Unit Assembling Check Sheet

KOMATSU ENGINE

107 SERIES

FORM：SEPC6004 (COMPLETE SET)

Printed in Japan 2012.4.1
Engine Parts Unit Assembling Check Sheet

107 Engine Parts Unit Assembling Check Sheet

INDEX
1. Cylinder Block ・・・・・・ 1
2. Crankshaft ・・・・・・ 2
3. Piston＆Connecting Rod ・・・・・・ 3,4
4. Gear Housing ・・・・・・ 5
5. Camshaft ・・・・・・ 6
6. Flywheel Housing ・・・・・・ 7
7. Rear Oil Seal ・・・・・・ 8
8. Flywheel＆Oil Pump ・・・・・・  9
9. Front Cover ・・・・・・ 10
10. Oil Pan ・・・・・・ 11
11. Crankshaft Pulley＆Vibration Damper＆Fuel Supply Pump ・・・・・・ 12
12. Engine Controller＆Oil Cooler ・・・・・・ 13
13. Cylinder Head Assembly ・・・・・・ 14
14. Fuel Injector ・・・・・・ 15
15. Push Rod&Rocker Arm ・・・・・・ 16
16. Adjusting of Valve Clearance ・・・・・・ 17
17. Rocker Housing&Head Cover&Air Intake Manifold Cover ・・・・・・ 18
18. Fuel Pressure Sensor&Relief Valve ・・・・・・ 19
19. Common Rail&High-Pressure Piping ・・・・・・ 20
20. Exhaust Manifold&Turbocharger ・・・・・・ 21
21. Water Pump&Alternator&Starting Motor Assembly ・・・・・・ 22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

1.Cylinder Block ・ Clean the cylinder block thoroughly,especially cylinder

bores,oil drillings,and coolant passages.

1 Cylinder Block

・ Apply Engine Oil to Tappets.

2.Tappet (Engine Oil:EO15W-40)

2 Tappet

・ Set Piston Cooling Nozzle and then tigetening them using

1 mouting bolt.

Piston Cooling
3.Piston Cooling Nozzle 3
Nozzle
・ Mounting bolt : 15 2 Nm ｛1.5 0.2 kgm ｝
kgm

・ Set the projection of each bearing to the notch of the

cylinder block.
Upper Main ・ When installing the bearings,check that their back sides are
4
Bearings free from foreign matter.
・ Apply engine oil to inner surface of bearings. Don`t apply the
4.Upper Main Bearings 5.Upper Thrust Bearings oil to the backside.
・ When reusing the bearings,check the marks made on them
when removed and install them to their original posisions.
・ When installing the bearings,check that their back sides are
free from foreign matter.
Upper Thrust ・ Apply engine oil to inner surface of bearings. Don`t apply the
5
Bearings oil to the backside.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

1/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

6.Crankshaft 7.Ring Dowel ・ Using a nylon sling,lift up and install crankshaft.

6 Crankshaft ・ When installing, take care so that the upper thrust bearing
may not be damaged.

・ Make sure ring dowel is installed on the main cap.

7 Main cap

Lower Main ・Fit lower bearing to the main cap, matching the projection of
8 the former to the notch of the later.
Bearing

9.Installation Order ※Apply Engine Oil to the bolts. ・ Before installation, check the No. stamped on main cap.
・ Installation shall start from the front side of the cylinder
block in a numerical order.
・ In the installation, make sure the stamped No. is faced to the
oil cooler.
・ Before tightening the main cap mounting bolt, check the
length of bolt stem.
・ Using limit length is less than 120.0mm
・ Tighten the bolts in order【1】∼【14】shown in the left of
figure.
9 Main Cap
・ Tightening Torque of main cap mounting bolt
When current bolts are used again When new bolts are used
(1) 60 5 Nm｛6.1 0.5 kgm｝ (1) 120 5 Nm｛12.2 0.5 kgm｝
kgm (2) 80 5 Nm｛8.2 0.5 kgm｝ (2) Loosen by 360
(3) 90 5 (3) 60 5 Nm｛6.1 0.5 kgm｝
(4) 85 5 Nm｛8.5 0.5 kgm｝
(5) 120 5
10.Measure the end play of the crankshaft
X
・ After tightening the bolt, make sure that the crankshaft turns
smoothly.

