Valve stem and valve guide:
a Hit the valve stem lightly with a plastic

hammer to make sure that the valve
collet is positively fitted to the groove
of the valve stem.
2) Before tightening the cylinder head
mounting bolt, check the following.
1] Measure stem length (a) of every bolt
3] Raise the cylinder head and install to make sure that they are within the
valve spring (3) and upper seat (5). using limit.
q Using limit length of bolt stem (a):
Max. 132.1 mm
a If a bolt is longer than the using
limit, do not reuse it but replace
it.
107E-1 Series 17
3) Check that the cylinder head mounting <4D107E-1>

face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (8).
a Make sure that the gasket is fitted in
the hole on the cylinder head.
<6D107E-1>
4) Set cylinder head assembly (2) on the cyl-

inder block and then tighten it using
mounting bolts (1).
q When the angle tightening tool J is not

used:
After applying a paint marking to the cylin-
der head and bolt, tighten the bolt by 90° ±
5°.
a First, tighten the mounting bolts by 2

– 3 turns or more by hand, and then
tighten them according to the follow-
ing procedure.
2 Apply engine oil (EO15W-40) to the
threaded portion and head seat of
each bolt.
3 Mounting bolt:
a Tighten the bolts 3 times in the order
shown in the figure.
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] 90 ± 3 Nm {9.2 ± 0.3 kgm}
3] 90° ± 5° (When tightened with
angle tightening tool J)
18 107E-1 Series
19. Fuel injector assembly 20. Push rod

a When replacing the injector, replace the 1) Install push rod (1).
inlet connector, too. a Check that the push rod is fitted in the
a Make sure that the injector sleeve is free tappet.
from damages or dirt. a Refill the push rod socket with engine
1) Attach the gasket and O-ring to injector oil (EO15W-40).
(2).
2) Apply engine oil (EO15W-40) to the O-ring
of injector (2) as well as the head side.
3) Insert injector (2) to the cylinder head
while directing its fuel inlet hole to the
manifold.
4) Install holder (4) and then tighten bolt (3) 3
to 4 threads.
5) Check the inlet connector for the following
items. If it is defective, replace it.
1] If there are burrs or deformation at
the inlet or outlet of the connector, do
not use the inlet connector.
2] If the edge filter is clogged or dirty or
there is sediment in it, do not use the
inlet connector. 21. Rocker arm assembly
3] If the sealing surface of the outlet side 1) Install crosshead (3).
is worn, in contact unevenly or has a 2) Install rocker arm assembly (2) and
trace of leakage, do not use the inlet tighten bolts (1).
connector. (If high-pressure fuel a Before tightening the mounting bolts,
leaks, the seat surface is eroded and check that the ball of the adjustment
has fine streaks or flaws.) screw is fitted to the socket of the
4] If the O-ring is broken or deteriorated, push rod.
do not use the inlet connector. 3 Bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm}
6) Apply engine oil (EO15W-40) to the O-ring
of inlet connector (1) as well as the head
side.
7) Install inlet connector (1) temporarily
(push it into the injector hole).
8) Tighten bolts (3) alternately.
3 Bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
9) Tighten retainer (5).
3 Retainer:
50 ± 5 Nm {5.1 ± 0.5 kgm}
107E-1 Series 19
a Shape of the holes (a) and (b) on the <4D107E-1, as an example>

crosshead is not identical. Thus when
using this part again, the same air
intake and exhaust valves must be
assembled in the same direction.
2) Adjust the valve clearance according to

the following procedure.
a If you cannot move the rocker arms of
the exhaust valves (on the EX side)
22. Adjusting valve clearance
with the hand, adjust the valves
Adjust the valve clearance according to the fol-
marked with Q in the valve arrange-
lowing procedure.
ment drawing.
a As the valve clearance, adjust the clear-
a If you can move the rocker arms of
ance between the crosshead and rocker
the exhaust valves (EX) with the hand
arm to the following value.
by the valve clearance, adjust the
a Valve clearance (when cold)
valves marked with q in the valve
Unit: mm arrangement drawing.
Air intake valve Exhaust valve <4D107E-1>
0.25 ± 0.05 0.51 ± 0.05
1) Using tool V, rotate the crankshaft forward

and set wide slit (b) on the disc having the
revolution sensor slits at the rear of the
crankshaft pulley to projection top (a) of
the front cover.
a Seeing from the air intake manifold
side, set projection top (a) into wide
slit (b).
k After this positioning, each cylin-
der is not set to the top dead cen-
ter. Take care. (Each cylinder is
set 76 – 88° before the top dead <6D107E-1>
center.)
20 107E-1 Series
3) Insert clearance gauge K in the clearance 3 Mounting nut:

between rocker arm (3) and crosshead 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
(4).
4) Loosen locknut (5) and adjust the valve
clearance with adjustment screw (6).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
gauge lightly.
5) While fixing adjustment screw (6), tighten
locknut (5).
3 Locknut:
20 – 28 Nm {2.04 – 2.86 kgm}
a After tightening the locknut, check the
valve clearance again.
3) Fit the gasket and then install head cover

