Gd535 6 Engine Manual

SEN06896-03
ENGINE 107E -5 SERIES

00 INDEX AND FOREWORD
107E-5 SERIES 00-1

INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
FOREWORD, SAFETY, BASIC INFORMATION ..................................................................................... 00-4
HOW TO READ THE ENGINE SHOP MANUAL .............................................................................. 00-4
SAFETY NOTICE FOR OPERATION............................................................................................... 00-6
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-14
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-16
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-17
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION .......................................... 00-18
PRECAUTIONS FOR DEF............................................................................................................. 00-19
STORE AdBlue/DEF ...................................................................................................................... 00-20
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-21
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-24
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-31
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-33
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-34
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-35
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-39
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-43
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-44
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-46
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-47
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-49
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-50
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-54
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-57
CONVERSION TABLE ................................................................................................................... 00-64
ABBREVIATION LIST .................................................................................................................... 00-69
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
SPECIFICATIONS .................................................................................................................................. 01-3
OUTLINE OF EXHAUST GAS REGULATION.................................................................................. 01-3
LIST OF APPLICABLE MACHINES: 107E-5.................................................................................... 01-6
SPECIFICATIONS ........................................................................................................................... 01-7
ENGINE GENERAL VIEW ............................................................................................................. 01-10
ENGINE PERFORMANCE CURVE ............................................................................................... 01-22
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM.............................................................................................................................. 10-4
LAYOUT DRAWING OF UREA SCR SYSTEM ................................................................................ 10-4
UREA SCR SYSTEM DIAGRAM ..................................................................................................... 10-6
FUNCTION OF UREA SCR SYSTEM.............................................................................................. 10-7
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-16
ENGINE SYSTEM ................................................................................................................................ 10-24
LAYOUT OF ENGINE COMPONENTS .......................................................................................... 10-24
INTAKE AND EXHAUST SYSTEM PARTS .................................................................................... 10-25
ENGINE MAIN BODY PARTS........................................................................................................ 10-30
TURBOCHARGER......................................................................................................................... 10-44
CRANKCASE VENTILATION SYSTEM ......................................................................................... 10-47
IMPACTOR (FILTERLESS) ............................................................................................................ 10-48
EXHAUST THROTTLE VALVE ...................................................................................................... 10-49
KDPF ............................................................................................................................................. 10-50
LUBRICATION SYSTEM................................................................................................................ 10-54
FUEL SYSTEM .............................................................................................................................. 10-63
COOLING SYSTEM....................................................................................................................... 10-73
ELECTRICAL SYSTEM ........................................................................................................................ 10-78
00-2 107E-5 SERIES

00 INDEX AND FOREWORD INDEX
COMPONENT PARTS OF ELECTRICAL SYSTEM ....................................................................... 10-78

SENSOR........................................................................................................................................ 10-92
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0,
D51PXI-24E0) .............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6)............................................ 20-6
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0) ....................................... 20-9
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ................................................. 20-12
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK
IN PERIOD: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0) .......... 20-12
IN PERIOD: SAA4D107E-5 (GD535-6) ...................................................................................... 20-14
IN PERIOD: SAA4D107E-5 (WA200-8E0).................................................................................. 20-16
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-3
HOW TO READ THIS MANUAL....................................................................................................... 50-3
COATING MATERIALS LIST............................................................................................................ 50-5
SPECIAL TOOLS LIST .................................................................................................................. 50-10
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-12
ENGINE SYSTEM ................................................................................................................................ 50-13
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY............................................................. 50-13
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-87
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ................................................................... 50-93
REMOVE AND INSTALL ENGINE REAR OIL SEAL...................................................................... 50-98
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE SYSTEM .................................................................................................................................. 60-3
INTAKE AND EXHAUST SYSTEM PARTS ...................................................................................... 60-3
ENGINE MAIN BODY PARTS.......................................................................................................... 60-4
LUBRICATION SYSTEM................................................................................................................ 60-22
INDEX..................................................................................................................................................................1
107E-5 SERIES 00-3

HOW TO READ THE ENGINE SHOP MANUAL 00 INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUC-
TURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
Symbol
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
00-4 107E-5 SERIES

00 INDEX AND FOREWORD HOW TO READ THE ENGINE SHOP MANUAL
Symbol Item Remark

This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
This symbol indicates the works which require special caution for the ma-
Safety
chine safety when assembling.
Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
107E-5 SERIES 00-5

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpo-
ses.
• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
00-6 107E-5 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
• Always wear the protective eyeglasses when hitting parts

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

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).
107E-5 SERIES 00-7

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

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.
00-8 107E-5 SERIES

• Install the disassembled parts again to the original position. Replace the damaged parts or the parts that
cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that
they do not touch and give damage to other parts when you operate the machine.
REMARK
When you replace the removed or disassembled parts with new ones, refer the parts book to find out the
part number.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.
,&
Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
107E-5 SERIES 00-9

• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kgf} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000kgf} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
00-10 107E-5 SERIES

Precautions for using overhead traveling crane

k When raising a heavy component (heavier than 25 kg), use a hoist or crane.
REMARK
Weight of component whose weight is heavier than 25 kg is shown with symbol in “DISASSEMBLY AND
ASSEMBLY”.
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
107E-5 SERIES 00-11

Nominal diameter of rope (mm) Allowable load (kN {t} )

60 318.3 {32.4}
Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
00-12 107E-5 SERIES

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, “Pre-
cautions for disconnection and connection of air conditioner
piping”.
107E-5 SERIES 00-13

PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.
00-14 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.
107E-5 SERIES 00-15

ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD
ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
00-16 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
107E-5 SERIES 00-17

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 00 INDEX AND FOREWORD
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION

This machine is applicable to the Stage V emission standards (EU) (2019 or later).
To agree with the requirements of the standards, the exhaust gas aftertreatment device consists of the 2 sys-
tems below is installed to the machine.
• Komatsu Diesel Particulate Filter (hereafter KDPF): Device that collects soot in the exhaust gas and purifies
it. To purify the collected soot, the device burn soot by the operation known as "regeneration".
• Urea SCR system: Device that changes harmful nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water. The device sprays aqueous urea solution into the exhaust gas to change nitrogen ox-
ides into nitrogen and water by chemical reaction with ammonia made from urea solution.
Use AdBlue® or DEF as aqueous urea solution for the urea SCR system.
AdBlue® is a registered trademark of VDA (Verband der Automobilindustrie e.V.).
DFE is an abbreviation of Diesel Exhaust Fluid.
The quality of AdBlue® is specified in ISO22241-1. Be sure to use AdBlue® that agrees with the quality stand-
ard.
In this manual, aqueous urea solution for the urea SCR system is given as AdBlue®.
AdBlue®
AdBlue® is required to the urea SCR system. AdBlue® is 32.5% aqueous urea solution, and it is colorless and
transparent. Urea, major component of AdBlue, is used for cosmetics, pharmaceuticals, fertilizers, or such.
If additive agent is added to AdBlue® or if it is diluted with water, the device cannot operate correctly. As a result,
the machine does not agree with the exhaust gas emission. Also, it can cause the failure of the machine.
• In the EU, use AdBlue®.
• In North America, use DEF with the certification of API (American Petroleum Institute). The certified DEF
has the API DEF Certification Mark as shown below. Be sure to purchase DEF with this mark.
API Diesel Exhaust Fluid Certification Mark is a registered
trademark of API (American Petroleum Institute).
00-18 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DEF
PRECAUTIONS FOR DEF

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

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

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

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

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.
107E-5 SERIES 00-19

STORE AdBlue/DEF 00 INDEX AND FOREWORD
STORE AdBlue/DEF
• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.
00-20 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

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

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.
Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.
107E-5 SERIES 00-21

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD
Preventing intrusion of foreign materials during refilling

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

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.
Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.
00-22 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.
107E-5 SERIES 00-23

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

When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and as-
sembly” of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.
00-24 107E-5 SERIES

00 INDEX AND FOREWORD INGS
Introduction of parts for the disassembly of the face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
Introduction of parts for the disconnection of the taper seal type hoses and
tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
107E-5 SERIES 00-25

Introduction of parts for the disconnection of the split flange type hoses and
tubes
Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
Introduction of parts for the removal of O-ring boss type joint
00-26 107E-5 SERIES

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

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Introduction of parts for the removal of taper pipe thread type joint
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222
14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026
Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
107E-5 SERIES 00-27

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.
00-28 107E-5 SERIES

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See “TEST-
ING AND ADJUSTING”.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.
107E-5 SERIES 00-29

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY
AND ASSEMBLY”.
00-30 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

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

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.
107E-5 SERIES 00-31

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.
Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.
00-32 107E-5 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

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

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.
107E-5 SERIES 00-33

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
00-34 107E-5 SERIES

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

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).
2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.
Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
107E-5 SERIES 00-35

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
2. After inserting the hose in the mating adapter perfectly, pull

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

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
00-36 107E-5 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
107E-5 SERIES 00-37

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.
00-38 107E-5 SERIES

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

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

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.
Connecting connectors
1. Check the connector visually.
107E-5 SERIES 00-39

NECTORS 00 INDEX AND FOREWORD
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.
• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.
• If the connector clamp is removed, be sure to return it

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

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.
00-40 107E-5 SERIES

00 INDEX AND FOREWORD NECTORS
1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.
2. Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.
Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.
107E-5 SERIES 00-41

NECTORS 00 INDEX AND FOREWORD
NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).
Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
00-42 107E-5 SERIES

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

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

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.
107E-5 SERIES 00-43

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

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

TOME-2)
Insert it straight until it clicks.
Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).
00-44 107E-5 SERIES

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR
2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.
Method for connecting slide lock type connector (FRAMATOME-24)

107E-5 SERIES 00-45

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

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

Insert the connector securely until it “clicks”.
00-46 107E-5 SERIES

00 INDEX AND FOREWORD WITH LOCK TO PUSH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series
• 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.
Method for connecting connector with lock to push (BOSCH-3)

107E-5 SERIES 00-47

WITH LOCK TO PUSH 00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
Method for connecting connector with lock to push (AMP-3)

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

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3)

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

While pressing lock (D), pull out connector (4) in the direction
of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)

00-48 107E-5 SERIES

00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

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

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
107E-5 SERIES 00-49

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE

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

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)
Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place
00-50 107E-5 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D
AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
(mm2)
d (approx.) - 0.9 - 1.1 - 1.4
107E-5 SERIES 00-51

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D
CAVS Standard - 1.6 - 1.8 - 2.1
REMARK
“f” of nominal No. denotes “flexible”.
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White
REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is “Green” and marking is “White”.
00-52 107E-5 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
107E-5 SERIES 00-53

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called “tolerance”.
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/
lower limit of tolerance).”
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-54 107E-5 SERIES

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called “standard value”, which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.
Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called “interference”.
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is “standard interference”.
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called “allowable value” or “allowable dimension”.
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called “allowable clearance”.
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called “allowable interference”.
• The allowable interference shows the repair limit of the part of smaller tolerance.
107E-5 SERIES 00-55

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
• The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-56 107E-5 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE

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

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

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.
107E-5 SERIES 00-57

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD
Thread diameter Width across flats

Tightening torque (Nm {kgfm} )
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.
Type of bolt A B
Nominal size - Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC
5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC
3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC
7/ -14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16
1/ -13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2
9/ -12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16
5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC
3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4
7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC
00-58 107E-5 SERIES

Type of bolt A B

1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}
11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}
11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}
11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.
Type of bolt A B

1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF
5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF
3/ -24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8
7/ -20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16
1/ -20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2
9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF
5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF
3/ -16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4
7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF
1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}
11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}
11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}
11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}
107E-5 SERIES 00-59

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread di- Width across Tightening torque (Nm {kgfm} )

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

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread diam- Width across Tightening torque (Nm {kgfm} )

Nominal No.
eter (mm) flats (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
00-60 107E-5 SERIES

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

Nominal No.
eter (mm) flats (mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Width Tightening torque (Nm {kgfm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter(mm)
hose (mm)
(mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -
107E-5 SERIES 00-61

Table of tightening torque for face seal joints

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

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter(mm) (refer-
(mm) threads per inch
pipe (mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

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

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2
Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter (mm) Tightening torque (Nm {kgfm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.
00-62 107E-5 SERIES

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

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}
Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16
1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8
1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4
3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8
1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2
3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4
107E-5 SERIES 00-63

CONVERSION TABLE 00 INDEX AND FOREWORD
CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898
mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
00-64 107E-5 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
ℓ to U.S.Gal
1 ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
107E-5 SERIES 00-65

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgfm to lbft
1 kgfm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kgf/cm2 to lb/in2
1 kgf/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
00-66 107E-5 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE
1 kgf/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9
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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
107E-5 SERIES 00-67

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-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
00-68 107E-5 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations for functions, devices, and parts which are used in the
shop manual.
• Commonly used abbreviations are not included.
• Special abbreviations which are not shown frequently are included in the text as additional information.
List of abbreviations used in the text
Abbreviation Actual word spelled out Explanation
API American Petroleum Institute API is the abbreviation for American Petroleum Institute.
CAN is one of networks that communicate between the machine
CAN Controller Area Network
monitor and controllers.
Crankcase Depression Regula-
CDR valve CDR valve is a valve that is attached to the KCCV ventilator.
tor valve
CRI is a function that is composed of the supply pump, common
CRI Common Rail Injection rail, and injector, and that controls the fuel injection rate and injec-
tion timing.
DEF Diesel Exhaust Fluid DEF is a urea solution that is used for the SCR system.
ECM is an electronic device that controls actuators adequately
ECM Electronic Control Module
with signals from sensors.
ECU is an electronic device that controls actuators adequately
ECU Electronic Control Unit
with signals from sensors.
EGR is a function that recirculates part of exhaust gas to the in-
EGR Exhaust Gas Recirculation
take side to control NOx emissions.
IMA is a device that controls fuel intake volume at the inlet of the
IMA Inlet Metering Actuator
supply pump.
IMV is a device that controls fuel intake volume at the inlet of the
IMV Inlet Metering Valve
supply pump.
KOMATSU Closed Crankcase KCCV is a function that isolates oil from blowby gas in the engine
KCCV
Ventilation and returns the blowby gas to the intake side.
KCSF KOMATSU Catalyzed Soot Filter KCSF is a filter that catches soot in exhaust gas.
KOMATSU Diesel Oxidation Cat-
KDOC KDOC is a device that purifies exhaust gas.
alyst
KOMATSU Diesel Particulate Fil- KDPF is a device that is composed of the KCSF and KDOC, and
KDPF
ter catches soot (Particulate Matter, PM) in exhaust gas.
KOWA is a preventive maintenance service that collects and ana-
KOWA Komatsu Oil and Wear Analysis lyzes oil in the machine at the specified interval so that wear of
the machine and other problems can be found at short time.
LIN is one of networks that communicate between controllers and
LIN Local Interconnect Network
sensors or actuators.
MAF sensor Mass Air Flow sensor MAF sensor is a device that measures the engine intake air flow.
NC is an electrical circuit where contact pair is closed while the
NC Normally Closed
device is not in operation.
NO is an electrical circuit where contact pair is open while the de-
NO Normally Open
vice is not in operation.
PC is a function that controls discharged volume of the hydraulic
PC Pressure Compensation
pump by use of the discharged pressure.
107E-5 SERIES 00-69

ABBREVIATION LIST 00 INDEX AND FOREWORD
Abbreviation Actual word spelled out Explanation

PCV is a device that controls fuel discharged volume at the outlet
PCV Pressure control valve
of the supply pump.
PPC is a function that controls the pressure of the hydraulic circuit
PPC Proportional Pressure Control
in proportion to the degree of the lever operation.
PTO Power Take Off PTO is a mechanism that takes out the engine power.
SCR is a device that purifies nitrogen oxides (NOx) in exhaust gas
SCR Selective Catalytic Reduction
from the engine.
VGT Variable Geometry Turbocharger VGT is a variable type turbocharger.
List of abbreviations used in the circuit diagrams

Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
00-70 107E-5 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST
Abbreviation Actual word spelled out