・ Measure the end play of the crankshaft with a dial gauge.

End play of
10 End play X : 0.24 0.175 mm Measurement：     mm
crankshaft

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

2/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

[A] [B] ・Set the oil ring (2)so that its aboutment joint comes in a
position at 180 to the end of expander(1)
(4)
・Fit second ring (3)with the stamp of ''TOP''near the abutment
joint up.
(2) 120
・Fit top ring (4)with the ''dot''mark near the abutment joint up.
・When fitting each ring, set the abutment joint off the thrust,
(1) anti-thrust, and piston axis directions.
180
・Set the piston and conecting rod, when ''FRONT''mark of
piston head is set at the top, conecting rod must be facing to
the direction shown in the figure( C )
120
・Apply Engine Oil to the piston pin hole and piston pin.( D )
[C]
(3) ・Insert piston pin and then assemblepiston to conecting rod.
[D]
・Check to install snap ring to both sides.
FRONT

11 Piston ・Install the bearing to the connecting rod and connecting rod
＆ ・cap.
Connecting rod ・Check that the back side of the bearing is free from foreign
[E] matter.
・Fit the bearing to the connecting rod and cap, matching the
[G] projection of the former to the notch of the connecting rod
and cap.
Hexagon wrench
・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.

[F] ・Insert the piston and connecting rod assembly setting

''FRONT'' mark of piston to the front side of the cylinder.
・Check the directions of the abutment joints of the piston
rings again.
・When inserting the connecting rod, take care not to damage
the wall of the cylinder.
・When installing the assembly, take care so that it may hit the
cooling nozzle.
FRONT

・Using tool (G) , reduce the piston rings and push in the piston
head with a wood bar,etc.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

3/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・Apply engine oil to the threaded portions of the bolts and

inside of the connecting rod bearings.
・Tighten the bolts of connecting rod cap as ①

・ Mounting bolts of connecting rod cap.

(1) 30 3 Nm｛ 3.06 0.31 kgm ｝
kgm (2) 60 5 Nm｛ 6.12 0.51 kgm ｝
(3) 60 5 

・Measure of side crearance between connecting rod and

crankshaft as ②
①
Side crearance ： 0.10 ∼ 0.33 mm
Piston
＆
Connecting rod No.1 No.2 No.3 No.4 No.5 No.6 No.7

Result

・After installing the piston and connecting rod assembly, rotate

the crankshaft to make sure that it turns smoothly without
getting hung up.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

4/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・Apply gasket sealant to part A of the mounting face of

A 2 housing(2).
・Diameter of gasket sealant line shall be 1-2mm.

・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.

・Make sure that each of the dowel ring of the gear housing is
B correctly inserted to the dowel hole at both the top and
bottom (indicated with ＊ mark).

・Otherwise, they can be damaged when bolt-toghtened.

・Press the gear housing against the cylinder block so that its
entire mating surface with the cylinder block is closely
C contacted.
12 Gear housing ・Don't apply torque to the mounting bolts until the entire   
mating surface is closely contacted.

② [8]△ [7]△
・Tighten the bolts according to the numbers【1】∼【10】
shown in the figure ②.

[9]△ [10]△ Mounting bolt of gear housing

(1) M12 : 77 7 Nm｛ 7.9 0.7 kgm ｝
[5]○ ( No marking)
(2) M10 : 43 5 Nm｛4.4 0.5 kgm｝
[6]○ kgm
  ( ○ mark ℓ = 30 , □ mark ℓ = 50 )
(3) M 8 : 24 4 Nm｛2.5 0.4 kgm｝
[2]□ ( △ mark)
[1]

[4]□ [3]□

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

5/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・Rotate the crankshaft to set the No.1 cylinder to the top dead
TDC center.