(3) using nut (2).
3 Mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Head cover (3) of 4D107E-1 will be
i ns tal l ed a ft er th e tu r b oc h ar g er
assembly is installed. Accordingly,
install the head cover temporarily at
this time.
4) Install duct (1).
6) Rotate the crankshaft forward by 1 turn

with tool V and set wide slit (b) to projec-
tion top (a) according to step 1).
7) Adjust the other valve clearances accord-
ing to steps 3) – 5).
a If the valves marked with Q in the
valve arrangement drawing were
adjusted in steps (4) and (5), adjust
the valves marked with q.
23. Rocker housing and head cover

1) Install rocker housing assembly (6) with
bolt (5).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install nuts (4) of the harness.
a Harness installation position
Color of cable Cylinder No.
White 1, 3, 5
Black 2, 4, 6
Cylinders No. 5 and No. 6 are applied for
6D107E-1 only.
107E-1 Series 21
24. Air intake manifold cover 25. Fuel pressure sensor and relief valve
1) Fit the gasket and then install manifold 1) Replace fuel pressure sensor (2), if neces-
covers (3) and (4). sary, according to the following procedure.
2) Fit the gasket and then install tube (1) and a Do not remove fuel pressure sensor
electrical intake air heater (2). (2) from common rail (1) for a pur-
3 Tube mounting bolt: pose other than replacement.
24 ± 4 Nm {2.4 ± 0.4 kgm} a Once the fuel pressure sensor is
<4D107E-1> removed from the common rail, be
sure to replace it.
1] Before removing the fuel pressure
sensor, remove mud etc. from around
it thoroughly and clean it.
2] Remove the fuel pressure sensor.
3] Check the fuel pressure sensor con-
nector for crack, breakage, damage
of the seal, foreign matter on the pin
and corrosion, bend and breakage of
the pin.
4] Install a new fuel pressure sensor.
2 Threaded part of fuel pressure
sensor:
Gear oil (#90)
<6D107E-1> 3 Fuel pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5] Connect the engine wiring harness.
At this time, take care not to connect
the wiring harness in reverse.
6] Start the engine and check that fuel
does not leak.
For the testing procedure, see Testing
and adjusting, "Testing fuel system for
leakage".
<Fuel pressure sensor of 6D107E-1 is shown
below>
22 107E-1 Series
2) Replace relief valve (3), if necessary, 26. Common rail and fuel high-pressure piping
according to the following procedure. (4D107E-1)
1] Before removing the relief valve, k It is prohibited to bend high-pressure
remove mud etc. from around it thor- pipings used.
oughly and clean it. k The clamps used for fixing high-pres-
2] Remove the relief valve. sure pipings must be the genuine part.
3] If the leakage from the relief valve And the specified tightening torque
exceeds the specified value, do not must be strictly observed.
reuse it. k A clearance of 10 mm minimum must
4] Check that high-pressure seal sur- be provided between the installed high-
faces (A) of the relief valve and rail pressure piping and harness.
are free from damage. a Fuel leakage can occur on a high-pressure
5] Install the relief valve. piping that has visible lengthwise slits (b)
2 Threaded part of relief valve: or dents such as patchy damages (c) on its
Gear oil (#90) taper seal of the piping connection (part
3 Relief valve: (a): 2 mm space from the tip). The same
100 ± 4 Nm {10.2 ± 0.4 kgm} holds true for a high-pressure piping that
Excessive tightening can cause catches claw because of fatigued steps in
leakage. Take care not to tighten part (d) (end of the taper seal: a 2 mm
too strongly. space from the tip). Such high-pressure
6] Start the engine and check that fuel piping must be replaced.
does not leak.
For the testing procedure, see Testing
and adjusting, "Testing fuel system for
leakage".
1) Temporarily install common rail (8) and

high-pressure pipings (1) to (5).
3 Sleeve nut and mounting bolt
(Temporary tighten):
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten high-pressure pipings (1) to (5)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
1] Head side of high-pressure pipings
(1) and (4)
2] Rail side of high-pressure pipings (1)
and (4)
(2) o (3)
o (3)
5] Pump side of high-pressure piping (5)
and then its rail side
107E-1 Series 23
3)Tighten the high-pressure pipe clamp