T/M Transmission
107E-5 SERIES 00-71

01 SPECIFICATIONS
107E-5 SERIES 01-1

CONTENTS 01 SPECIFICATIONS
CONTENTS
SPECIFICATIONS ......................................................................................................................................... 01-3
OUTLINE OF EXHAUST GAS REGULATION......................................................................................... 01-3
SYSTEM DIAGRAM OF ENGINE CONFORMED TO STAGE V REGULATION............................... 01-5
LIST OF APPLICABLE MACHINES: 107E-5........................................................................................... 01-6
SPECIFICATIONS .................................................................................................................................. 01-7
SPECIFICATIONS: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0) ..... 01-7
SPECIFICATIONS: SAA4D107E-5 (GD535-6)................................................................................. 01-8
SPECIFICATIONS: SAA4D107E-5 (WA200-8E0) ............................................................................ 01-9
ENGINE GENERAL VIEW .................................................................................................................... 01-10
ENGINE GENERAL VIEW: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0).
................................................................................................................................................... 01-10
ENGINE GENERAL VIEW: SAA4D107E-5 (GD535-6)................................................................... 01-14
ENGINE GENERAL VIEW: SAA4D107E-5 (WA200-8E0) .............................................................. 01-18
ENGINE PERFORMANCE CURVE ...................................................................................................... 01-22
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0,
D51PXI-24E0) ............................................................................................................................ 01-22
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (GD535-6)..................................................... 01-23
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (WA200-8E0) ................................................ 01-24
01-2 107E-5 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION
SPECIFICATIONS
OUTLINE OF EXHAUST GAS REGULATION
• The main hazardous materials and influences on the hu-
man bodies and environment caused by the exhaust from
the diesel engine are as follows. 2 1
NOx (Nitrogen oxide): Respiratory disorder, acid rain
HC (Hydrocarbon): Photochemical smog O2
N2
PM (Particulate Matters such as soot): Carcinogen, respi- NOX
HC
ratory disorder PM
• NOx is generated when nitrogen (N2) and oxygen (O2) in

atmosphere are heated at high temperature. During the
diesel engine combustion, it is generated by the excessive 3
supply of air (nitrogen). To reduce NOx, it is necessary to
decrease the combustion temperature and to reduce the
oxidation of nitrogen. Accordingly, the air-cooled aftercool-
er (2) is installed to the machine to lower the air tempera-
ture from the turbocharger (1). To further reduce NOx dis-
charged from the engine by the AdBlue/DEF, the urea
SCR system is used as an aftertreatment device.
• HC (Hydrocarbon) is the main material of fuel. HC (Hydro-
carbon) in the blowby gas, the main hazardous material of
G0087318
the diesel engine, was released in atmosphere.
• PM (Particulate Matter) is a particle (solid matter) that attaches to soot by the incomplete combustion of
fuel. Generally, if NOx or PM is reduced, the other will increase. Accordingly, the common rail (3) is installed
to reduce PM, and the combustion system is improved by the electronic controlled fuel high-pressure injec-
tion system to make more fine atomized powders, shorter injection period and timing. To further reduce PM
discharged from the engine, the KDPF is used as an aftertreatment device.
• The different standard for the exhaust gas regulation is ap-
plied in Japan, United States, European Union, and China.
The figure below shows the transition of the exhaust gas
regulation in the United States (from Tier1 to Tier4 Final).
(Transition of the exhaust gas regulation in the United
States EPA (*1) (when engine rated horsepower is 130 to
560kW))
The horizontal line shows NOx+NMHC (*2) and the vertical
line shows PM (Particulate Matter). The exhaust gas regu-
lation is enhanced to approximately 10% for NOx+NMHC G0087319
and PM from Tier3 to Tier4 Final. This exhaust gas regula-
tion is told "Tier4 Final Emissions Regulations". In addition, the EU Stage V emission regulation, which is
the most stringent standard of all exhaust emissions regulations, is now in effect. With this standard, the
25% decrease of PM discharge and the PN (*3) regulation are added to the Tier4 Final emissions regula-
tions. This engine is applicable to the EU Stage V emission regulation.
*1: United States Environmental Protection Agency
*2: General term of hydrocarbon (HC) with high photochemical reaction
*3: Abbreviation for Particle Number, the number of individual particles which exceeds 23nm in diameter dis-
charged from the engine
107E-5 SERIES 01-3

OUTLINE OF EXHAUST GAS REGULATION 01 SPECIFICATIONS
The figure below shows the trend of the exhaust gas regulation for each country.
CY 2013 2014 2015 2016 2017 2018 2019 2020 2021

Q 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
kW < 56 H18
Japan 56 ӌ kW < 130 H23 H26
130 ʿ kW < 560
kW < 56
North 56 䍺 kW < 130
Tier4 I Tier4 F
America 130 ʿ kW < 560
560 ʿ kW
kW < 56
56 䍺 kW < 130 Stage 䊢㻌b
EU Stage 䊣
130 ʿ kW < 560 Stage 䊤
560 ʿ kW
kW < 56
56 䍺 kW < 130 ᅜ㻌㻞
China ᅜ㻌㻟
130 ʿ kW < 560
560 ʿ kW
*
01-4 107E-5 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION
SYSTEM DIAGRAM OF ENGINE CONFORMED TO STAGE V REGULATION
13 12
14
A B
1 7 8 11
16 16
3 10 9
5
4 16
15
G0121957
A: From atmosphere B: To atmosphere

1: Air cleaner 9: Flywheel housing
2: Turbocharger 10: Engine
3: Air-cooled aftercooler 11: SCR assembly
4: Intake air heater 12: AdBlue/DEF tank
5: Intake manifold 13: AdBlue/DEF pump
6: Exhaust manifold 14: AdBlue/DEF injector
7: Exhaust throttle valve 15: Engine controller
8: KDPF 16: Sensors
107E-5 SERIES 01-5

LIST OF APPLICABLE MACHINES: 107E-5 01 SPECIFICATIONS
LIST OF APPLICABLE MACHINES: 107E-5

Engine Applicable machines
D51EX-24E0
D51EXI-24E0
Bulldozer
D51PX-24E0
SAA4D107E-5
D51PXI-24E0
GD535-6 Motor grader
WA200–8E0 Wheel loader
01-6 107E-5 SERIES

01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0,
D51PXI-24E0)
Engine model SAA4D107E-5
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}
Firing order - 1-3-4-2
Overall length mm 822
Overall width mm 733
Dimensions Overall height (excluding

mm 1042
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 99.2±5 {133±6.7}/ 2200 {2200}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 584±29.2 {59.6±3}/ 1450 {1450}
min-1{rpm}
Performance Max. speed with no load

min-1{rpm} 2270±50 {2270±50}
(high idle speed)
Min. speed with no load
min-1{rpm} 1075±25 {1075±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 218{163}
rated point
Dry weight (aftertreatment devices are not inclu-
kg 445.2
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Lubricating oil amount (Refill capacity) ℓ 17(15.5)
Amount of coolant ℓ 6.7
Alternator - 24 V, 85 A
Starting motor - 24 V, 5.5 kW
Turbocharger - HE200
107E-5 SERIES 01-7

SPECIFICATIONS 01 SPECIFICATIONS
SPECIFICATIONS: SAA4D107E-5 (GD535-6)

No. of cylinders - bore x stroke mm 4 - 107×124
Piston displacement ℓ{cc} 4.46{4460}

mm 1009
exhaust pipe)
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 110.3±5.5{147.9±7.4}/2000{2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 640±32{65.2±3.26}/1500{1500}
min-1{rpm}

min-1{rpm} 2250±50{2250±50}
(high idle speed)
min-1{rpm} 825±25{825±25}
(low idle speed)
g/kWh{g/HPh} 210{157}
rated point
kg 479
ded)
Lubricating oil amount (Refill capacity) ℓ 14.8(14.0)
Alternator - 24V, 60A, or 85A
01-8 107E-5 SERIES

01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS: SAA4D107E-5 (WA200-8E0)

No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement ℓ{cc} 4.46 {4460}

mm 1082
exhaust pipe)
mm -
haust pipe)
kW{HP}/
Rated horsepower (Gross) 95.2±4.8{128±6.4}/2000{2000}
min-1{rpm}
Nm{kgfm}/
Max. torque (Gross) 599±30.0{61.1±3.1}/1350{1350}
min-1{rpm}

min-1{rpm} 2250±50{2250±50}
(high idle speed)
min-1{rpm} 825±25{825±25}
(low idle speed)
g/kWh{g/HPh} 211{157}
rated point
kg 463
ded)
Lubricating oil amount (Refill capacity) ℓ 17.5(15.5)
Alternator - 24 V, 100 A
107E-5 SERIES 01-9

ENGINE GENERAL VIEW 01 SPECIFICATIONS
ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0,
D51PX-24E0, D51PXI-24E0)
REMARK
The shape is subject to machine models.
Left side view
1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 822 mm
01-10 107E-5 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW
Right side view
107E-5 SERIES 01-11

Front view
2: Center of cylinder
Dimension (B): 1042 mm
Dimension (C): 334 mm
Dimension (D): 733 mm
01-12 107E-5 SERIES

Rear view
107E-5 SERIES 01-13

ENGINE GENERAL VIEW: SAA4D107E-5 (GD535-6)

REMARK
Left side view
G0152408
Dimension (A): 816 mm
01-14 107E-5 SERIES

Right side view
G0152409
107E-5 SERIES 01-15

Front view
1
B
G0152410
01-16 107E-5 SERIES

Rear view
G0152411
107E-5 SERIES 01-17

ENGINE GENERAL VIEW: SAA4D107E-5 (WA200-8E0)

REMARK
Left side view
Dimension (A) : 826 mm
01-18 107E-5 SERIES

Right side view
107E-5 SERIES 01-19

Front view
01-20 107E-5 SERIES

Rear view
107E-5 SERIES 01-21

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS
ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0,
D51PX-24E0, D51PXI-24E0)
Rated output:99.2±5 kW {133±6.7 HP} /2200 min-1 {2200 rpm} (Gross)
Max. torque: 584±29.2 Nm {59.6±3 kgfm} /1450 min-1 {1450 rpm} (Gross)
700
600
500
Torque (Nm)
400
300
200
100
0
120
100
80
Flywheel output (kW)
60
40
20
Engine speed (min-1)
G0121966
01-22 107E-5 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (GD535-6)

Rated output: 110.3 ± 5.5 kW {147.9 ± 7.4 HP}/ 2000 min-1 {2000 rpm} (Gross)
Max. torque: 640 ± 32 Nm {65.2 ± 3.26 kgfm}/1500 min-1 {1500 rpm}(Gross)
800.0
Torque (Nm)
600.0
400.0
200.0
0.0
120
100
80
60
40
20
G0152412
107E-5 SERIES 01-23

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (WA200-8E0)

Rated output:95.2±4.8 kW {128±6.4 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 599±30.0 Nm {61.1±3.1 kgfm} /1350 min-1 {1350 rpm} (Gross)
700
600
500
Torque (Nm)
400
300
200
100
0
120
100
80
60
40
20
G0121967
01-24 107E-5 SERIES

10 STRUCTURE AND FUNCTION
107E-5 SERIES 10-1

CONTENTS 10 STRUCTURE AND FUNCTION
CONTENTS
UREA SCR SYSTEM..................................................................................................................................... 10-4
LAYOUT DRAWING OF UREA SCR SYSTEM ....................................................................................... 10-4
UREA SCR SYSTEM DIAGRAM ............................................................................................................ 10-6
FUNCTION OF UREA SCR SYSTEM..................................................................................................... 10-7
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM .............................................................................. 10-7
INDUCEMENT STRATEGY ............................................................................................................. 10-9
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-16
SCR ASSEMBLY ........................................................................................................................... 10-16
AdBlue/DEF TANK ......................................................................................................................... 10-18
AdBlue/DEF PUMP ........................................................................................................................ 10-20
AdBlue/DEF INJECTOR................................................................................................................. 10-21
AdBlue/DEF HOSE ........................................................................................................................ 10-22
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-23
ENGINE SYSTEM ....................................................................................................................................... 10-24
LAYOUT OF ENGINE COMPONENTS ................................................................................................. 10-24
LAYOUT DRAWING OF ENGINE COMPONENTS ........................................................................ 10-24
INTAKE AND EXHAUST SYSTEM PARTS ........................................................................................... 10-25
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................... 10-25
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM................................................................ 10-26
FUNCTION OF INTAKE AND EXHAUST SYSTEM ....................................................................... 10-26
AIR CLEANER ............................................................................................................................... 10-28
INTAKE AIR HEATER .................................................................................................................... 10-29
ENGINE MAIN BODY PARTS............................................................................................................... 10-30
CYLINDER HEAD .......................................................................................................................... 10-30
CYLINDER BLOCK........................................................................................................................ 10-32
MAIN MOVING PARTS .................................................................................................................. 10-34
CRANKSHAFT PULLEY ................................................................................................................ 10-37
TIMING GEAR ............................................................................................................................... 10-38
FRONT COVER............................................................................................................................. 10-39
VALVE SYSTEM ............................................................................................................................ 10-40
FLYWHEEL AND FLYWHEEL HOUSING ...................................................................................... 10-42
TURBOCHARGER................................................................................................................................ 10-44
STRUCTURE OF TURBOCHARGER ............................................................................................ 10-44
SPECIFICATIONS OF TURBOCHARGER..................................................................................... 10-45
FUNCTION OF TURBOCHARGER ............................................................................................... 10-45
CRANKCASE VENTILATION SYSTEM ................................................................................................ 10-47
SYSTEM DIAGRAM OF CRANKCASE VENTILATION SYSTEM .................................................. 10-47
FUNCTION OF CRANKCASE VENTILATION SYSTEM ................................................................ 10-47
IMPACTOR (FILTERLESS) ................................................................................................................... 10-48
STRUCTURE OF IMPACTOR (FILTERLESS) ............................................................................... 10-48
OPERATION OF IMPACTOR (FILTERLESS)................................................................................. 10-48
EXHAUST THROTTLE VALVE ............................................................................................................. 10-49
STRUCTURE OF EXHAUST THROTTLE VALVE.......................................................................... 10-49
FUNCTION OF EXHAUST THROTTLE VALVE ............................................................................. 10-49
OPERATION OF EXHAUST THROTTLE VALVE ........................................................................... 10-49
KDPF .................................................................................................................................................... 10-50
STRUCTURE OF KDPF ................................................................................................................ 10-50
FUNCTION OF KDPF .................................................................................................................... 10-51
TYPES OF REGENERATION FUNCTION ..................................................................................... 10-52
LUBRICATION SYSTEM....................................................................................................................... 10-54
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS............................................................. 10-54
LUBRICATION SYSTEM CIRCUIT DIAGRAM............................................................................... 10-55
ENGINE OIL PUMP ....................................................................................................................... 10-56
ENGINE OIL FILTER ..................................................................................................................... 10-57
ENGINE OIL COOLER .................................................................................................................. 10-58
ENGINE OIL REGULATOR VALVE ................................................................................................ 10-60
10-2 107E-5 SERIES

10 STRUCTURE AND FUNCTION CONTENTS
SAFETY VALVE OF ENGINE OIL .................................................................................................. 10-61