・Apply engine oil to the camshaft bore, camshaft journal and

lobed surface.
・Then lightly push in and rotate camshaft to install.

12 O click
1】・Install the thrust plate.
Torque Value : 24 4 Nm

2】・Align the timing marks on the camshaft gear with the

timing marks on the crankshaft gear and tighten the
camshaft capscrews.
・Rotate the camshaft so that the camshaft dowel pin aligns
① kgm with the slot on the camshaft gear.Install the camshaft gear
and capscrews.
Torque Value : 36 4 Nm
13 Camshaft
A 3】・Tighten the capscrews.
36 4 Nm{3.7 0.4kgm}

・Measure the end play and backlash of the camshaft with a

dial gauge.

Limit of End play ： 0.10 ∼ 0.36 mm

②
Result ：             mm

Limit of Backlash ： 0.076 ∼ 0.280 mm

Result ：             mm

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

6/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① [15] [7] [14]

・Apply gasket sealant to the flanged housing installation
[6] surface as well as circumference of the mounting bolt hole.
[16] [8] ・Diameter of gasket sealant iine shall be 1-3 mm.
・Tighten the mounting bolts in the numeric order【1】∼【20】
[17] [13] shown in the figure ①.
[5] ・2 types of bolts are used. Make sure when tightening that the
[18] [12] specified torque is used.
[11]
[1]
[19] [2] Mounting bolt of Flywheel housing.
kgm
[20] (1) M12 : 85 10 Nm｛ 8.7 10 kgm｝ ( △ mark )
(2) M10 : 49 5 Nm ｛ 5.0 0.5 kgm｝ ( □ mark )
[4] [9] [10] [3]
・After installing the flywheel housing, measure the radial runout
and facial runout.
Measurement of radial runout
② ① ・Contact the probe of the dial gauge at right angle against part
of the spigot joint of the flywheel houjing.
・Set graduations of the dial gauge to ''0''and then rotate the
14 Flywheel crankshaft by a turn to measure differences in the maximum
Housing deflections of the gauge poiter.
② ・Make sure after rotating the crankshaft by a turn that the
gauge pinter is returned to the position where it had situated
④ when the crankshaft was started to turn.
Radial runout ： MAX. 0.20 mm <All engine>
          MAX. 0.50 mm <Generator>
Result ：           mm

③
Measurement of facial runout
③ ・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.
・Before conducting the measurement, move the crankshaft
either in the front or rear side in order to prevent errors due
to the end play.
・Set graduations of the dial gauge to ''0''and then rotate the
crankshaft by a turn to measure differences in the maximum
deflections of the gauge poiter.
Facial runout  ： MAX. 0.20 mm <All engine>
          MAX. 0.28 mm <Generator>
Result ：           mm

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

7/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・ Before inserting the pilot, clean, degrease and dry the oil seal
lip surface.

・ Before inserting the oil seal, clean, degrease and dry the
surface where the seal is contacted against the crankshaft.

・Using tool G, insert the oil seal until it is flush with the flywheel
② 4 housing end face.
・When pushing in the oil seal, make sure that the seal carrier is
free from bending.

・Measurement of installed dimension X.

[2]
15 Rear oil seal

MAX. 0.38mm   Result：        mm 

③

G ④
1
X

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

8/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・ Install guide bolt and flywheel.

・ Tighten the mounting bolts in the order indicated in the

figure ①.
kgm
Mounting bolt of flywheel
137 7 Nm｛ 14.0 0.7 kgm ｝

16 Flywheel ・ After installing the flywheel, measure the radial runout and
facial runout with tool L as figure ② .
②
Radial runout:MAX.0.13mm   Result：          mm

a
b
Facial runout:MAX. 0.20mm   Result：          mm

L L

・ Fill up the oil pump rotor space and the idler shaft bore with
engine oil and then rotate by two turns.