bracket mounting bolts.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4) Tighten common rail (7) with 4 bolts.
a Apply sealant (LG-7) to the threaded
part of 2 bolts inside the engine.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Install boots (8).
k Set the slits of each boots out and
down.
a The boots are installed so that fuel
will not spout over the hot parts of the
engine and catch fire when it leaks for
1) Temporarily install common rail (10) and
some reason.
high-pressure pipings (1) to (7).
3 Sleeve nut and mounting bolt
6) Install fuel return hose (9).
3 Joint bolt:
(Temporary tighten):
24 ± 4 Nm {2.4 ± 0.4 kgm}
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
<4D107E-1>
2) Tighten high-pressure pipings (1) to (7)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
(6) and (1)
and (1)
(2) o (3) o (4) o (5)
o (3) o (4) o (5)
5] Pump side of high-pressure piping (7)
and then its rail side
3) Tighten the clamp of high-pressure piping
(7).
3 Mounting bolt:
27. Common rail and fuel high-pressure piping
(6D107E-1)
k It is prohibited to bend high-pressure
24 ± 4 Nm {2.4 ± 0.4 kgm}
4) Tighten common rail (10) with 4 bolts.
pipings used.
a Apply sealant (LG-7) to the threaded
k The clamps used for fixing high-pres-
part of 2 bolts inside the engine.
3 Mounting bolt:
sure pipings must be the genuine part.
And the specified tightening torque
24 ± 4 Nm {2.4 ± 0.4 kgm}
must be strictly observed.
k A clearance of 10 mm minimum must
5) Install boots (9).
a Set the slits of each boots out and
be provided between the installed high-
down.
pressure piping and harness.
a The boots are installed so that fuel
a Fuel leakage can occur on a high-pressure
will not spout over the hot parts of the
piping that has visible lengthwise slits (b)
engine and catch fire when it leaks for
or dents such as patchy damages (c) on its
some reason.
taper seal of the piping connection (part
6) Install fuel return hose (8).
3 Joint bolt:
(a): 2 mm space from the tip). The same
holds true for a high-pressure piping that
24 ± 4 Nm {2.4 ± 0.4 kgm}
catches claw because of fatigued steps in
part (d) (end of the taper seal: a 2 mm
space from the tip). Such high-pressure
piping must be replaced.
24 107E-1 Series
<6D107E-1>
30. Exhaust manifold

28. Harness assembly 1) Fit a new gasket and then install exhaust
Connect harness assembly (1) to the controller manifold (4) to the cylinder head. Tighten
and sensor and then fix it to the engine. the mounting bolts according to the num-
k Before connecting the harness connec- bers shown in the figure.
tor, clean sands, dusts or water in the 3 Mounting bolts tightening proce-
controller side connector. dure:
1] Tighten every bolt with 24 ± 4
Nm {2.4 ± 0.4 kgm}.
2] Tighten every bolt with 53 ± 6
Nm {5.4 ± 0.6 kgm}.
3] Tighten [1] to [4] bolts alone in
the figure in this order with 53
± 6 Nm {5.4 ± 0.6 kgm}.
<4D107E-1>
29. Fuel filter assembly

1) Install filter bracket assembly (4).
2) Install drain hose (3) to the filter bracket.
3) Install filter inlet hose (1) and outlet hose
(2).
4) Install fuel filter (5).
a As the gasket touched the filter head,
tighten the fuel filter 1/2 turn to install
<6D107E-1>
it.
107E-1 Series 25
31. Turbocharger assembly (4D107E-1) 5) Install oil feed tube (2) to the turbocharger
1) Remove the head cover installed in the assembly and then install heat insulation
previous step. cover (1).
2) Fit gasket (9) and place turbocharger 3 Mounting nut on oil cooler side:
assembly (4) temporarily on the exhaust 24 ± 4 Nm {2.4 ± 0.4 kgm}
manifold stud bolts. Then, fit gasket (8) to 3 Mounting nut on turbocharger side:
the turbocharger and install oil return tube 36 ± 5 Nm {3.6 ± 0.5 kgm}
(7). 3 Heat insulation cover mounting
a Tighten oil return tube mounting bolt bolt:
(6) with hexagonal wrench [1] under 24 ± 4 Nm {2.4 ± 0.4 kgm}
the condition shown in the figure.
3 Oil return tube mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
32. Turbocharger assembly (6D107E-1)