ENGINE OIL PAN .......................................................................................................................... 10-62
FUEL SYSTEM ..................................................................................................................................... 10-63
LAYOUT DRAWING OF FUEL SYSTEM PARTS ........................................................................... 10-63
FUEL SYSTEM CIRCUIT DIAGRAM ............................................................................................. 10-64
CRI SYSTEM ................................................................................................................................. 10-65
SUPPLY PUMP.............................................................................................................................. 10-67
COMMON RAIL ............................................................................................................................. 10-68
INJECTOR ..................................................................................................................................... 10-69
FUEL PREFILTER ......................................................................................................................... 10-71
FUEL MAIN FILTER....................................................................................................................... 10-72
COOLING SYSTEM.............................................................................................................................. 10-73
LAYOUT DRAWING OF COOLING SYSTEM PARTS.................................................................... 10-73
COOLING SYSTEM CIRCUIT DIAGRAM ...................................................................................... 10-74
DRIVE PULLEY ............................................................................................................................. 10-75
WATER PUMP ............................................................................................................................... 10-76
THERMOSTAT............................................................................................................................... 10-77
ELECTRICAL SYSTEM ............................................................................................................................... 10-78
COMPONENT PARTS OF ELECTRICAL SYSTEM .............................................................................. 10-78
ALTERNATOR ............................................................................................................................... 10-78
STARTING MOTOR ....................................................................................................................... 10-81
ENGINE WIRING HARNESS......................................................................................................... 10-82
ENGINE CONTROLLER ................................................................................................................ 10-84
SENSOR............................................................................................................................................... 10-92
LAYOUT DRAWING OF ENGINE SENSOR .................................................................................. 10-92
STRUCTURE OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR .................. 10-95
FUNCTION OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR...................... 10-95
STRUCTURE OF ENGINE OIL PRESSURE SWITCH .................................................................. 10-96
FUNCTION OF ENGINE OIL PRESSURE SWITCH ...................................................................... 10-96
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR ................... 10-97
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR....................... 10-97
STRUCTURE OF COOLANT TEMPERATURE SENSOR.............................................................. 10-98
FUNCTION OF COOLANT TEMPERATURE SENSOR ................................................................. 10-98
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ............................................................. 10-99
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ................................................................ 10-99
STRUCTURE OF Bkup (CAM) SPEED SENSOR .........................................................................10-100
FUNCTION OF Bkup (CAM) SPEED SENSOR ............................................................................10-100
STRUCTURE OF COMMON RAIL PRESSURE SENSOR ...........................................................10-101
FUNCTION OF COMMON RAIL PRESSURE SENSOR ...............................................................10-101
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .....10-102
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .........10-102
STRUCTURE OF CRANKCASE PRESSURE SENSOR...............................................................10-103
FUNCTION OF CRANKCASE PRESSURE SENSOR ..................................................................10-103
STRUCTURE OF ENGINE OIL LEVEL SENSOR.........................................................................10-104
FUNCTION OF ENGINE OIL LEVEL SENSOR ............................................................................10-104
STRUCTURE OF AIR CLEANER CLOGGING SENSOR .............................................................10-105
FUNCTION OF AIR CLEANER CLOGGING SENSOR .................................................................10-105
STRUCTURE OF WATER-IN-FUEL SENSOR..............................................................................10-106
FUNCTION OF WATER-IN-FUEL SENSOR .................................................................................10-106
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR.................................................10-107
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR ....................................................10-107
STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)............10-108
FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR) ...............10-108
107E-5 SERIES 10-3

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction
LAYOUT DRAWING OF UREA SCR SYSTEM

General view
REMARK
This figure shows the D51-24E0 model.
1: AdBlue/DEF tank 9: AdBlue/DEF breather

2: AdBlue/DEF pump 10: Ambient temperature sensor
3: Engine room temperature sensor 11: AdBlue/DEF pressure hose (low-temperature side)
4: AdBlue/DEF pressure hose (high-temperature side) 12: AdBlue/DEF suction hose
5: KDPF 13: AdBlue/DEF return hose
6: SCR assembly 14: AdBlue/DEF tank heating valve
7: AdBlue/DEF filler port 15: AdBlue/DEF coolant outlet hose
8: AdBlue/DEF tank sensor 16: AdBlue/DEF coolant inlet hose
10-4 107E-5 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM
17: SCR outlet temperature sensor 20: AdBlue/DEF injector coolant hose
18: SCR outlet NOx sensor 21: AdBlue/DEF injector
19: SCR temperature sensor 22: Turbocharger outlet NOx sensor
107E-5 SERIES 10-5

UREA SCR SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM DIAGRAM
1
5 8 9 17
2 3 6 7 18 19
10 23
4 12 13 14 16
A 20 21
11 B 24
15 22
25
26
27
32
34 29
A
B
33
36
37 35 30
31 28
G0124095
A: Coolant inlet B: Coolant outlet

1: Intake manifold pressure and temperature sensor 20: SCR temperature sensor
2: Engine 21: SCR outlet temperature sensor
3: Exhaust throttle valve 22: SCR temperature sensor controller
4: Engine controller 23: SCR outlet NOx sensor
5: KDPF assembly 24: SCR outlet NOx sensor controller
6: KDOC unit 25: Smart sensor
7: KCSF unit 26: Ambient temperature sensor
8: KDPF differential pressure sensor 27: Engine room temperature sensor (*1)
9: KDPF outlet pressure sensor 28: AdBlue/DEF system
10: Turbocharger outlet NOx sensor 29: AdBlue/DEF tank heating valve
11: Turbocharger outlet NOx sensor controller 30: AdBlue/DEF tank
12: KDOC inlet temperature sensor 31: AdBlue/DEF tank sensor
13: KDOC outlet temperature sensor 32: AdBlue/DEF suction line
14: KDPF outlet temperature sensor 33: AdBlue/DEF return line
15: KDPF temperature sensor controller 34: AdBlue/DEF pressure line
16: AdBlue/DEF injector 35: AdBlue/DEF pump
17: SCR assembly 36: AdBlue/DEF line heater relay
18: SCR catalyst 37: Machine monitor
19: Ammonia oxidation catalyst
*1: It is not installed on some machine models.
10-6 107E-5 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
FUNCTION OF UREA SCR SYSTEM

REMARK
The figure shows the divided type system.
5
CO N2
1 NOx H 2O
HC CO2
6 7 8 9
2 4
3
G0124096
1: Engine 6: KDOC
2: Engine controller 7: KCSF
3: AdBlue/DEF pump 8: SCR catalyst
4: AdBlue/DEF tank 9: Ammonia oxidation catalyst
5: AdBlue/DEF injector
• The urea SCR system is the device that changes harmful nitrogen oxides (NOx) in the exhaust gas into
harmless nitrogen and water.
• The system sprays AdBlue/DEF in the exhaust gas to mix and hydrolyze it to make ammonia, and ammo-
nia and nitrogen oxides change into nitrogen and water by chemical reaction.
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM

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

pump, may not start functioning till certain conditions are fulfilled.
107E-5 SERIES 10-7

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at -11 °C.
Function of AdBlue/DEF injection system
• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the mixer inside the SCR assembly
through the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the charge (boost) pres-
sure and temperature sensor.
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the mixer and result in deposit of
urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF injection can be
blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passages.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
• In the case of the AdBlue/DEF purging of the engine shut- 3C
down, the purging operation continues several minutes af-
ter the engine stops. 3B 3
NOTICE
Do not turn the battery disconnect switch to OFF position
A4P15762
till the System Operating Lamp in the battery box goes out.
The System Operating Lamp will go out when the system
shuts itself down after the purging operation completes.
Function of AdBlue/DEF thawing and preventing from freezing
• This function has the thawing mode and freeze prevention mode.
• One operation mode is “Thaw mode”.
• At engine start-up if the Engine Controller judges AdBlue/DEF is frozen, it automatically commands
heating the AdBlue/DEF injection system.
• The AdBlue/DEF pump and the AdBlue/DEF injector hold their operation till the Engine Controller judg-
es the completion of AdBlue/DEF thawing operation.
• The other operation mode is “Freeze Prevention mode”.
• While the machine is in operation if the Engine Controller judges AdBlue/DEF is likely to freeze, it auto-
matically commands heating the AdBlue/DEF system.
10-8 107E-5 SERIES

• While the heating is on during machine operation if the Engine Controller judges that cooling by the
ambient exceeds the heating capacity of the system, it automatically starts AdBlue/DEF purging and
shuts down the operation of the AdBlue/DEF pump and the AdBlue/DEF injector. However, the heating
system is kept on as long as the machine is in operation.
• Thawing and freeze prevention mode are controlled by sensor and the sensors vary by devices which AdBl-
ue/DEF system consists of. The following table shows the relationship among the object devices, heating
system and the sensors for each mode.
Relationship among the object devices, heating system and the sensors for each mode
When the engine room temperature sensor is equipped
Object devices for function of
Sensors for Thawing Sensors for Freeze Pre-
AdBlue/DEF thawing and prevent- Heating system
mode vention mode
ing from freezsing
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
When the engine room temperature sensor is not equipped

Object devices for function of
Sensors for Thawing Sensors for Freeze Pre-
AdBlue/DEF thawing and prevent- Heating system
mode vention mode
ing from freezsing
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
sensor sensor
AdBlue/DEF pressure hose
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed.
The warning steps of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
107E-5 SERIES 10-9

• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)
5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red
2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red
CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)
*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
10-10 107E-5 SERIES

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN AdBlue/DEF

QUALITY, AdBlue/DEF INJECTION, AND UREA SCR SYSTEM DEVICES (EU
SPECIFICATION)
• When abnormality is found in the AdBlue/DEF quality, AdBlue/DEF injection, and urea SCR system devi-
ces, the AdBlue/DEF system caution lamp lights up on the machine monitor, and the action level is shown.
When abnormality occurs, a caution is given with the AdBlue/DEF system caution lamp on the machine
monitor. And also an alarm sound occurs as the time goes by after the abnormality is found. Then the in-
ducement strategy starts and the engine power will be lowered.
• Operator can check the inducement strategy and abnormalities that cause Inducement with “SCR Informa-
tion” (user menu) on the machine monitor.
• The table below shows the warning indications and engine power derations by each Inducement strategy
status.
Display on machine monitor
AdBlue/DE
Inducement strat- Length of F system Failure code
Message of caution Failure code Engine de-
egy time (*1) Alarm buz- for current
SCR Infor- lamp for level of at- ration (*5)
zer sound abnormality
mation tention (*4)
(Action lev- (*2) (*3)
el)
Yellow
1
1: Please
inspect and CA3571 No warning/
Warning 5 hours maintain No display No display
Yellow CB3571 inducement
SCR sys-
tem.
Yellow
2: Without Triple-beep
AS00R2
Continuous treatment, alarm (*6)
CA3571 (Warning 2 No warning/
2 Warning 10 hours engine Short inter-
power will Yellow CB3571 (SCR Device inducement
(Warning 2) mittent
be derated. Abnormality))
alarm (*7)
Red
AS00R3
Low-Level 3: Engine
Inducement power is Intermittent CA3571 (Inducement Torque: Min.
3 20 hours 1 (SCR De-
(Induce- under dera- Red alarm CB3571 25%
tion. vice Abnor-
ment 1)
mality))
107E-5 SERIES 10-11

Display on machine monitor

AdBlue/DE
Inducement strat- Length of F system Failure code
Message of caution Failure code Engine de-
egy time (*1) Alarm buz- for current
SCR Infor- lamp for level of at- ration (*5)
zer sound abnormality
mation tention (*4)
(Action lev- (*2) (*3)
el)
Red
4: Engine AS00R4
Severe In- Torque:
ducement Until abnor- power is (Inducement
Continuous CA3571 50%
4 mality is re- under 2 (SCR De-
(Induce- Red alarm CB3571 Engine
paired heavy dera- vice Abnor-
ment 2) tion. speed: 40%
mality))
*1: Length of time of each stage shows an accumulated time to go to the next stage after “Warning” stage is
started.
*2: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the
service mode. The failure code shown here is an example of failure code when an abnormality occurs. For the
failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS OF LIST OF FAILURE CODES FOR
OUTPUT LIMITATION”.
*3: The failure code which starts with CB can be shown for the machine with aftertreatment devices which are
divided into 2 lines.
*4: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the
service mode.
*5: These percentages show a torque reduction ratio from the torque curve of engine performance curve, and
an engine speed reduction ratio from the rated speed.
*6: For construction machinery with track system
*7: For construction machinery with wheel system
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 4, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning ”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
10-12 107E-5 SERIES

Machine monitor
Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)
Red
1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 5 hours maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
Continuous treatment,
2 Warning 10 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))
Red
Red
Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA4151 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red
107E-5 SERIES 10-13

Machine monitor
Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)
Red
4: Engine Red AS00R4 Torque: over

Severe In- 50%
ducement power is CA4151 (Inducement
Until repair- Continu-
4 under 2 (SCR De- and
(Induce- ing ously CB4151
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red
*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.
10-14 107E-5 SERIES

REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.
107E-5 SERIES 10-15

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF UREA SCR SYSTEM

SCR
SCR ASSEMBLY
SCR
STRUCTURE OF SCR ASSEMBLY

REMARK
• The shape is possibly different on some machine models.
A: From KDPF B: To exhaust pipe

1: Mixer 7: SCR temperature sensor controller
2: SCR outlet NOx sensor 8: SCR inlet temperature sensor
3: Water baffle 9: SCR body
4: Hanger plate 10: AdBlue/DEF injector
5: SCR outlet temperature sensor 11: Water drain port
6: SCR outlet NOx sensor controller
• The SCR assembly consists of the mixer (1), SCR catalyst, and ammonia oxidation catalyst.
• The ammonia oxidation catalyst purifies (oxidizes) ammonia to water and nitrogen not to discharge ammo-
nia to outside. Ammonia supplied to the SCR assembly cannot be consumed with the SCR catalyst fully in
some cases.
• Each 1 piece of the SCR inlet temperature sensor (8), SCR outlet temperature sensor (5), and SCR outlet
NOx sensor (2) are installed to the SCR assembly. These sensors are used for different types of trouble-
shootings, such as they are used to monitor that the SCR catalyst functions correctly.
10-16 107E-5 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
• The mixer (1) makes the swirling flow with the partition plate installed in front of the SCR catalyst. The swirl-
ing flow mixes AdBlue/DEF sprayed from the AdBlue/DEF injector (10) with the exhaust gas in a short dis-
tance.
• AdBlue/DEF sprayed from the AdBlue/DEF injector (10) is mixed with the exhaust gas, and it is changed to
ammonia that is used to purify NOx.
• The SCR catalyst has the ceramic honeycomb structure.
• The catalyzer holding mat is put around the outside perimeter of the catalyzer to protect the ceramic from
the damage caused by vibrations of the engine and machine body. It is made of the special fibers. It also
prevents the high temperature around the SCR assembly caused by the high temperature heat from the
ceramics during the operation.
• The water baffle (3) is installed at the downstream side of the outlet, and it protects the detection part of the
SCR outlet NOx sensor (2) from rainwater at the outlet.
107E-5 SERIES 10-17

AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK
A: Coolant inlet D: From AdBlue/DEF pump

B: Coolant outlet E: To breather
C: To AdBlue/DEF pump
1: AdBlue/DEF tank 5: Sensor flange assembly
2: Sight gauge 6: Drain plug
3: AdBlue/DEF filler cap 7: AdBlue/DEF tank filter
4: AdBlue/DEF tank sensor
10-18 107E-5 SERIES

AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
1: Connector 4: Level sensing part

2: Cover 5: Concentration Sensing part
3: Temperature sensing part
FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.
107E-5 SERIES 10-19

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

• The AdBlue/DEF pump has the filter to collect dirt in AdBl-
ue/DEF, the valve to change the flow direction at purging,
and the heater to thaw AdBlue/DEF when it is frozen.
• The pump sucks AdBlue/DEF from the AdBlue/DEF tank,
pressurizes it at 900 kPa {9.18 kgf/cm2} , and supplies to
the AdBlue/DEF injector. 2 3 4
• The return connector is white to identify it easily to prevent
the incorrect assembly of the connector. And the hose can-
not be connected to the inlet connector and outlet connec-
tor as each connector size is different.
P
A4P15769
10-20 107E-5 SERIES

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

• The AdBlue/DEF injection sprays AdBlue/DEF that is pressurized with the AdBlue/DEF pump into the mix-
er.
• The injection rate is controlled by open-close time of the valve at the specified pressure.
• Engine coolant is supplied through to prevent heats from the exhaust pipe.
OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.
107E-5 SERIES 10-21

AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE
1: Connector 5: Insulation tape

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

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent AdBlue/DEF from freezing again while machine is operated.
10-22 107E-5 SERIES

AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE
A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring
FUNCTION OF AdBlue/DEF TANK HEATING VALVE

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

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.
107E-5 SERIES 10-23

LAYOUT OF ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION
ENGINE SYSTEM
LAYOUT OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
REMARK
• The figure shows the divided type of aftertreatment.
• The shape is possibly different on some machine models.
General view
1: Turbocharger 8: Starting motor