・ Tighten the mounting bolts of oil pump assembly, in the order

indicated in figure ④.

Mounting bolt of oil pump

17 Oil pump kgm
1st time : 8 1 Nm ｛ 0.8 0.1 kgm ｝( Fig a )
2nd time : 24 4 Nm ｛ 2.4 0.4 kgm ｝( Fig b )

④ [3] [3]
[1] [2]
・ Stop move of a gear of either side and then measure
backlash C of the pump and idler gear.

Total amount of backlash C ： 0.2 0.05 mm

[4] [4] Result ：           mm
[2] [1]
a C b

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

9/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・Apply gasket sealant to installation surface A of cover ①.

・Diameter of gasket sealant line shall be 1-2mm.
A

・Tighten the mounting bolts according to the numbers

【1】∼【13】 shown in the figure ②.

Mounting bolt of Front cover

kgm
24 4 Nm｛ 2.4 0.4 kgm ｝     

②
[8] [7]
[9] [6]
[2] 18 Front cover ・Using tool H, install front seal as figure ③.
[10] ・Before installing the seal, check that the end corners and lip
[11] [5]
sliding surfaces of the crankshaft are free from flaw , burr,
[4] and rust of the housing.

[12] [3]
[13]

④ ・When installing the seal, do not apply oil or grease to the

[1]
shaft and seal lip.
③ Wipe off the oil bfrom the shaft.
・The deflection of front oil seal from front cover must meet
the following criteria.(Figure4)

• Protrusion x: Max. 0.38 mm

• Facial runout (TIR) y: Max. 0.25 mm

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

10/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・ Adjustment of installing position of the Engine Bkup speed

sensor is unnecessary.
☆ ☆ 18 Front cover kgm

Mounting bolt of Engine Bkup speed sensor

8 2 Nm ｛ 0.82 0.20 kgm ｝ 

・ Install the plate. 

Mounting bolt of plate ： 43 5 Nm ｛ 4.4 0.5 kgm｝
☆ ☆
kgm

② A
・ Install the suction tube. 
Mounting bolt of suction tube ： 24 4 Nm ｛ 2.4 0.4 kgm｝

・ Apply gasket sealant, and Remove the gasket sealant

projected from between the cylinder block and front cover
and between the cylinder block and gear housingwith a
Φ1 Φ3 scraper.
19 Oil pan (4 places marked with ☆ on figure ①)
③ [15] [11] [7] [1] [3] [5] [9] [13]
・ Diameter of gasket sealant line : 3mm
<4D107E-1>
[17]
・ When removing only the oil pan, remove the used gasket
[21]
sealant filled in the borders with a scraper too.
[23]
[19] (4 places marked with ☆ on figure ①)

[20]
[24]
・ Apply gasket sealant to installation surface A as figure ②
[22] [18]
・ Diameter of gasket sealant line
:Straight line:3 mm , Curved line:1 mm)
[16] [12] [8] [4] [2] [6] [10] [14]

④ [21][17][13] [9] [5] [1] [3] [7] [11][15][19] [23]

<6D107E-1>
[25] [29]
・ Tighten the mounting bolts according to the numbers shown
[27] [31] in the figure ③,④.
kgm
[32]
[28] Mounting bolt of Oil pan ： 28 2 Nm ｛ 2.9 0.2 kgm｝
[26] [30]

[22][18][14][10] [6] [4] [2] [8] [12][16][20][24]

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

11/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ Install crankshaft pulley( 4D107E-1) and vibration damper(

① 6D107E-1) by fitting in their knock holes to dowel pin of the
crankshaft.
14 ・ Bolt tightening procedure
20 Crankshaft pulley (1) Tighten the bolt's opposing corner sequentiallly with
16 ＆
55 5 Nm｛ 5.6 0.5 kgm ｝
15 Vibration damper
(2) Loosen the bolt by 180  
11 (3) Tighten the bolt's opposing corner sequentially with
55 5 Nm｛ 5.6 0.5 kgm ｝
(4) 90 5 (Used by angle tightening tool)

・ How to install the gear.