1) Fit the gasket and install turbocharger
assembly (3) to exhaust manifold (4).
3) Install turbocharger assembly (4) to the 3 Mounting nut:
exhaust manifold with mounting nuts (3). 43 ± 6 Nm {4.4 ± 0.6 kgm}
4) Check that the oil return tube (7) does not a Tighten the mounting nuts in the diag-
interfere with the exhaust manifold and onal order.
install head cover (5).
3 Turbocharger mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Tighten the mounting nuts in the diag-
onal order.
3 Head cover mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
26 107E-1 Series
2) Install the turbocharger assembly oil feed 34. Thermostat

tube. 1) Install thermostat (2).
3 Mounting nut on oil cooler side:
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Mounting nut on turbocharger side:
36 ± 5 Nm {3.6 ± 0.5 kgm}
3) Fit the gasket to the turbocharger assem-
bly and install oil return tube (2).
3 Oil return tube mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install coolant outlet connector (1).
33. Water pump

1) Attach the seal ring and then install water
pump (2).
2) Attach the seal ring and then install cool-
ant inlet connector (1).
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
35. Alternator
1) Install front side sling bracket (5) and
alternator bracket (4).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 27
2) Install alternator (3) temporarily using 37. Belt tensioner

mounting bolt (2). Install tensioner (2) with mounting bolt (1).
3) Install plate (1). 3 Mounting bolt:
4) Tightening alternator mounting bolt (2). 43 ± 6 Nm {4.4 ± 0.6 kgm}
a Check visually or using a ruler, that the
belt mounts of the tensioner pulley and
alternator pulley are parallel.
36. Fan hub

Install fan hub (2) with mounting bolt (1).
3 Mounting bolt:
32 ± 5 Nm {3.3 ± 0.5 kgm} 38. Fan pulley
1) Install fan pulley (4) with mounting bolt (3).
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
2) Install fan belt (1).
q Insert a wrench to the portion (A)
(width across flats T 12.7 mm) of the
tensioner assembly (2), and rotate it
to the opposite to the winding-up
direction to decrease the fan belt (1)
tension, then install.
k Make sure that the wrench is
secured at the portion (A) before
rotating it. (The spring of the ten-
sioner assembly (2) is strong. If the
wrench is loosely inserted, the
wrench may accidentally come off
w h i l e b e i n g r o ta t e d a n d i t i s
extremely dangerous.)
k After removing the fan belt (1),
return the tensioner assembly (2)
slowly with care.
caught between the pulley and fan
belt (1) during work.
28 107E-1 Series
<6D107E-1>
39. Engine sling bracket on rear side

Install engine sling bracket (1) to the cylinder 41. Removal from engine repair stand
bracket. 1) Lift engine assembly (1) temporarily and
then separate it from tool A.
4 Engine assembly:
Approx. 430 kg (4D107E-1)
4 Engine assembly:
Approx. 520 kg (6D107E-1)
(The weight depends on the appli-
cable machines.)
2) Remove tool B.
40. Starting motor assembly

Fit the gasket and then install starting motor
assembly (2) with bolt (1).
2 Apply 1 mm wide gasket sealant (LG-
7) to the entire circumference of the
front and back sides of the gasket.
<4D107E-1>
107E-1 Series 29
3)Set engine assembly (1) on stable engine

stand [1] provided on both sides.
4) Install oil gauge assembly (2).
<4D107E-1>
<6D107E-1>
42. Refilling with oil

1) Check that the engine oil drain plug is
tightened.
2) Add oil through the oil filler to the specified
level.
5 Engine oil pan:
Approx. 16 l (4D107E-1)
5 Engine oil pan:
Approx. 23 l (6D107E-1)
30 107E-1 Series
SEN00259-02
© 2006 KOMATSU
All Rights Reserved
32

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SEN00161-12

Engine 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual .......................................................................................................................... 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00161-12

00 Index and foreword SEN00162-12

10 Structure, function and maintenance standard SEN00167-00

20 Standard value table SEN00247-09

30 Testing and adjusting SEN00249-02

50 Disassembly and assembly SEN00256-02

Foreword and general information SEN00164-05

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Troubleshooting of electrical system (E-mode), Part 1 SEN00254-02

Troubleshooting of electrical system (E-mode), Part 2 SEN00255-01

Troubleshooting of mechanical system (S-mode) SEN00253-01

50 Disassembly and assembly

Disassembly and assembly, Part 1 SEN00258-01

Disassembly and assembly, Part 2 SEN00259-02

KOMATSU 107E-1 Series Diesel engine

Form No. SEN00163-12

Engine 1SHOP MANUAL

00 Index and foreword 1

Safety notice (Rev. 2008/06)

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-