2: Exhaust throttle valve 9: SCR assembly
3: Alternator 10: Air cleaner
4: Engine oil pan 11: Supply pump
5: Auto-tensioner 12: Engine controller
6: Engine oil cooler 13: KDPF
7: Engine oil filter
10-24 107E-5 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS
INTAKE AND EXHAUST SYSTEM PARTS

LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
REMARK
The shape is possibly different on some machine models.
A: From air cleaner D: To air intake manifold

B: To aftercooler E: To KDPF
C: From aftercooler
1: Air intake connector 4: Turbocharger
2: Intake air heater 5: Exhaust manifold
3: Exhaust throttle valve
107E-5 SERIES 10-25

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM
1 11 7 10
3 9 8
5
4
G0124752
A: From atmosphere B: To atmosphere

1: Air cleaner 7: KDPF
2: Turbocharger 8: Flywheel housing
3: Air-cooled aftercooler 9: Engine
4: Intake air heater 10: SCR assembly
5: Intake manifold 11: Exhaust throttle valve
6: Exhaust manifold
FUNCTION OF INTAKE AND EXHAUST SYSTEM

• This engine uses the air cleaner, air-cooled aftercooler, turbocharger, exhaust throttle valve, KDPF (KO-
MATSU Diesel Particulate Filter) which is an exhaust gas purification device, and urea SCR system.
• Clean air is required to keep the engine performance. If dirt is sucked into the engine, the engine can be
damaged and its performance can be degraded.
• Air flows through the air cleaner (1), turbocharger (2), and air-cooled aftercooler (3), and being sucked into
the engine. Be sure to use the high-quality air cleaner (1). If foreign material is mixed into the air, the turbo-
charger (2) can be damaged largely. Clean or replace the air cleaner element as in the Operation and Main-
tenance Manual. Be very careful to prevent entry of foreign material when you replace it.
• The intake air is sucked from the air cleaner (1) into the compressor side of the turbocharger (2). The air
supercharged from the turbocharger (2) is cooled by the air-cooled aftercooler (3). And then, the air flows
from the air intake manifold (5) into the cylinder, and it is used for combustion.
• The exhaust gas flows from the exhaust manifold (6) to the turbine of the turbocharger (2). And the turbine
wheel is operated by the energy of the exhaust gas.
• The KDPF (7) is installed to agree with the exhaust gas regulation and consists of the KDOC (oxidation
catalyst) and KCSF (soot collecting filter).
• The KCSF (soot collecting filter) collects soot particles in the exhaust gas, and cleans the exhaust gas.
10-26 107E-5 SERIES

• The SCR assembly (10) changes the ammonia decomposed in the mixer and harmful nitrogen oxides
(NOx) by chemical reaction inside the catalyzer into harmless nitrogen and water.
107E-5 SERIES 10-27

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION
AIR CLEANER
STRUCTURE OF AIR CLEANER
REMARK
General view and sectional view
1 2 3 4 5 6 7 8
G0124753
1: Outlet 6: Outer element

2: Dust indicator mounting part 7: O-ring
3: Inlet 8: Cover assembly
4: Body 9: Vacuator valve
5: Inner element
SPECIFICATIONS OF AIR CLEANER

Type: Cyclopac type
OPERATION OF AIR CLEANER

1. As the inlet (3) is installed tangentially, the intake air becomes the swirling flow along the body (4) and being
sucked in. Centrifugal force is made by the swirling flow.
2. Dirt is removed from the intake air by the centrifugal force.
3. The outer element (6) removes 99.9 % or more of dirt. Only clean air flows through the inner element (5),
and it is sucked into the engine through the outlet (1).
4. The removed dirt is discharged automatically from the vacuator valve (9) to the outside when the engine is
stopped.
10-28 107E-5 SERIES

INTAKE AIR HEATER

STRUCTURE OF INTAKE AIR HEATER
REMARK
The structure is possibly different on some machine models.
General view
1: Air intake connector 4: Housing

2: Intake air heater 5: Internal connection diagram
3: Heater coil
SPECIFICATIONS OF INTAKE AIR HEATER

Type of heater: Ribbon heater
Rated voltage : 22 V (DC)
Load current : 110 A
107E-5 SERIES 10-29

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION
ENGINE MAIN BODY PARTS

CYLINDER HEAD
STRUCTURE OF CYLINDER HEAD
REMARK
A
6
A-A
2 3 4
G0124755
A: To atmosphere (blowby gas)

1: Cylinder head mounting bolt 2: Cap
10-30 107E-5 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS
3: Impactor (built-in) 5: Cylinder head

4: Cylinder head cover 6: Injector
SPECIFICATIONS OF CYLINDER HEAD

Cylinder head
Direct fuel injection type
Integrated type
4-valve
Valve seat
Press-fitted valve seat inserts on both intake and exhaust sides
Injector assembly
Installation: Dry type (without sleeve)
107E-5 SERIES 10-31

CYLINDER BLOCK
STRUCTURE OF CYLINDER BLOCK
REMARK
3 4
A
1 2 a b
A-A
G0124756
a: Center of crankshaft b: Rear face of cylinder block

1: Main bearing cap 3: Cam bushing
2: Main bearing cap bolt 4: Cylinder block
10-32 107E-5 SERIES

SPECIFICATIONS OF CYLINDER BLOCK

Cylinder block
Crankshaft part: 5 bearings
Camshaft part: 5 bearings
Linerless
107E-5 SERIES 10-33

MAIN MOVING PARTS

STRUCTURE OF MAIN DRIVE PARTS
REMARK
Sectional view
4 5 6 7
8
2
1
A 9
P
16
10
17
18
11 P
12
15 14 A-A 13
G0124757
1: Crankshaft 5: Piston
2: Front crankshaft gear (number of teeth: 36) 6: Piston pin
3: Connecting rod 7: Thrust bearing
4: Cylinder block 8: Rear crankshaft gear (number of teeth: 36)
10-34 107E-5 SERIES

9: Main bearing 14: Main bearing cap

10: Connecting rod bushing 15: Connecting rod bearing
11: Connecting rod cap bolt 16: Top ring
12: Connecting rod cap 17: Second ring
13: Main bearing cap bolt 18: Oil ring
Structure of crankshaft and main bearing
• The crankshaft is made of balanced type forging steel, and
it has journals at 5 places.
• The lower bearing shells of the 5 main bearings are the
same parts.
• The upper bearing shells other than the one on the 4th
journal (from the front side) are the same parts.
• The 4th journal (from the front side) has the flanged upper
bearing shell. This flange sets the end thrust of the crank-
shaft.
• The upper bearing has 2 holes. The larger hole receives

oil from the main oil line. The smaller hole connects to the
camshaft journal. And it is used as the orifice of oil that
flows to the camshaft journal.
G0126749
Structure of piston and connecting rod

• The piston has the cast aluminum body with the oil path for
piston cooling, and also it has 3 ring grooves.
• The 3 types of the piston rings are installed. The top ring is
the trapezoidal-shaped ring, and is supported by the cast
Ni-resist insert of the piston.
G0126750
• The hollow piston pin that can float freely connects the pis-
ton and connecting rod.
• Oil is sprayed to lubricate the pin and journal when the pis-
ton is cooled down.
G0126751
107E-5 SERIES 10-35

• The connection part of the connecting rod and piston is cut

at an angle, and the bearing surface is wide.
• The bronze bushing is press fitted into the pin hole of the
connecting rod.
G0126752
SPECIFICATIONS OF MAIN MOVING PARTS

Crankshaft
Closed die forging
Journal: Induction hardening
Piston
Toroidal combustion chamber for direct fuel injection
Aluminum piston (shaker)
Connecting rod
Closed die forging
Cap bolt: Screwed-in type (torque plus angle method tightening)
PISTON RING
STRUCTURE OF PISTON RING
Sectional view
1: Top ring
2: Second ring
3: Oil ring
G0126753
Structure
The top ring (1) is the keystone type, with inner cut, barrel face, and PVD coating treatment.
The second ring (2) is a taper shape.
The oil ring (3) is with the coil expander, M-shaped steel ring, and hard chrome plating treatment.
10-36 107E-5 SERIES

CRANKSHAFT PULLEY
STRUCTURE OF CRANKSHAFT PULLEY
REMARK
General view
1: Plate 3: Crankshaft pulley

2: Crankshaft pulley mounting bolt 4: Dowel pin
107E-5 SERIES 10-37

TIMING GEAR
STRUCTURE OF TIMING GEAR
REMARK
Structure drawing
a: Matchmark b: Chamfered tooth

1: Supply pump drive gear (number of teeth: 27) 3: Timing (crankshaft) gear (number of teeth: 36)
2: Camshaft drive gear (number of teeth: 72)
FUNCTION OF TIMING GEAR

The timing (crankshaft) gear (3) and cam shaft drive gear (2) are installed with their engaged parts aligned with
the matchmarks (a) and chamfered tooth (b). This adjusts the timing of open/close of the air intake and exhaust
valve and up/down movement of the piston.
10-38 107E-5 SERIES

FRONT COVER
STRUCTURE OF FRONT COVER
REMARK
5 P 6
G0124761
1: Front gear housing 4: NE (crankshaft) speed sensor mounting hole

2: Engine oil pressure switch mounting hole 5: Front oil seal dust cover
3: Bkup (camshaft) speed sensor mounting hole 6: Engine front oil seal
107E-5 SERIES 10-39

VALVE SYSTEM
STRUCTURE OF VALVE SYSTEM
REMARK
1 2
7 10 11
12
6
5
13
14
3 IN EX 9 8
G0124762
1: Air intake valve 2: Exhaust valve
10-40 107E-5 SERIES

3: Camshaft 9: Thrust plate

4: Valve seal 10: Rocker arm
5: Valve spring 11: Adjustment screw
6: Upper seat 12: Lock nut
7: Valve cotter 13: Push rod
8: Camshaft gear (number of teeth: 72) 14: Tappet
Structure of camshaft, tappet, and push rod
• The camshaft is driven by the gear of the crankshaft.
• The journal at each end uses the camshaft bushing to re-
ceive the side load from the accessory drive.
• The other journals are supported by the cast iron bores of
the cylinder block.
G0126754
• The camshaft has the cam lobes (threads) that operate the
air intake and exhaust valve.
• The cam lobe contacts the tappet that moves the push rod
up and down.
• The tappet is the mushroom-shaped part.

• Its convex portion contacts the cam lobe, and the tappet
rotates while it pushes up the push rod.
G0126755
• The sphere end at the lower part of the push rod goes in
the ball socket of the tappet.
• The push rod has the socket at the upper part, and the
sphere end of the adjustment screw on the rocker arm
goes in the socket.
G0126756
107E-5 SERIES 10-41

FLYWHEEL AND FLYWHEEL HOUSING

STRUCTURE OF FLYWHEEL AND FLYWHEEL HOUSING
REMARK
1 2
A-A A
G0124764
1: Flywheel housing 4: Ring gear (number of teeth: 127)

2: Flywheel 5: Engine rear oil seal
3: Starting motor
10-42 107E-5 SERIES

SPECIFICATIONS OF FLYWHEEL AND FLYWHEEL HOUSING

Engine rear oil seal
For dry type: Single lip with dust seal
For wet type: Double lip
107E-5 SERIES 10-43

TURBOCHARGER 10 STRUCTURE AND FUNCTION
TURBOCHARGER
STRUCTURE OF TURBOCHARGER
REMARK
A: Intake air inlet C: Exhaust gas inlet

B: Intake air outlet D: Exhaust gas outlet
10-44 107E-5 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER
E: Oil inlet G: Coolant inlet

F: Oil outlet H. Coolant outlet
1: Turbine housing 10: O-ring
2: Clip 11: Retainer ring
3: Adjusting link end 12: Clamp
4: Bolt 13: Actuator
5: Nut 14: Hose clamp
6: Turbocharger core 15: Screw
7: Nut 16: Hose
8: Bracket (actuator) 17: Coupling
9: Compressor housing
SPECIFICATIONS OF TURBOCHARGER
Model: Cummins Turbo Technologies HE200WG/HE250WG (water-cooled type)
Allowable temperature of exhaust gas: 700℃ or less (turbine inlet)
Rotation direction: Clockwise (seen from intake air inlet)
FUNCTION OF TURBOCHARGER
2 C T
1 3 4
G0116638
C: Blower impeller T: Turbine impeller

1: Air cleaner 4: Aftertreatment (KDPF, SCR)
2: Turbocharger 5: Aftercooler
The blower impeller (C) is driven via the shaft connected to the turbine impeller (T), and the large quantity of air
is sent to the cylinder for combustion.
When the air sent by the turbocharger (2) increases, the fuel injection rate is increased, and the engine output
will be enhanced.
Also, the density of air cooled by the aftercooler is increased, and the quantity of oxygen is also increased. The
fuel injection rate can be increased and the engine output will be enhanced.
The waist gate valve is installed on the turbocharger to prevent the damage of the turbine impeller caused by
overspeed.
The actuator operates mechanically when the boost pressure exceeds the specified level, and a part of the ex-
haust gas is bypassed by the waist gate valve to reduce the operation and speed of the turbocharger.
NOTICE
Sufficient quantity of high-quality and clean oil is required to keep the turbocharger performance. Be
sure to use the Komatsu-genuine high-quality oil. Change oil and replace the oil filter as in the “Opera-
tion and Maintenance Manual”.
107E-5 SERIES 10-45

TURBOCHARGER 10 STRUCTURE AND FUNCTION
REMARK
After the relief operation, you will hear the sound from the turbocharger or boost piping as if air leaks. It is not a
problem.
10-46 107E-5 SERIES

10 STRUCTURE AND FUNCTION CRANKCASE VENTILATION SYSTEM
CRANKCASE VENTILATION SYSTEM

SYSTEM DIAGRAM OF CRANKCASE VENTILATION SYSTEM
2
1 7 8 9
6 A
3
4
G0116639
A: Blowby gas
1: Air cleaner 6: Impactor (filterless)
2: Turbocharger 7: Exhaust throttle valve
3: Aftercooler 8: KDPF
4: Cylinder block (crankcase) 9: SCR assembly
5: Cylinder head
FUNCTION OF CRANKCASE VENTILATION SYSTEM

• The gas leaked from the space between the cylinder and piston ring is blowby gas.
• Blowby gas contains oil mist of engine oil.
• The filterless impactor integrated in the cylinder head cover is installed on this engine to reduce oil mist dis-
charged outside the engine when the blowby gas is released in the air.
• The blowby gas (A) in the cylinder block (4) hits the medium integrated in the impactor (6), and engine oil is
separated from the blowby gas (A).
• The separated engine oil flows into the cylinder head (5). The blowby gas (A) is released in the air at the
same time.
107E-5 SERIES 10-47

IMPACTOR (FILTERLESS) 10 STRUCTURE AND FUNCTION
IMPACTOR (FILTERLESS)
STRUCTURE OF IMPACTOR (FILTERLESS)
REMARK
Sectional view
B
D
1
A C
G0124251
A: Blowby gas C: Oil

B: Gas D: Boost gas
1: Medium
OPERATION OF IMPACTOR (FILTERLESS)

1. The blowby gas (A) that contains oil mist hits the medium (1) integrated in the impactor, and it is separated
into the gas (B) and oil mist.
2. The gas (B) is released in the air, separated oil mist changes to oil (C), and it accumulates at the upper part
of the impactor.
3. Oil (C) accumulated at the upper part of the impactor flows into the crankcase by the boost gas (D) charged
by the turbocharger, and it goes back to the engine.
10-48 107E-5 SERIES

10 STRUCTURE AND FUNCTION EXHAUST THROTTLE VALVE
EXHAUST THROTTLE VALVE

STRUCTURE OF EXHAUST THROTTLE VALVE
A: Exhaust gas inlet C: Coolant inlet

B: Exhaust gas outlet D: Coolant outlet
1: Body 4: Speed reduction gear (built-in)
2: Exhaust throttle valve motor 5: Valve
3: Connector
FUNCTION OF EXHAUST THROTTLE VALVE