・ The shaft and gear mating face must be clean and dry prior
to assembly.
(1) Install the gear (16) onto the shaft(14).
(2) Install the lock washer (15) and nut (11) and finger
21 Fuel supply tighten.
pump (3) Use the support Y and 1/2inch breaker bar(10) to hold
② the gear in place while tightening the nut(11).

Mounting nut of Fuel supply pump gear

Y kgm
: 105 5 Nm ｛ 10.7 0.51 kgm ｝

・ Install supply pump with 3 nuts.

・ If grease is applied too much to the O-ring when the supply
pump is installed, it will ooze out during operation.Accordingly,
do not apply grease too much.
・ When removing and installing the supply pump mounting stud
bolts of the gear housing, apply LOCTITE to the root side.
10

Mounting nut of Fuel supply pump gear

11 : 24 4 Nm ｛ 2.4 0.4 kgm ｝

・ Install new hose.

・ The internal parts of the adapter may be damaged when the
hose is removed.
・ Accordingly, do not reuse the adapter but use new one when
installing the hose again, as a rule.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

12/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・ Install cooling plate assembly and tighten mounting bolts.

Mounting bolt ： 24 4 Nm｛ 2.4 0.4 kgm ｝
22 Engine
controler ・ IInstall Engine controller and tighten mounting bolts.
Mounting bolt ： 24 4 Nm｛ 2.4 0.4 kgm ｝

・ Install the ground wire.

kgm

・ Install gaskets and oil cooler and cover with bolts shown by
figure ①.
 
・ Tighten the bolts in the numeric order shown in the figure ②.

② Mounting bolt of oil coler ： 24  4 Nm｛ 2.4 0.4 kgm｝

[15] [14] [13]

[12]
・ For a model such as WA380-6 which has the oil filter on its
[2] Engine, install the oil filter.
23 Oil cooler

[9] [10]

・ Apply Engine oil to the filter seal.

kgm

[11] [8] ・ Torque of filetr:13 2Nm {1.3 0.2kgm} or tighten 3/4

[6] turns after contacting mating part.

[4] [1]

[3]

[7] [5]

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

13/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

① ・ Install valve seal.

・ Apply Engine oil to the valve stem and inside of valve guide
and install valve.
・ Raise the cylinder head and install valve spring and upper
If a bolt is linger than seat.
the using limit, do not
a reuse it but replace it. ・ Compress valve spring to install valve cotter.
・ H i t the valve stem lightly with a plastic hammer to make
② sure that the valve collet is correctly fitted to the groove of
the valve stem.

・ Before tightening the cylinder head mounting bolt, measure

the stem length a of every bolt to make sure that they are
less than the using limit.

Using limit length of bolt stem (a) ： Max. 132.1 mm

③ ( 4D107E-1 )
24 Cylinder
[16] [12] [8] [4] [1] [5] [9] [13] [17] ・ Check that the cylinder head mounting face and inside of the
head
assembly cylinder are free from foreign matter and then set cylinder
head gasket.

・ Make su re t hat the gasket is fi t ted in t he hole on the

[14] cylinder head.
[18]
・ Set cylinder head assembly on the cylinder block and then
tighten it using mounting bolts.
[15] [11] [7] [3] [2] [6] [10]
・ First , tighten the mounting bolts by 2 - 3 turns or more by
④ ( 6D107E-1 ) hand , and then tighten them according t o the fol lowing
procedure.
[16][12] [8] [4] [1] [5] [9] [13][17][21][25]
[24] [20]

・ Tighten the bolts 3 times in the order shown in the figure ③,④.
kgm
(1) 90 3 Nm｛ 9.2 0.3 kgm ｝
(2) 90 3 Nm｛ 9.2 0.3 kgm ｝
(3) 90 5

[23] [15] [7] [2] [10] [18] [26]

[19] [11] [3] [6] [14] [22]

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

14/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ When replacing the injector, replace the inlet connector, too.