The exhaust throttle valve throttles the exhaust gas path to control the exhaust temperature and optimizes the
function of the KDPF and SCR assembly.
OPERATION OF EXHAUST THROTTLE VALVE

1. Exhaust throttle valve is operated upon receiving the electrical signals from the engine controller.
2. The driving force of the exhaust throttle valve motor (1) is transmitted through the built-in deceleration gear
(2) to the valve (4).
3. The open/close position of the valve (4) is controlled by the electrical signals from the engine controller.
107E-5 SERIES 10-49

KDPF 10 STRUCTURE AND FUNCTION
KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
STRUCTURE OF KDPF
REMARK
A: From exhaust throttle valve B: To SCR assembly

1: Inlet unit 9: KDPF differential pressure sensor
2: Hanger bracket 10: KDOC outlet temperature sensor
3: Outlet unit 11: Turbocharger outlet NOx sensor
4: KDPF differential pressure sensor port 12: KDOC inlet temperature sensor
5: Sensor bracket band 13: Turbocharger outlet NOx sensor controller
6: KDPF differential pressure sensor port 14: Temperature sensor controller
7: KDPF outlet temperature sensor 15: KCSF unit
8: Sensor bracket
Structure
• The KDPF has a function to introduce the exhaust gas and consists of the inlet unit (1) that stores the oxi-
dation catalyst (KDOC), KCSF unit (15) that stores the soot collection filter with the catalyst, and outlet unit
(3) that discharges the exhaust gas.
• The inlet unit (1) stores the KDOC that consists of the ceramic honeycomb with the oxidation catalyst.
• The ceramic honeycomb is used to optimize the 2 functions. The first is to oxidize NO (nitrogen monoxide)
in the exhaust gas into NO2 (nitrogen dioxide). The second is to burn the sprayed fuel during the automatic
10-50 107E-5 SERIES

10 STRUCTURE AND FUNCTION KDPF
regeneration or manual stationary regeneration. (Automatic regeneration is a method that purifies (oxidizes)
the soot accumulated on the soot collection filter (KCSF) in the KDPF.)
• The ceramic honeycomb is protected by a special fiber mat to prevent ceramic breakage caused by engine
and body vibrations. It also prevents the high temperature around the KDPF caused by the high tempera-
ture heat from the ceramics during the operation.
• The KCSF unit (15) consists of the ceramic honeycomb with the oxidation catalyst same as the KDOC.
The ceramic honeycomb catches the soot.
The KCSF unit (15) consists of many cells divided by the ceramic walls inside. The cells sealed on the inlet
side and the cells sealed on the outlet side are put alternately.
• The KDPF temperature sensor and differential pressure sensor are installed on the KDPF. The KDPF tem-
perature sensor is an integrated unit that consists of the KDOC inlet temperature sensor, KDOC outlet tem-
perature sensor, and KDPF outlet temperature sensor. The differential pressure sensor is an integrated unit
that consists of the KDPF differential pressure sensor and KDPF outlet pressure sensor.
With the combination of the temperature values measured by the 3 temperature sensors, the system moni-
tors that the KCSF unit (15) and KDOC operate normally. It is also used for different types of troubleshoot-
ings.
The differential pressure sensor senses the pressure difference between the front and rear sides of the
KCSF unit (15) and monitors the soot accumulated in the KCSF unit (15). It is also used for different types
of troubleshootings, similarly to the temperature sensor.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramic honeycomb
• The KDPF catches most of PM that is contained in the ex-
haust gas and purifies it. PM is particulate material such as
soot, or chains of the particulate soot.
• The KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen
monoxide) in the exhaust gas into NO2 (nitrogen dioxide)
and regenerates (*1) the soot accumulated in the KCSF.
• The KCSF (2) catches the soot.
• In the operation range where the temperature of exhaust
gas is relatively high, the accumulated soot in the KCSF
(2) is naturally oxidized and decreased by the effect of the
KDOC (oxidation catalyst) (1). (This is “passive regenera-
tion”.)
REMARK
If relatively low temperature state of the exhaust gas con-
tinues, such as when the light load operation continues,
the “passive regeneration” cannot be done. Accumulated
soot gradually increases.
• The engine controller monitors two values of accumulated soot quantity and compares them at all times.
One is the accumulated soot that is estimated based on the engine operation conditions. The other is the
accumulated soot that is calculated based on the signal from the differential pressure sensor that is attach-
ed to the KCSF (2).
• If the accumulated soot and temperature of the engine exhaust gas exceed the specified level during the
operation, the engine controller starts the “automatic regeneration” automatically to burn (oxidize) the soot.
107E-5 SERIES 10-51

KDPF 10 STRUCTURE AND FUNCTION
During automatic regeneration, the engine controller calculates the exhaust gas temperature at the KDOC
inlet and exhaust gas quantity, and controls the engine to raise the temperature of the engine exhaust gas.
(This is “exhaust gas temperature raise control”.)
The temperature of the exhaust gas at the KDOC inlet is controlled by the fuel level sprayed from the injec-
tor, and the exhaust gas quantity is controlled by the exhaust throttle valve.
The engine controller raises the temperature of the engine exhaust gas automatically. This enhances the
oxidation power in the KDOC (1), and increases combustion efficiency of the soot caught in the KCSF (2).
REMARK
When relatively low exhaust temperature continues such as when the regeneration function is disabled on
the machine monitor, when ambient temperature is very low, or when the light load operation continues, the
“automatic regeneration” does not start, and the accumulated the soot increases.
• If the “automatic regeneration” does not start because of the excessive soot accumulated in the KCSF (2),
do the “manual stationary regeneration” to burn (oxidize) the soot and reduce the soot inside the KCSF (2).
REMARK
If the soot exceeds the allowable level, the soot interferes the flow of exhaust gas, and it deteriorates the
fuel consumption and engine combustion state. This possibly leads to other failures.
If the soot increases more, the “manual stationary regeneration” cannot be done safely. Accordingly, the
KDPF becomes defective and replacement will be required. Be sure to do the “manual stationary regenera-
tion”. For details, see the Operation and Maintenance Manual.
*1: Soot purification (oxidation) treatment
TYPES OF REGENERATION FUNCTION

Regeneration is a function that purifies (oxidize) the soot accumulated on the soot collecting filter (KCSF) in the
KDPF, and it keeps the function of the urea SCR system normal.
Passive regeneration
The passive regeneration is a natural oxidation (combustion) to remove the soot accumulated in the KCSF. This
is done when the exhaust gas temperature is relatively high. The oxidation power is enhanced by the catalytic
effect of the KDOC.
Active regeneration (engine exhaust temperature raise control + fuel dosing)
• Automatic regeneration
• The automatic regeneration is a function that starts the regeneration automatically when the accumula-
ted soot exceeds the specified level, or when there is a command from the urea SCR system to keep
the system normal, and the engine controller becomes the exhaust temperature raise control (*1) and
starts fuel dosing (*2).
The automatic regeneration is also done by the command from the engine controller after a specified
period of time from the previous regeneration regardless of the accumulated soot in the KCSF.
*1: Control to increase the engine exhaust temperature by the control of the fuel injection timing and
exhaust throttle valve
*2: Fuel injection to accelerate regeneration by increase of the exhaust temperature
• Manual stationary regeneration
• The Manual Stationary Regeneration is shown on the machine monitor for the operator to do regenera-
tion by operation on the machine monitor screen. The screen is shown on the cases that follow. The
first case is when the exhaust temperature does not reach a specified level because of the operation
condition of the machine. The second case is when the automatic regeneration is not done because
the operator disables regeneration even when there is a command from the urea SCR system, and ac-
cordingly, accumulated soot in the KCSF increases.
In addition, when the engine controller or KDPF is replaced or ash in the KCSF is cleaned, a technician
does regeneration by the operation on the machine monitor screen. (“Active Regeneration for Service”)
10-52 107E-5 SERIES

10 STRUCTURE AND FUNCTION KDPF
NOTICE
• For the operation method to start and stop the KDPF regeneration, see the Operation and Mainte-
nance Manual for each machine.
• Be sure to use ultra low-sulfur diesel fuel. If you use fuel other than the specified fuel, it possibly
causes a failure in the KDPF.
• For engine oil, be sure to use the Komatsu genuine oil that is specified for the KDPF. If you use oil
other than the specified oil, it possibly causes degradation of fuel consumption and a failure in the
KDPF because of fast clogging of the KDPF.
• Do not make modification on the KDPF and exhaust pipe. If modification is made, the KDPF cannot
operate normally and possibly causes a failure.
• Do not apply strong shock to the KDPF. Do not stand on, drop, or hit it. The KDPF has a built-in ce-
ramic that can be damaged by a strong shock.
• The white smoke is possibly discharged through the exhaust pipe outlet for a short time during “Au-
tomatic Regeneration” and “Manual Stationary Regeneration”, especially at low temperature, but this
is not a problem. Be sure to do regeneration in a well-ventilated area. Carbon monoxide possibly oc-
curs.
• The temperature of the exhaust gas from the exhaust pipe can become 650 °C or more during “Auto-
matic Regeneration” and “Manual Stationary Regeneration”. Make sure that there is no flammable
around the exhaust pipe to prevent the fire. Check the safety around the machine carefully. Make
sure that there is no person at the area where the exhaust gas is discharged to.
REMARK
• If diesel fuel is mixed with bio-fuel at a high ratio, KDPF regeneration is done more frequently.
• Even when a small quantity of soot is accumulated, the engine controller possibly starts “automatic regener-
ation”. This is a treatment to keep the functions of the KDPF and urea SCR system normal. It is not a prob-
lem. Automatic regeneration to keep the urea SCR system normal or manual stationary regeneration re-
quires approximately 1 hour.
• The exhaust throttle valve are activated automatically and the sound of the engine changes during “automat-
ic regeneration” and “manual stationary regeneration”. Also, the flow rate of the exhaust gas in the KDPF
changes and the exhaust sound changes. They are not problems.
• The exhaust pipe can smell differently from usual during “automatic regeneration” or “manual stationary re-
generation”, but this is not a problem.
• The KDPF has “KDPF dry operation” function to prevent excessive collection of fuel that is not burned in the
KDPF when the operation continues at relatively low temperature for long hours. This is a function that the
engine controller increases the engine exhaust temperature automatically and does dry operation of the
KCSF when the set condition is agreed with. When the automatic dry operation is not sufficient to complete
the operation, manual stationary regeneration can be required.
• The standard temperature of the KDPF is shown as follows.
KDOC_In (KDOC inlet KDOC_Out (KDOC out- KDPF Out (KDPF outlet
temperature sensor) let temperature sensor) temperature sensor)
While regeneration is not done (idle
100 to 250 °C
state)
During regeneration (thermal mode) 100 to 250 °C 400 to 550 °C
107E-5 SERIES 10-53

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION
LUBRICATION SYSTEM
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
REMARK
1: Turbocharger 4: Engine oil cooler

2: Engine oil pump 5: Engine oil filter
3: Engine oil pan
10-54 107E-5 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM CIRCUIT DIAGRAM

6
5
10
4
8
11
9
2
3
12
G0126757
1: Engine oil pan strainer 7: Turbocharger

2: Engine oil pump 8: Main gallery
3: Engine oil regulator valve 9: Bearing parts
4: Engine oil cooler 10: Piston cooling gallery
5: Engine oil filter 11: Piston cooling
6: Engine oil safety valve 12: Engine oil pan
107E-5 SERIES 10-55

ENGINE OIL PUMP

STRUCTURE OF ENGINE OIL PUMP
REMARK
1 2 3 4 5
8 9
7 6
G0126758
1: Bushing 6: Idler gear

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

Type: Trochoid pump
Speed: Engine speed x 1.5
FUNCTION OF ENGINE OIL PUMP

• The engine oil pump supplies engine oil inside the engine for lubrication.
• The pump is installed between the engine oil pan and regulator valve circuit, and it is driven by the power
from the front crankshaft gear.
10-56 107E-5 SERIES

ENGINE OIL FILTER

STRUCTURE OF ENGINE OIL FILTER
REMARK
General view
A: Oil outlet B: Oil inlet

1: Plug 3: Filter cartridge
2: Filter head
FUNCTION OF ENGINE OIL FILTER

• When engine oil is supplied inside the engine for lubrication, foreign materials such as carbon, sludge, and
abrasion powder will be mixed.
The filter is installed to remove these foreign materials.
• The engine oil filter safety valve is also installed to bypass engine oil to each part of the engine when the
filter is clogged.
107E-5 SERIES 10-57

ENGINE OIL COOLER

STRUCTURE OF ENGINE OIL COOLER
REMARK
1
B
A A
2 A-A B-B
G0124769
1: Engine oil cooler core assembly 3: Regulator valve

2: Safety valve
SPECIFICATIONS OF ENGINE OIL COOLER

Number of elements: 7
10-58 107E-5 SERIES

FUNCTION OF ENGINE OIL COOLER

The engine oil cooler is used to cool down the engine oil supplied inside the engine for lubrication, and it is in-
stalled between the engine oil pump and engine oil filter circuit.
107E-5 SERIES 10-59

ENGINE OIL REGULATOR VALVE

STRUCTURE OF ENGINE OIL REGULATOR VALVE
REMARK
A-A
G0124771
1: Regulator valve
SPECIFICATIONS OF ENGINE OIL REGULATOR VALVE

Cracking pressure: 499 kPa {4.58 kgf/cm2}
FUNCTION OF ENGINE OIL REGULATOR VALVE

The regulator valve adjusts (reduces) the oil pressure from the engine oil pump.
10-60 107E-5 SERIES

SAFETY VALVE OF ENGINE OIL

STRUCTURE OF SAFETY VALVE OF ENGINE OIL
REMARK
General view
A A
1 A-A
G0124770
1: Safety valve
SPECIFICATIONS OF SAFETY VALVE OF ENGINE OIL

Cracking pressure: 344 kPa {3.51 kgf/cm2}
FUNCTION OF ENGINE OIL SAFETY VALVE

• The engine oil safety valve is installed to adjust the pressure of engine oil that lubricates inside the engine.
• It is installed between the engine oil cooler and engine oil filter circuit.
• Engine oil flows to the engine oil filter when its pressure is lower than the set cracking pressure of the safe-
ty valve. If the pressure exceeds the cracking pressure by the clogging of the engine oil filter or other cau-
ses, oil does not go through the engine oil filter and bypasses to the turbocharger, main gallery, or piston
cooling gallery. As a result, engine oil is supplied continuously for lubrication.
107E-5 SERIES 10-61

ENGINE OIL PAN

STRUCTURE OF ENGINE OIL PAN
REMARK
1: Engine oil pan 3: Engine oil suction pipe

2: Engine oil level gauge
10-62 107E-5 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
LAYOUT DRAWING OF FUEL SYSTEM PARTS
REMARK
A: From fuel prefilter B: To fuel cooler

1: Injector 5: Supply pump
2: Inlet connector 6: Fuel high-pressure pipe
3: Fuel injection pipe 7: Fuel main filter
4: Common rail
107E-5 SERIES 10-63

FUEL SYSTEM 10 STRUCTURE AND FUNCTION
FUEL SYSTEM CIRCUIT DIAGRAM
Engine
3 5
Supply pump unit
2 4
6
1
7 8
Pre filter unit
12 10
11
9
G0124774
1: Fuel main filter 7: Fuel cooler

2: Supply pump 8. Fuel tank
3: Injector 9: Water separator
4: Common rail 10: Fuel prefilter
5: Check valve 11: Priming pump
6: Pressure limiter valve 12: Feed pump
10-64 107E-5 SERIES

CRI SYSTEM
CRI
Abbreviation for Common Rail Injection
SYSTEM DIAGRAM OF CRI SYSTEM
9
Other infomation 4
(Temperature, pressure)
5
(Engine load) (Leak)

6

1 7
2
G0126759
1: NE (crankshaft) speed sensor 6: Common rail

2: Bkup (cam) speed sensor 7: Inlet metering valve (IMV)
3: Accelerator pedal (*1) 8: Supply pump
4: Engine controller 9: Injector
5: Common rail pressure sensor
*1: It is not installed on some machine models.
STRUCTURE OF CRI SYSTEM