① ・ Make sure that the injector sleeve is free from damages or
dirt.
(a)
・ Attach the gasket and O-ring to injector.
(b)
・ Apply engine oil to the O-ring of injector.as well as the head
side.

・ Insert injector to the cylinder head wh ile directing it s fuel

inlet hole to the manifold.

・ Install holder and then tighten bolts 3 to 4 threads.

・ Apply engine oil to the O-ring of inlet connector as well as the

head side.
②
25 Fuel injector
・ Insert inlet connector in the mounting hole of injector and
tighten retainer temporarily.
Retainer 15 5 Nm｛ 1.5 0.5 kgm ｝
 The
・ above is temporary tightening

・ Tighten bolts alternately shown as figure (a),(b).

Mounting bolt of injector 8 0.8 Nm ｛ 0.8 0.08 kgm ｝
kgm

・ Tighten retainer.
③ (c)
Retainer ｛ 50 5Nm ｝

・ Appl y l i qu i d g a s ket onto O - r ing of i nject or h a rn ess

connector(c) and flange surface(d) prior to installation.
(d) ・ Apply liquid gasket with 3mm width until the groove for
O-ring is fully filled.
・ If O-ring is damaged, replace the harness as an assembly.

Mounting bolt of injector harness connector

10 2 Nm ｛ 1 0.2 kgm ｝

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

15/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ Check that the push rod is fitted in the tappet.

① Push rod ・ Refill the push rod socket with engine oil.
A B
・ Before tightening the mounting bolts, check that the ball of
the adjustment screw is fitted to the socket of the push rod.

kgm
Mounting bolt of Rocker arm
Rocker arm 36 5 Nm｛ 3.7 0.5 kgm ｝

・ Shape of the holes (A) and (B)on the crosshead is not

identical.
・ Thus when using this part again, it must be assembled in the
same direction on the same intake and exhaust valves.

26 ・ As the valve clearance, adjust the clearance between the

crosshead and rocker arm to the following value.
・ Valve clearance(when engine cold)
Unit：mm
② Air intake valve Exhaust valve

0.25 0.05 0.51 0.05

・ The position of plug is subject to the applicable machine.

Valve clearance ・ Rotate the crankshaft forward and set wide slit on the disc
having the revolution sensor slits at the rear of the
crankshaft pulley to projection top of the front cover.

・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.)

・ 4D107E-1 : No.1 cylinder or No.4 cylinder

・ 6D107E-1 : No.1cylinder or No.6 cylinder
<Referance> 
The position for wide slit on the damper of 6D107E-1
is painted white.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

16/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ If you cannot move the rocker arms of the exhaust valves (on
FigureⅠ the EX side) with the hand, adjust the valves marked with ○
in figureⅠ.

No. 1 2 3 4 5 6 ・ If you can move the rocker arms of the exhaust valves (on
the EX side) with the hand by the valve clearance, adjust the
EX valves marked with ● in the figureⅠ.

IN ・ Insert clearance gauge in the clearance between rocker arm

and crosshead.
・L o o s e n l o c k n u t a n d a d j u s t t h e v a l v e c l e a r a n c e w i t h
adjustment screw. (figureⅡ)

FigureⅡ ・ With the clearance gauge inserted, turn the adjustment screw
to a degree that you can move the clearance gauge lightly.

Valve Valve
26 Valve clearance clearance 0.25 (mm) clearance 0.51 (mm)
No.1 No.1
No.2 No.2
No.3 No.3
IN EX
No.4 No.4
No.5 No.5

No.6 No.6

kgm ・ Locknut：20 ∼ 28Nm{2.04 ∼ 2.86Kgm}

・ After tightening the locknut, check the valve clearance again.