• The CRI system uses the high pressure common rail that is controlled electronically.
• The CRI system consists of the supply pump, common rail, injector, engine controller that controls those
parts, and sensors.
FUNCTION OF CRI SYSTEM

• The engine controller has the self-diagnosis function (do the self-diagnosis for the main component parts)
and the alarm function to give a notice to the operator in case of trouble.
The controller also has the fail safe function to stop the engine and the backup function to change the con-
trol method and continue the operation if a trouble is found in the specified location.
• The functions of the CRI system can be divided in the fuel system function and control system function.
107E-5 SERIES 10-65

FUNCTION OF FUEL SYSTEM OF CRI SYSTEM

The fuel system of the CRI system supplies the high pressure
fuel generated at the supply pump to the common rail, and di-
vides it to each injector. Each injector sprays fuel from the noz-
zle to each cylinder in the form of fine mist, and mixes it with air
)XHOWDQN
to improve the combustion efficiency.
)XHOVXSSO\SXPS
'HOLYHU\
FRQWURO
&RPPRQUDLO (OHFWURQLF
FRQWURO
1HHGOHOLIWFRQWURO
E\VROHQRLGYDOYH
,QMHFWRU
*
CONTROL FUNCTION OF CRI SYSTEM

• The CRI system can control the fuel injection rate, fuel injection timing, and fuel injection pressure more
effectively compared with the mechanical governor and timer used in the conventional fuel injection pump.
• The engine controller senses the state of the engine (such as engine speed and accelerator throttle posi-
tion) by the signal from each sensor. The CRI system controls the fuel injection rate, fuel injection timing,
and fuel injection pressure with the engine controller to keep the engine in the optimal condition.
• The fuel injection rate is controlled sufficiently based on the engine speed and accelerator throttle position.
• The fuel injection timing is controlled sufficiently based on the engine speed and fuel injection rate control-
led by the engine controller.
• To control the fuel injection pressure, the fuel pressure is measured with the common rail pressure sensor,
and the data is sent to the engine controller as a feedback to control the discharged pressure of the supply
pump. The feedback control of the fuel pressure is done to set the fuel pressure to the optimal value (com-
mand value) in response to the engine speed and fuel injection rate controlled by the engine controller.
10-66 107E-5 SERIES

SUPPLY PUMP
STRUCTURE OF SUPPLY PUMP
General view
2 C
A
D 3
G0126761
A: Fuel inlet (from fuel prefilter) D: Fuel outlet (to common rail)
B: Fuel outlet (to fuel main filter) E: Drain (to fuel tank)
C: Fuel outlet (from fuel main filter)
1: Feed pump 3: IMV (*) solenoid connector
2: Supply pump
* IMV: Abbreviation for Inlet Metering Valve
SPECIFICATIONS OF SUPPLY PUMP

Type: Rotary type pressurized sending method with plunger
Lubrication method: Fuel lubrication
FUNCTION OF SUPPLY PUMP

• The supply pump consists of the feed pump (low-pressure pump) and supply pump (high-pressure pump),
and it is driven by the power from the camshaft.
• The feed pump (low-pressure pump) supplies fuel to the fuel main filter.
• The supply pump (high-pressure pump) supplies fuel to the common rail.
• Fuel supplied to the supply pump is pressurized by the 3 radial pumping chambers.
107E-5 SERIES 10-67

COMMON RAIL
STRUCTURE OF COMMON RAIL
General view
A: No1. injector D: No4. injector

B: No2. injector E: From supply pump
C: No3. injector F: Fuel spill
1: Pressure limiter valve 2: Common rail pressure sensor
FUNCTION OF COMMON RAIL

• The common rail sends the high-pressure fuel made at the supply pump to the injector of each cylinder.
• The common rail consists of the common rail pressure sensor (2), pressure limiter (1), and HP connections
(A to D).
• The high-pressure pipes are installed to the HP connections (A to D), and the high-pressure fuel is sent to
the injector through them.
• The fuel pressure is sensed by the common rail pressure sensor installed to the common rail.
• The pressure limiter is the safety valve that releases the common rail pressure when it exceeds the set val-
ue. The fuel pressure that exceeds the set value goes back to the fuel tank.
10-68 107E-5 SERIES

INJECTOR
STRUCTURE OF INJECTOR
Sectional view
1: Upper body 5: Nozzle shaft

2: O-ring 6: Fuel return port
3: Connection of inlet connector 7: Electric terminal
4: Seal ring
Structure
The injector consists of the nozzle part, the orifice that selects the fuel injection rate, the hydraulic piston part,
and the two-way solenoid valve part.
107E-5 SERIES 10-69

FUNCTION OF INJECTOR
During injection When fuel injection finishes
&RPPRQUDLO &RPPRQUDLO
4 4
)XHOVXSSO\ (QJLQH
SXPS FRQWUROOHU )XHOVXSSO\ (QJLQH
SXPS FRQWUROOHU
G0124789
The injector (4) sprays the high-pressure fuel in the common rail to the combustion chamber of the engine at the
most applicable timing, rate, and state in response to the signal from the engine controller.
The fuel pressure in the common rail is applied to the injector through the high-pressure pipe of each injector.
The solenoid activates the needle valve of the nozzle. The start and stop timing of the fuel injection and the fuel
injection rate are controlled by this valve.
The orifice controls the cracking speed of the nozzle to adjust the fuel injection rate.
The nozzle sprays fuel.
OPERATION OF INJECTOR
High-pressure fuel is supplied from the common rail (5) to the
injector (1) through the high-pressure pipe (4) and inlet connec-
tor (2).
When the retaining nut (3) of the inlet connector (2) is tight-
ened, the inlet connector (2) is pushed against the body of the
injector (1). When the retaining nut (3) is tightened, the high-
pressure pipe (4) connects to the inlet connector (2).
The inlet connector (2) has the edge filter that breaks small for-
eign materials mixed in fuel. The edge filter breaks particles by
the high pulsation pressure to let foreign materials go through
the fuel circuit of the injector.
Each injector is connected to the fuel circuit in the cylinder
head. Excessive fuel goes back to the fuel tank through the
spill tube installed at the rear part of the cylinder head. The
check valve is also installed at the rear part of the cylinder
head.
The cylinder head and spill tube are connected by eyejoint.
10-70 107E-5 SERIES

FUEL PREFILTER
STRUCTURE OF FUEL PREFILTER
REMARK
A
6
2 4
5
A
B
G0126762
A: Fuel outlet B: Fuel inlet

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

• Fuel flows from the fuel tank to the supply pump through the fuel prefilter.
• The fuel prefilter has the water separator to separate water remained in the filter.
• The water-in-fuel sensor is installed to sense the level of separated water.
107E-5 SERIES 10-71

FUEL MAIN FILTER

STRUCTURE OF FUEL MAIN FILTER
REMARK
1
2
1
G0126763
1: Pressure pickup plug 3: Filter cartridge

2: Filter head
FUNCTION OF FUEL MAIN FILTER

• Fuel flows from the feed pump (low pressure pump) to the supply pump (high pressure pump) through the
fuel main filter.
• The fuel main filter removes foreign materials mixed in fuel.
• The fuel main filter is mounted separately for some machines to replace the cartridge easily.
10-72 107E-5 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
REMARK
A: From radiator B: To radiator

1: Turbocharger 4: Water pump
2: Air vent (to radiator) 5: Engine oil cooler
107E-5 SERIES 10-73

COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COOLING SYSTEM CIRCUIT DIAGRAM
2 9
a d
3
b c
6
1 11 4 10 8
G0124776
a: Flow when thermostat valve is open c: Flow when solenoid valve is closed
b: Flow when thermostat valve is closed d: Flow when solenoid valve is open
1: Radiator 7: Water pump
2: Thermostat 8: AdBlue/DEF tank
3: Cylinder head 9: Solenoid valve
4: Turbocharger 10: AdBlue/DEF injector
5: Cylinder block 11: Exhaust throttle valve
6: Engine oil cooler
10-74 107E-5 SERIES

DRIVE PULLEY
STRUCTURE OF DRIVE PULLEY
REMARK
A: From radiator B: To radiator

1: Alternator 4: Crankshaft pulley
2: Idler pulley 5: Water pump
3: V-belt 6: Auto-tensioner
REMARK
The auto-tensioner (6) automatically adjusts the V-belt (3) at a constant tension.
107E-5 SERIES 10-75

COOLING SYSTEM 10 STRUCTURE AND FUNCTION
WATER PUMP
STRUCTURE OF WATER PUMP
REMARK
General view
1 2 3 4 5
G0126764
A: Coolant inlet B: Coolant outlet (to each part of engine)

1: Impeller 4: Pulley
2: Water seal 5: Drive shaft
3: Pump body
SPECIFICATIONS OF WATER PUMP

Type: Centrifugal type, poly V-belt drive
FUNCTION OF WATER PUMP

• The water pump supplies coolant through the engine to prevent overheating of the engine.
• The rotation of the engine is transmitted to the pulley by the fan belt to drive the impeller.
10-76 107E-5 SERIES

THERMOSTAT
STRUCTURE OF THERMOSTAT
REMARK
General view
1
A
G0126765
A: To radiator
1: Thermostat
SPECIFICATIONS OF THERMOSTAT
Thermostat opening temperature: 79.4±83.3 °C
Full open temperature: 95 °C
Valve lift: Min. 9.1 mm
107E-5 SERIES 10-77

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION
ELECTRICAL SYSTEM
COMPONENT PARTS OF ELECTRICAL SYSTEM
ALTERNATOR
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 60A)
REMARK
The shape may vary depending on the machine models.
General view and circuit diagram
2
1 3
G0152426
1: Alternator (body) 3: Terminal B

2: Alternator pulley
SPECIFICATION OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

60A)
Type: Manufactured by DENSO, open type
Specifications: 24 V, 60 A
Number of pulley grooves: 8
Outside diameter of pulley: 77.5 mm
Weight: 6.3 kg
10-78 107E-5 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 85A)

REMARK
1 2
G0126766

2: Alternator pulley 5: Terminal E
3: Terminal R
SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

85A)
Type: Manufactured by NIKKO DENKI, open type
Number of pulley grooves: 8
Pulley outside diameter: 85 mm
Weight: 11 kg
107E-5 SERIES 10-79

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

100A)
REMARK
1 2
3
G0126767

2: Alternator pulley 5: Terminal E
3: Terminal R
SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

100A)
Type: Manufactured by NIKKO DENKI, open type
Number of thread of pulley: 8
Pulley outside diameter: 80 mm
Weight: 16 kg
10-80 107E-5 SERIES

STARTING MOTOR
STRUCTURE OF STARTER WITH BUILT-IN SAFETY RELAY (5.5kW)
REMARK
1 2 3 4
5 7 6
G0124779
1: Pinion 5: “Start by short-circuiting” prevention cover

2: Magnetic switch 6: 50 (Terminal C)
3: Starting motor assembly 7: 30 (Terminal B)
4: Prohibition of “start by short-circuiting” warning plate
SPECIFICATION OF STARTER BUILT IN SAFETY RELAY (5.5kW)

Type: DENSO, drip proof, oil proof
Specifications: 24 V, 5.5 kW
Number of teeth of pinion: 10
Weight: 10.5 kg
107E-5 SERIES 10-81

ENGINE WIRING HARNESS

STRUCTURE OF ENGINE WIRING HARNESS
REMARK
General view
No. Connector Connector label

1 Exhaust manifold pressure sensor EXHAUST PRESSURE
2 Crankcase pressure sensor CRANK CASE PRESSURE
3 Injector wiring harness #1&#2 INJECTOR CYL 1&2
4 Exhaust throttle valve ETV
5 Injector wiring harness #3&#4 INJECTOR CYL 3&4
6 Common rail pressure sensor FUEL RAIL PRESS
7 Charge (boost) temperature and pressure sensor TMAP
8 Supply pump IMV
10-82 107E-5 SERIES

No. Connector Connector label

9 Engine controller connector J1 ECM J1
10 Chassis wiring harness connector OEM CONNECTION
11 NE (crankshaft) speed sensor EPS MAIN (CRANK)
12 Terminating resistor RESISTOR CAN B
13 Bkup (camshaft) speed sensor EPS BACKUP (CAM)
14 Engine oil pressure switch OIL PRESSURE SWITCH
15 Coolant temperature sensor COOLANT TEMP
107E-5 SERIES 10-83

ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view
FUNCTION OF ENGINE CONTROLLER

• The engine controller by the joint development of Komatsu and Cummins is used.
• The controller calculates the input signal from each sensor installed to the machine, and controls the opti-
mum engine performance with the output signal.
• The controller shares information from other controllers installed to the machine via network (CAN) and
controls the optimum performance between the engine and machine.
• The serviceability in the field is improved by the engine controller installed to the engine.
• The controller is installed with the rubber vibration isolator to decrease the vibration.
ENGINE CONTROLLER SYSTEM DIAGRAM
10-84 107E-5 SERIES

ACC(Key switch)
Idle Validation 1
Main(Crank)Pulse Idle Validation 2
Backup(Cam)Pulse Throttle
Wake
Intake Heater Sub-Relay 1
Injector #1 Busy Lamp
Injector #2 (PC Service TOOL)
Injector #3 KOMNET/r
Injector #4
KOMNET/c(Public J1939)
IMV
Fuel Rail Pressure Communications

via KOMNET (Vehicle Monitor)
To Engine ECM
1.Li Control
2.HSI Control (Vehicle ECM#1)
Charge Pressure (Ex.T/M ECM)
3.AS Control
Charge Temperature
CooIant Temp. Throttle Command (Vehicle ECM#2)
Comp In Temp/Press. Throttle Limitation (Ex.Brake ECM)
Ambient Air Press. Throttle Adjustment
Oil Press.SW 4.Power Mode Selection (Vehicle ECM#3)
Exhaust Maniforld Pressure (Ex.Pump ECM)
5.CyIinder Cut-Out
CrankCase Pressure
WiF Cranking w/o Injection (KOMTRAX)
Exhaust Throttle Position Engine controller Anti-Theft
Exhaust Throttle Valve Dynamic Torque Control
6.KDOC/SCR control
7.Memory Clear
From Engine ECM

KDOC Inlet Temp
1.Engine Operation Info.
KDOC OutIet Temp RPM. etc.
KDPF OutIet Temp
Turbo out NOx 2.Error Code
SCR Outlet NOx 3.Monitoring Info.
SCR Inlet Temp Ambient Press. ect.
SCR Outlet Temp KDOC/SCR status
Engine Room Temp
Ambient Air Temp
AdBlue/DEF injector
AdBlue/DEF Pump
Temp/Driver AdBlue/DEF
Tankheating Valve
AdBIue/DEF
Concentraion AdBlue/DEF
Pump Heater Relay
AdBlue/DEF Level
AdBlue/DEF Temp AdBlue/DEF FCV
AdBlue/DEF Pump AdBlue/DEF
Pressure Line Heater Relay 1
AdBlue/DEF Pump AdBlue/DEF
Temp Line Heater 1
AdBlue/DEF
Line Heater Relay 2
AdBlue/DEF
Line Heater 2
Sensor Supply Relay
G0124781
107E-5 SERIES 10-85

INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

Delphi96Pin“ECM J1”
Pin No. Signal name Input/output signal
1 Injector #1 (-) Ground/Shield/Return
2 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Smart sensor start-up signal Output
10 IMV (-) Ground/Shield/Return
11 IMV (+) Output
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 Injector #1 (+) Output
26 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 (*1) -
33 (*1) -
34 GND Ground/Shield/Return
35 (*1) -
36 Exhaust manifold pressure sensor Input
10-86 107E-5 SERIES


37 Exhaust throttle valve position Input
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Intake pressure (TBAP) sensor Input
45 Boost pressure sensor Input
46 (*1) -
47 (*1) -
48 (*1) -
49 (*1) -
52 Engine oil pressure switch Input
53 (*1) -
56 (*1) -
59 Common rail pressure sensor Input
60 (*1) -
61 Mass air flow (TBAP) temperature sensor Input
62 Boost temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 Datalink3 (+) (KOMNET/r) Communication
71 Exhaust throttle valve (-) Ground/Shield/Return
72 Exhaust throttle valve (+) Output
73 (*1) -
107E-5 SERIES 10-87


76 (*1) -
77 (*1) -
78 Sensor 5 V power supply Power supply
80 (*1) -
83 Coolant temperature sensor Input
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -
*1: Do not connect these pins. Malfunctions or failures can occur.

Delphi96Pin“EC02/ECM J2”
1 Power supply (Continuously +24 ) Power supply
2 (*1) -
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/AdBlue/DEF pump driver Input/output
7 AdBlue/DEF line heater relay 2 Output
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
10-88 107E-5 SERIES


15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (sensor controller) Communication
22 Datalink1 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (Continuously +24 V) Power supply
29 Wake Input
30 (*1) -
31 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater Diag2 Input
39 AdBlue/DEF line heater Diag1 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1) Machines with fuel control dial
43 Input
Idle validation switch 2: Machines with accelerator pedal
(*1) Machines with fuel control dial
44 Input
Idle validation switch 1: Machines with accelerator pedal
45 Datalink4 (-) (sensor controller) Communication
46 Datalink1 (-) (KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
49 Power GND Ground/Shield/Return
107E-5 SERIES 10-89


53 AdBlue/DEF injector (-) Ground/Shield/Return
55 (*1) -
56 Ambient temperature sensor Input
58 (*1) -
59 (*1) -
60 (*1) -
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 (*1) -
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
10-90 107E-5 SERIES


91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
*1: Do not connect these pins. Malfunctions or failures can occur.
107E-5 SERIES 10-91

SENSOR 10 STRUCTURE AND FUNCTION
SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
General view 1
1: Coolant temperature sensor 4: NE (crankshaft) speed sensor

2: Exhaust manifold pressure sensor 5: Bkup (cam) speed sensor
3: Exhaust throttle valve actuator 6: Engine oil pressure switch
10-92 107E-5 SERIES

10 STRUCTURE AND FUNCTION SENSOR
General view 2
7: KDOC outlet temperature sensor 11: Common rail pressure sensor

8: Air cleaner clogging sensor 12: Supply pump solenoid (IMV)
9: Intake manifold pressure and temperature sensor 13: Charge (boost) pressure and temperature sensor
10: Crankcase pressure sensor 14: KDPF outlet temperature sensor
107E-5 SERIES 10-93

General view 3
15: SCR inlet temperature sensor 19: KDPF differential pressure sensor
16: SCR outlet Nox sensor 20: KDOC inlet temperature sensor
17: SCR outlet temperature sensor 21: Turbocharger outlet NOx sensor
18: KDPF differential pressure sensor
10-94 107E-5 SERIES

STRUCTURE OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR

The intake manifold pressure and temperature sensor is installed on the turbocharger air intake pipe of the ma-
chine.
General view
1: Connector (SUMITOMOP-4P) 2: Sensor
FUNCTION OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR

The sensor senses the intake manifold pressure and temperature, and outputs the variable voltage. And also it
uses the intake pressure as an ambient pressure for the control.
107E-5 SERIES 10-95

STRUCTURE OF ENGINE OIL PRESSURE SWITCH

The switch is installed at the side surface of the cylinder block.
Contact configuration: Normally closed
General view
1 2 3
G0126769
1: Connector (DT-2P) 3: O-ring

2: Sensor
FUNCTION OF ENGINE OIL PRESSURE SWITCH

The engine oil pressure switch senses the engine oil pressure, and it is set to “ON” when the pressure lowers
below the specified value.
10-96 107E-5 SERIES

STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

The sensor is installed on the intake manifold of the engine.
General view
1 2
G0126770
1: Connector (SUMITOMO-4P) 3: O-ring

2: Sensor
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

The sensor senses the air intake pressure to the engine and temperature, and uses pressure as the variable
voltage and temperature as the resistance change to output signals.
REMARK
“Charge pressure and temperature” shows the intake pressure and temperature of the engine with the turbo-
charger. It is also known as “Boost pressure and temperature” or “Intake pressure and temperature”.
107E-5 SERIES 10-97

STRUCTURE OF COOLANT TEMPERATURE SENSOR

The coolant temperature sensor is installed to the cylinder head of the engine.
General view
1 2 3
G0126771
1: Connector (DELPHI-2P/PACKRD-2P) 3: O-ring

2: Sensor
FUNCTION OF COOLANT TEMPERATURE SENSOR

The sensor uses the temperature change as the resistance change to output the signal.
10-98 107E-5 SERIES

STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR

The sensor is installed on the front cover of the engine.
General view
G0126772
1: O-ring 3: Connector (FRAMATOME-3P)

2: Sensor
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR

The sensor outputs the pulse voltage by the rotation of the gear.
107E-5 SERIES 10-99

STRUCTURE OF Bkup (CAM) SPEED SENSOR

The sensor is installed on the front cover of the engine.
General view
G0126772

2: Sensor
FUNCTION OF Bkup (CAM) SPEED SENSOR

The sensor outputs the pulse voltage by the rotation of the gear.
10-100 107E-5 SERIES

STRUCTURE OF COMMON RAIL PRESSURE SENSOR

The sensor is installed to the common rail of the engine.
General view
1 2
G0126773
1: Connector (BOSCH-3P) 2: Sensor
FUNCTION OF COMMON RAIL PRESSURE SENSOR

The sensor senses the fuel pressure and outputs the variable voltage.
107E-5 SERIES 10-101

STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
The KDPF differential pressure and outlet pressure sensor is installed to the KDPF.
General view
1 2 3
G0126774
1: High-pressure port 3: Connector (FRAMATOME-4P)

2: Low-pressure port 4: Sensor
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
• The sensor senses the KDPF inlet and outlet pressure, and outputs the variable voltage.
• The differential pressure sensor outputs the difference between the KDPF inlet pressure sensed at the
high-pressure port (1) and KDPF outlet pressure sensed at the low-pressure port (2).
• The outlet pressure sensor outputs the KDPF outlet pressure sensed at the low-pressure port (2).
10-102 107E-5 SERIES

STRUCTURE OF CRANKCASE PRESSURE SENSOR

The crankcase pressure sensor is installed on the cylinder head cover.
General view
1: Connector (FRAMATOME-3P) 3: O-ring

2: Sensor
FUNCTION OF CRANKCASE PRESSURE SENSOR

The sensor senses the crankcase pressure (blowby pressure), and outputs the variable voltage.
107E-5 SERIES 10-103

STRUCTURE OF ENGINE OIL LEVEL SENSOR

The engine oil level sensor is installed at the side surface of the engine oil pan.
REMARK
It is installed only on the hydraulic excavator.
General view
1 2 3
G0126775
1: Connector (DT-2P) 3: Float

2: Bracket 4: Switch
FUNCTION OF ENGINE OIL LEVEL SENSOR

If the oil level lowers below the specified value, the float lowers, and the switch is set to “OFF”.
10-104 107E-5 SERIES

STRUCTURE OF AIR CLEANER CLOGGING SENSOR

The air cleaner clogging sensor is installed at the outlet side of the air cleaner.
General view
1 2 3 4
G0126776
1: Adapter 3: Indicator
2: Hood 4: Connector (DT-2P)
FUNCTION OF AIR CLEANER CLOGGING SENSOR

When the pressure lowers below the specified value (negative value) caused by the clogging of the air cleaner,
the switch is set to “ON”.
107E-5 SERIES 10-105

STRUCTURE OF WATER-IN-FUEL SENSOR

General view
The sensor is installed on the clear bowl of the fuel prefilter.
1 2 3 4
G0126777
1: Connector 3: Sensor
2: Tube 4: O-ring
FUNCTION OF WATER-IN-FUEL SENSOR

If water mixed in fuel is sensed, the sensor outputs the signal.
10-106 107E-5 SERIES

STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR

The sensor is installed on the pressure pick-up tube at the exhaust manifold of the engine.
General view
1 2 3
G0126778

2: Sensor
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR

The sensor senses the exhaust gas pressure, and outputs the variable voltage.
107E-5 SERIES 10-107

STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SEN-

SOR)
General view
1: Exhaust throttle valve motor (with built-in position 3: Valve

sensor)
2: Connector (AMP-6P)
FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SEN-

SOR)
• The small-sized exhaust throttle valve is driven by the DC motor.
• The exhaust throttle valve motor has the built-in position sensor to sense the opening of the valve.
10-108 107E-5 SERIES

20 STANDARD VALUE TABLE
107E-5 SERIES 20-1

CONTENTS 20 STANDARD VALUE TABLE
CONTENTS
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0,
D51PXI-24E0) ..................................................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6)................................................... 20-6
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0) .............................................. 20-9
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ........................................................ 20-12
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN
PERIOD: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0) ...................... 20-12
PERIOD: SAA4D107E-5 (GD535-6) .................................................................................................. 20-14
PERIOD: SAA4D107E-5 (WA200-8E0) ............................................................................................. 20-16
20-2 107E-5 SERIES

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5
20 STANDARD VALUE TABLE (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (D51EX-24E0,
D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
Performance
Engine SAA4D107E-5
Standard value
Item Test condition Unit for the new ma- Repair limit
chine
At Max. speed 2270±50 2270±50
with no load
(high idle) {2270±50} {2270±50}
Engine coolant temperature: 60 min-1
Engine speed
to 100℃ At Min. speed {rpm}
1075±25 1075±25
with no load
(low idle) {1075±25} {1075±25}
Air intake and exhaust system

Engine SAA4D107E-5
Standard value
chine
Intake resist- kPa Max. 3.73 Max. 7.45

Full speed range
ance {mmH2O} {Max. 380} {Max. 760}
kPa Min. 151 Min. 124
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1130} {Min. 930}
Exhaust tem-
Full speed range (20 °C) °C Max. 650 Max. 700
perature
• Engine coolant tempera- Engine outlet

ture: 60 to 100℃ (between tur-
- Max. 2.0
bocharger and Bosch in-
Exhaust color • At rated horsepower KDPF) dex
• After held at the normal SCR outlet (tail
state for 5 seconds - Max. 0.5
pipe outlet)
Valve clear- Air intake valve 0.25±0.05 0.152 to 0.381

mm
ance Exhaust valve 0.51±0.05 0.381 to 0.762
Main body
Engine SAA4D107E-5
Standard value
chine
Compression • Engine oil temperature: 40 to 60℃ MPa Min. 2.41 Min. 1.69
pressure • Engine speed: 250 to 280rpm {kgf/cm2} {Min. 24.6} {Min. 17.2}
Blowby pres- kPa Max. 0.98 Max. 1.96

At rated horsepower
sure {mmH2O} {Max. 100} {Max. 200}
107E-5 SERIES 20-3

(D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0) 20 STANDARD VALUE TABLE
Fuel system
Engine SAA4D107E-5
Standard value
chine
207 to 650 207 to 650
At Max. speed with no load (high idle)
Pressure of kPa {2.11 to 6.63} {2.11 to 6.63}
low pressure
circuit {kgf/cm2} 207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
Pressure dif- At Max. speed with no load (high idle)
ference be- kPa Max. 81 Max. 81
tween front
and rear of At cranking {kgf/cm2} {Max. 0.83} {Max. 0.83}
main filter
Pressure in the At Max. speed with no load (high idle) kPa Max. 18.6 Max. 18.6
return circuit At cranking {kgf/cm2} {Max. 0.19} {Max. 0.19}
Pressure in the kPa -40.7 to 0 -40.7 to 0
negative pres- At Max. speed with no load (high idle)
sure circuit {mmHg} {-305 to 0} {-305 to 0}
Discharge vol- • At cranking

ume of the mℓ Min. 70 Min. 70
supply pump • Measurement time: 30 seconds
• At Min. speed with no load (low idle)

Return volume • Measurement time: 30 seconds
of the supply mℓ Max. 750 Max. 750
pump • At cranking (Min. 150 rpm)
• Measurement time: 30 seconds
Max. 125 Max. 125
mℓ
of the injector • At cranking (Min. 150 rpm)
Max. 45 Max. 45
mℓ Max. 8 Max. 8
Leakage of the • Measurement time: 30 seconds
pressure limit-
er valve • At cranking (Min. 150 rpm)
- Max. 5 drops Max. 5 drops
Lubrication system
Engine SAA4D107E-5
Standard value
chine
• Engine oil temperature: At rated horse- Min. 0.29 Min. 0.25
Min. 80℃ power {Min. 3.0} {Min. 2.5}
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA At Min. speed {kgf/cm2} Min. 0.10 Min. 0.07
EO15W40-LA with no load
EOS5W30-LA (low idle) {Min. 1.0} {Min. 0.7}
EOS5W40-LA
20-4 107E-5 SERIES

Engine SAA4D107E-5
Standard value
chine
Engine oil tem-
Full speed range (oil pan) °C 80 to 110 Max. 120
perature
Oil consump- • At rated horsepower continuously

% Max. 0.075 Max. 0.15
tion rate • Fuel consumption ratio
*1: KES diesel engine oil
Electric system
Engine SAA4D107E-5
Standard value
chine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when it is pushed with finger at 98N ment ment
mm
ternator belt {10kgf}
(Auto-tensioner) (Auto-tensioner)
107E-5 SERIES 20-5

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6) 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6)

Performance
Engine SAA4D107E-5
Standard value
chine
At Max. speed 2250±50 2250±50
with no load
(high idle) {2250±50} {2250±50}
Engine speed
825±25 825±25
with no load
(low idle) {825±25} {825±25}

Engine SAA4D107E-5
Standard value
chine

Full speed range
kPa Min. 154 Min. 67
{mmHg} {Min. 1152} {Min. 503}
Exhaust tem-
perature

- Max. 2.0
pipe outlet)

mm
Main body
Engine SAA4D107E-5
Standard value
chine

At rated horsepower
20-6 107E-5 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6)
Fuel system
Engine SAA4D107E-5
Standard value
chine
207 to 650 207 to 650
low pressure
At cranking
{2.11 to 5.1} {2.11 to 5.1}
tween front
main filter


Max. 125 Max. 125
mℓ
Max. 45 Max. 45
mℓ Max. 8 Max. 8
pressure limit-
Lubrication system
Engine SAA4D107E-5
Standard value
chine
Min. 80℃ power {Min. 3.0} {Min. 2.5}
EOS5W40-LA
107E-5 SERIES 20-7

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6) 20 STANDARD VALUE TABLE
Engine SAA4D107E-5
Standard value
chine
Engine oil tem-
perature

% Max. 0.075 Max. 0.15
Electric system
Engine SAA4D107E-5
Standard value
chine
mm
20-8 107E-5 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0)
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0)

Performance
Engine SAA4D107E-5
Standard value
chine
At Max. speed 2250±50 2250±50
with no load
(high idle) {2250±50} {2250±50}
Engine speed
825±25 825±25
with no load
(low idle) {825±25} {825±25}

Engine SAA4D107E-5
Standard value
chine

Full speed range
kPa Min. 94 Min. 67
{mmHg} {Min. 705} {Min. 503}
Exhaust tem-
perature

- Max. 2.0
pipe outlet)

mm
Main body
Engine SAA4D107E-5
Standard value
chine

At rated horsepower
107E-5 SERIES 20-9

STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0) 20 STANDARD VALUE TABLE
Fuel system
Engine SAA4D107E-5
Standard value
chine
207 to 650 207 to 650
low pressure
At cranking
{2.11 to 5.1} {2.11 to 5.1}
tween front
main filter


Max. 125 Max. 125
mℓ
Max. 45 Max. 45
mℓ Max. 8 Max. 8
pressure limit-
Lubrication system
Engine SAA4D107E-5
Standard value
chine
Min. 80℃ power {Min. 3.0} {Min. 2.5}
EOS5W40-LA
20-10 107E-5 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0)
Engine SAA4D107E-5
Standard value
chine
Engine oil tem-
perature

% Max. 0.075 Max. 0.15
Electric system
Engine SAA4D107E-5
Standard value
chine
mm
107E-5 SERIES 20-11