・ Rotate the crankshaft in normal direction.

・ If the vaive marked with ○ in the valve arrangement drawing
were adjusted in the first steps and adjust the valves marked
with ●.
・ Adjusting the another valve clearance.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

17/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

FigureⅠ
kgm ・ Mounting bolt of rocker housing ：24 4Nm {2.4 0.4Kgm}

・ Harness installation position

Color of cable Cylinder No.

27 Rocker housing White １，３，５

Brack ２，４，６

・ Check to the harness interfere with the rocker arm

kgm ・ Mounting nut：1.5 0.25Nm {0.15 0.03Kgm}

FigureⅡ

・ Fit the gasket and then install head cover using nut.
(FigureⅠ)
28 Head cover

kgm ・ Mounting nut：24 4Nm {2.4 0.4Kgm}

・ Fit the gasket and then install manifold covers shown as

figureⅡ.
29 Air intake
manifold cover

kgm ・ Air intake manifold cover mounting bolt

： 24 4Nm {24 0.4Kgm}

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

18/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ Do not remove fuel pressure sensor from common rail for a

FigureⅠ purpose other than replacement. (FigureⅠ)
・ Once the fuel pressure sensor is removed from the common
rail, be sure to replace it.
・ Before removing the fuel pressure sensor, remove mud etc.
from around it thoroughly and clean it.

30 Fuel pressure ・ Check the fuel pressure sensor connector for crack,
sensor breakage, damage of the seal, foreign matter on the pin and
2
corrosion, bend and breakage of the pin.
3 ・ Take care not to connect the wiring harness in reverse when
connect the engine wiring harness.

1 ・ Start the engine and check that fuel does not leak.

・ Apply gear oil(#90) for threaded part of fuel pressure sensor.

FigureⅡ
kgm ・ Fuel pressure sensor：70 5Nm｛7.1 0.5Kgm｝
A

・ Before removing the relief valve, remove mud etc. from

around it thoroughly and clean it. (FigureⅡ)
・ If the leakage from the relief valve exceeds the specified
value, do not reuse it.
・ Check that high-pressure seal surfaces of the relief valve and
31 Relief valve rail are free from damage.

・ Apply gear oil(#90) for threaded part of relief valve.

3
・ Relief valve：100 4Nm{10.2 0.4Kgm}
kgm
・ Excessive tightening can cause leakage.
・ Take care not to tighten too strongly.

・ Start the engine and check that fuel does not leak.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

19/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

・ Fuel leakage can occur on a high-pressure piping that has visible

FigureⅠ lengthwise slits (b) or dents such as patchy damages (c) on its taper
seal of the piping connection (part (a): 2 mm space from the tip).
b The same holds true for a high-pressure piping that catches claw
because of fatigued steps in part (d) (end of the taper seal: a 2 mm
Connecting space from the tip). Such high-pressure piping must be replaced.
part of (FigureⅠ)
32
high-pressure ・ It is prohibited to bend high-pressure pipings used.
piping
・ The clamps used for fixing high-pressure pipings must be the
genuine part. And the specified tightening torque must be strictly
observed.
・ A clearance of 10 mm minimum must be provided between the
a c installed highpressure piping and harness.
・ Sleeve nut and mounting bolt
d 33 Common rail kgm
：0.2 ∼ 0.8Nm{0.02 ∼ 0.08Kgm} (Temporary tighten)

・ Tighten high-pressure pipings according to the following procedure.

【1】to【3】(FigureⅡ)
FigureⅡ
【1】 Head side of high-pressure pipings (6) and (1) → Rail side of
high-pressure pipings (6) and (1)
1 9 2 8 3 4 5 10 6 Fuel
34 high-pressure 【2】 Head side of high-pressure pipings (2),(3),(4),(5) → Rail side of
piping high-pressure pipings (2),(3),(4),(5)
kgm
【3】 Pump side of high-pressure piping (7) and then its rail side.

・ Sleeve nut：35 3.5Nm{3.57 0.36Kgm}

・ Mounting bolt of high pressure piping clamp
：10 2Nm{1.0 0.2Kgm}

・ Mounting bolt of common rail(10)：24 4Nm{2.4 0.4Kgm}

kgm
・ Apply sealant (LG-7) to the threaded part of 2 bolts inside the
35 Common rail engine.
7 ・ Set the slits of each boots(9) out and down.

Fuel ・ Joint bolt：24 4{2.4 0.4Kgm}

36 kgm
return hose
Fuel ・ As the gasket touched the filter head, tighten the fuel filter 1/2 turn
37
filter assembly to install it.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

20/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

Figure ・ Fit a new gasket and then install exhaust manifold to the
Ⅰ ⑪ ⑦ ③ ② ⑥ ⑩ cylinder head.

・ Tighten the mounting bolts according to the numbers

shown in the figureⅠ.

１】Tighten every bolt with

38 Exhaust 24 4Nm{2.4 0.4Kgm}
manifold kgm

⑫ ⑧ ① ④ ⑤ ⑨ ２】Tighten every bolt with

53 6Nm{5.4 0.6Kgm}
Figure
Ⅱ
３】Tighten ① to ④ bolts alone in the figure in this order with
53 6Nm{5.4 0.6Kgm} (FigureⅠ)

2
・ Fit the gasket and install turbocharger assembly to exhaust
manifold. (FigureⅡ)
・ Tighten the mounting nuts in the diagonal order.

kgm ・ Mounting nut of turbocharger：43 6Nm {4.4 0.6Kgm}

・ Install the turbocharger assembly oil feed tube. (FigureⅢ)

Figure ・ Mounting nut of oil feed tube on oil cooler side

Ⅲ kgm ：24 4Nm {2.4 0.4Kgm} 
・ Mounting nut of oil feed tube on turbocharger side
39 Turbocharger ：36 5Nm {3.6 0.5Kgm}

・ Fit the gasket to the turbocharger assembly and install oil

return tube.

kgm ・ Oil return tube mounting bolt:：24 4Nm{2.4 0.4Kgm}

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

21/22
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGIN 107 SERIES PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

FigurⅠ ・ Attach the seal ring and then install water pump coolant
inlet connector. (FigureⅠ)
40 Water pump
kgm ・ Mounting bolt of water pump：43 6Nm{4.4 0.6Kgm}

・ Mounting bolt of sling bracket

41 Bracket kgm
：43 6Nm {4.4 0.6Kgm}
・ Mounting bolt of alternator bracket
：24 4Nm { 2.4 0.4Kgm}

・ Install alternator temporarily using mounting bolts.

FigureⅡ ・ Install plate.
・ Tightening the alternator mounting bolt.
①
42 Alternator
・ Mounting bolt of bracket side
③ kgm ：43 6Nm {4.4 0.6Kgm}
・ Mounting bolt of plate side
：24 4 Nm {2.4 0.4Kgm}
④ ②
43 Fan hub kgm ・ Mounting bolt of fan hub：32 5Nm {3.3 0.5Kgm}

FigureⅢ ・ Check visually or using a ruler, that the belt mounts of the
tensioner pulley and alternator pulley are parallel.
44 Belt tensioner
kgm
・ Mounting bolt of belt tensioner：43 6Nm {4.4 0.6Kgm}

45 Fan pulley kgm ・ Mounting bolt of fan pulley：43 6Nm {4.4 0.6Kgm}

・ Make sure that the wrench is secured before rotating it.

(FigureⅢ)
FigureⅣ
46 Fan belt ・ After removing the fan belt, return the tensioner assembly
slowly with care.

・ Be careful not to get your fingers caught between the pulley

and fan belt during work.

Starting ・ Apply 1 mm wide gasket sealant (LG-7) to the entire

47 circumference of the front and back sides of the gasket.
motor assembly
(FigureⅣ)

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

22/22