PERFORMANCE TEST STANDARD AND STANDARD FOR OPERA-
TION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5
(D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0) 20 STANDARD VALUE TABLE
RUNNING-IN STANDARD AND PERFORMANCE TEST

STANDARD
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF
ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (D51EX-24E0,
D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
Standard for operation of engine for break in period
Engine SAA4D107E-5
Procedure
Item
1 2 3 4 5
Operation time min 2 10 2 3 3
min-1{rpm
Engine speed 1075{1075} 1100{1100} 1200{1200} 1600{1600} 2200{2200}
}
Dynamometer load N{kgf} 0{0} 98{10} 215{21.9} 460{46.9} 600.7{61.3}
Output kW{HP} 0{0} 8{10.9} 27{36.2} 77{103} 99.2{133}
REMARK
• This table shows the value when the fan is not installed to the machine.
• The dynamometer load value in this table is the value when the arm length of the dynamometer is 716 mm.
Performance test standard

Engine SAA4D107E-5
Max. speed with Min. speed with no
Test item Rated horsepower Maximum torque
no load load
99.2±5 kW/ 584±29.2 Nm/
Specification value 2200 min-1 1450 min-1 2270±50 min-1 1075±25 min-1
-
(Gross) {133±6.7 HP/ {59.6±3 kgfm/ {2270±50 rpm} {1075±25 rpm}
2200 rpm} 1450 rpm}
min-1
Engine speed 2200{2200} 1450{1450} - -
{rpm}
Dynamometer load N{kgf} 600.7{61.3} 815.7{83.2} - -
Horsepower (Gross) kW {HP} 99.2{133} - - -
Nm
Torque (Gross) - 584±29.2{59.6±3} - -
{kgfm}
sec/
Fuel consumption 41.5 - - -
300 cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil tem-
°C 82 to 94 82 to 94 82 to 94 82 to 94
perature
Lubricating oil pres- kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
sure {kgf/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 560 Max. 650 - -
20-12 107E-5 SERIES

REMARK
• The horsepower and torque shown in this table are the standard values when the fan is not installed to the
machine. The values are different from the specification values.
• This table shows the standard values when the air cleaner is not installed, KEPF and SCR are installed to
the machine, and no load is applied to the alternator.
• For fuel, use ultra low-sulfur diesel fuel.
• During the engine break-in operation, use EO15W40-LA as lubricating oil.
107E-5 SERIES 20-13

TION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (GD535-6) 20 STANDARD VALUE TABLE

ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (GD535-6)
Engine SAA4D107E-5
Procedure
Item
1 2 3 4 5
min-1{rpm
Engine speed 825{825} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
}
Dynamometer load N{kgf} 0{0} 98{10} 245{25} 440{45} 735.5{75}
Output kW{HP} 0{0} 7.4{9.9} 22{29.5} 53{71.0} 110.3{147.9}
REMARK

Engine SAA4D107E-5
no load load
110.3±5.5 kW/ 640±32 Nm/
-
(Gross) {147.9±7.4 HP/ {65.2±3.26 kgfm/ {2250±50 rpm} {825±25 rpm}
2000 rpm} 1500 rpm}
min-1
Engine speed 2000{2000} 1500{1500} - -
{rpm}
Dynamometer load N{kgf} 735.5{75} 893.9{91.2} - -
Horsepower (Gross) kW {HP} 110.3{147.9} - - -
Nm
Torque (Gross) - 640±32{65.2±3.26} - -
{kgfm}
sec/
Fuel consumption 38 - - -
300 cc
°C 82 to 94 82 to 94 82 to 94 82 to 94
perature
20-14 107E-5 SERIES

20 STANDARD VALUE TABLE TION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (GD535-6)
REMARK
107E-5 SERIES 20-15

(WA200-8E0) 20 STANDARD VALUE TABLE

ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (WA200-8E0)
Engine SAA4D107E-5
Procedure
Item
1 2 3 4 5
min-1{rpm
Engine speed 825{825} 1000{1000} 1200{1200} 1600{1600} 2000{2000}
}
Dynamometer load N{kgf} 0{0} 98{10} 245{25} 440{45} 634.9{64.8}
Output kW{HP} 0{0} 7.4{9.9} 22{29.5} 53{71.0} 95.2{128}
REMARK

Engine SAA4D107E-5
no load load
95.2±4.8 kW/ 599±30.0 Nm/
-
(Gross) {128±6.4 HP/ {61.1±3.1 kgfm/ {2250±50 rpm} {825±25 rpm}
2000 rpm} 1350 rpm}
min-1
Engine speed 2000{2000} 1350{1350} - -
{rpm}
Dynamometer load N{kgf} 634.9{64.8} 836.1{85.3} - -
Horsepower (Gross) kW {HP} 95.2{128} - - -
Nm 599±30.0{61.1±3.1
Torque (Gross) - - -
{kgfm} }
sec/
Fuel consumption 44.5 - - -
300 cc
°C 82 to 94 82 to 94 82 to 94 82 to 94
perature
20-16 107E-5 SERIES

20 STANDARD VALUE TABLE (WA200-8E0)
REMARK
107E-5 SERIES 20-17

50 DISASSEMBLY AND ASSEMBLY
107E-5 SERIES 50-1

50 DISASSEMBLY AND ASSEM-
CONTENTS BLY
CONTENTS
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-3
HOW TO READ THIS MANUAL.............................................................................................................. 50-3
COATING MATERIALS LIST................................................................................................................... 50-5
SPECIAL TOOLS LIST ......................................................................................................................... 50-10
SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-12
ENGINE SYSTEM ....................................................................................................................................... 50-13
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY.................................................................... 50-13
DISASSEMBLE ENGINE GENERALLY ......................................................................................... 50-14
ASSEMBLE ENGINE GENERALLY ............................................................................................... 50-41
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ......................................................................... 50-87
REMOVE SUPPLY PUMP ASSEMBLY.......................................................................................... 50-87
INSTALL SUPPLY PUMP ASSEMBLY ........................................................................................... 50-90
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .......................................................................... 50-93
REMOVE ENGINE FRONT OIL SEAL ........................................................................................... 50-93
INSTALL ENGINE FRONT OIL SEAL ............................................................................................ 50-95
REMOVE AND INSTALL ENGINE REAR OIL SEAL............................................................................. 50-98
REMOVE ENGINE REAR OIL SEAL ............................................................................................. 50-98
INSTALL ENGINE REAR OIL SEAL .............................................................................................. 50-99
50-2 107E-5 SERIES

BLY HOW TO READ THIS MANUAL
RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
Warning
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.
Reading the signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.
107E-5 SERIES 50-3

HOW TO READ THIS MANUAL BLY
Symbol Item Remark

REMARK Remarks This signal word contains useful information to know.
Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
50-4 107E-5 SERIES

BLY COATING MATERIALS LIST
COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.(Rev.2022.04)
Liquid adhesive
Komatsu code Part No. Volume Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, poly-
Polyethy- propylene, tetrafluoroethylene and vinyl
20 g
LT-1B 790-129-9050 lene con- chloride), rubber, metal, and non-metal
(2 pieces)
tainer parts which require immediate and strong
adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from coming
loose. It can also be used as a sealant.
Adhesive
790-129-9060
1 kg • Use to bond and seal metal, glass, and
LT-3 Set of adhesive Container
Hardener plastics etc.
and hardener
500 g
Polyethy-
• Used as sealant for plugs for machined
LT-4 790-129-9040 250 g lene con-
holes.
tainer
Holts
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines
MH705
• Instantaneous adhesive
ThreeBond Polyethy-
• Curing time: From 5 sec. to 3 min.
790-129-9140 50 g lene con-
1735 tainer • Use to bond mainly metals, rubbers, plas-
tics, and woods.
• Instantaneous adhesive
Aron Alpha Polyethy-
• Quick-curing type (max. strength is ob-
790-129-9130 2 g lene con-
201 tained after 30 minutes)
tainer
• Use to bond rubbers, plastics, and metals.
• General-purpose instantaneous adhesive
with excellent resistance to heat and im-
Loctite
428-99-80070 20 cc Tube pact
499
• Use for the bushing mounting faces of axle
supports.
Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.
Liquid gasket
• Use to seal various threaded portions, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
107E-5 SERIES 50-5

COATING MATERIALS LIST BLY
• Features: Silicon-based heat and cold-re-
sistant
• Use to seal flange surface and threaded
LG-6 790-129-9160 200 g Tube
portions
• Use to seal the Oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing seal-
ant
LG-7 790-129-9170 1 kg Tube
• Use to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
LG-8 • Features: Silicon-based heat, vibration,
ThreeBond 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for coarse rough surfaces such as the
LG-9 upper seal of a circle gear that does not re-
ThreeBond 790-129-9310 200 g Tube quire fastening and waterproof for weld
1206D
gaps etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when inserting
ThreeBond 790-129-9320 200 g Tube radiator hoses
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid

gaskets.
ThreeBond 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
LG-12
50 mℓ • Feature: Acrylic, flexible after hardening
Loctite - Tube
300 mℓ • Use as flange sealant for rigid case
515
ThreeBond
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
• Apply on the outer circumference of the oil
790-129-9340 150 g Tube seal and dust seal to prevent oil leakage
SEALEND
790-129-9350 500 g Container • Thick viscous liquid, and can be used with
242 rubber packing
790-129-9360 1 kg Container
• Semi-dry viscoelastic type
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitting portions, shrink-fitted portions,
LM-P - 200 g Tube and threaded portion.
• Use to lubricate linkages, bearings, etc.
50-6 107E-5 SERIES

• Spray type
• Thin molybdenum disulfide films are made
on metal surfaces to prevent the metals
LM-S - 190 g Container
from galling.
• Use for drive shaft splines, needle bear-
ings, various link pins, bolts, etc.
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
- - Container
NEVER-SEEZ • Use for the mounting bolt in the high tem-
perature area of the exhaust manifold and
the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) • Lithium grease with extreme pressure lubri-
SYGA-160CNLI Various Various
*: For cold re- cation performance, general purpose type.
gions SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Grease that in- Bellows-

• Caution: DO NOT use this grease for roller
SYG2-400M 400 g×10 bearings, such as swing circle bearings,
cludes molybde- type con-
num disulfide SYG2-400M-A 400 g×20 tainer etc. or splines.
LM-G (G2-M) SYGA-16CNM 16 kg Container • Caution: Use this grease for work equip-
ment pins only when installing them, but do
not use it afterwards.
Hyper white
grease SYG2-400T-A • Higher seizure resistance, heat resistance,
Bellows-
and waterproof than molybdenum disulfide
G2-T SYG2-16CNT 400 g type con-
grease
G0-T (*) SYG0-400T-A (*) 16 kg tainer
Container
• Not conspicuous on machine since color is
*: For cold re- SYG0-16CNT (*) white.
gions
Biogrease
SYG2-400B
G2-B Bellows-
SYGA-16CNB • Reduces effect on microorganisms, ani-
G2-BT (*) 400 g type con-
SYG2-400BT (*) tainer mals, and plants. This is based on swift de-
*: For use at high 16 kg composition by natural bacteria.
SYGA-16CNBT Container
temperature and
(*)
under high load
107E-5 SERIES 50-7

COATING MATERIALS LIST BLY
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superior
ThreeBond - 200 g Tube thermal oxidative stability to prevent deteri-
1855
oration of rubber and plastic.
• Use for oil seals of the transmission, etc.
• Feature: Urea (organic) grease with heat
resistance and long service life, inclusion
G2-U-SENS type.
427-12-11871 2 kg Container
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.
Primer
Loctite Glass con- • Use to accelerate hardening of instantane-
428-99-80080 100 mℓ
712 tainer ous adhesive.
Primer 435-98
Glass con- • Use as primer for cab side (Expiration
For adhered window glass
for SUNSTAR 22M-54–27260 150 mℓ

tainer date: 4 months after its production date)
Coating
• Use as primer for black ceramic-coated
SUNSTAR Pri-
glass surface and for hard polycarbon-
mer 435-41 for 22M-54-27240 150 mℓ Steel can
ate-coated surface (expiration date: 6
glass
months after its production date)
• Use as primer for ceramic coated glass
SUNSTAR sash
22M-54-27250 900 mℓ Steel can (expiration date: 6 months after its pro-
primer GP-402
duction date)
Adhesive
Polyethy-
Japan Sikaflex • Use as adhesive for glass (Expiration

20Y-54-39850 310 mℓ lene con-
256HV date: 6 months after its production date)
tainer
Ecocart
SUNSTAR Pen- • Use as adhesive for glass (Expiration
22M-54-27210 320 mℓ (special
guin Super 560 date: 6 months after its production date)
container)
Ecocart
SUNSTAR Pen- • Use as adhesive for glass (Expiration
416-926-6950 320 mℓ (special
guin Seal #560 date: 6 months after its production date)
container)
50-8 107E-5 SERIES

Caulking material
SUNSTAR Pen- Polyethy- • Use to seal for joint between glasses

guin Seal No. 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its pro-
2505 tainer duction date)
Polyethy-
SEKISUI Silicone • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
Sealant date: 6 months after its production)
tainer
• Translucent white seal used for joint be-
GE TOSHIBA tween glasses (Expiration date: 12
SILICONES 22M-54-27220 333 mℓ Cartridge months after its production date)
TOSSEAL381
• Translucent white seal
107E-5 SERIES 50-9

SPECIAL TOOLS LIST BLY
SPECIAL TOOLS LIST

How to read the tool list
• Part No.:
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity:
■: Not substitutable, and work cannot be done without the tool.
●: Very useful tools which can be replaced with commercially available tools.
• New/Redesign:
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch:
○: Sketches are provided for the tool with this mark.
The sketches are introduced in “SKETCHES OF SPECIAL TOOLS”. It includes all sketches for part num-
bers that start with “79*T-***-***”.
Special tools to be used when you disassemble and assemble the engine generally
No. Part name Part No. Specifications Q'ty Remarks
790-501-2001 1
A Repair stand
795-799-1150 1
1 Adapter (for repair stand) 790T-901-6020 1
B Adapter (for Cummins re-
2 795-799-7210 1
pair stand)
795-102-2103 1 Removal and installation of
C Spring pusher
795-799-8800 1 air intake and exhaust valve
Removal and installation of

D Piston ring tool 795-100-2800 1
piston ring
E Piston holder 795-921-1100 1 Installation of piston
F Puller 795-799-6700 1 Removal of injector
G Seal puller 795-799-6700 1
rear oil seal
H Seal puller 795-799-6400 1
front oil seal
1 Wrench (angle) 790-331-1120 1
J Angle tightening of bolt
2 Angle gauge 795-799-2240 1
Commercially
K Feeler gauge 1
available
Commercially
L Dial gauge, stand 1
available
M Remover 795-799-8150 1
N Support 795-799-6130 1
Commercially gear
P 1/2-inch spinner handle 1
available
50-10 107E-5 SERIES

BLY SPECIAL TOOLS LIST

Commercially
Q Bearing puller 1
available
Commercially
R Push puller 1 Removal of gear
available
Commercially
S Center bolt 1
available
T Lifting tool 795-799-9300 1
U Nut 01580-11210 1
Commercially Removal and installation of
V Ratchet 1
available alternator belt
W Bolt 01011-81210 1
X Remover, installer 795-799-2270 1
Y Gear 795-799-1131 1
Z Torque wrench 795-799-7110 1
AA Gauge 795-790-4510 1
Special tools to be used when you remove and install the supply pump assembly
A Support 795-799-6130 1
Commercially gear
B 1/2-inch spinner handle 1
available
Commercially
C Bearing puller 1
available
Commercially
1 Push puller 1 Removal of gear
available
D
Commercially
2 Center bolt 1
available
Special tools to be used when you remove and install the engine front oil seal
Commercially
A Ratchet 1 Removal and installation of
available
alternator belt
B Seal puller 795-799-6400 1
1 Wrench (angle) 790-331-1120 1 Removal and installation of
C
2 Angle gauge 795-799-2240 1 engine front oil seal
Special tools to be used when you remove and install the engine rear oil seal
A Seal puller 795-799-6700 1
Commercially engine rear oil seal
B Dial gauge 1
available
107E-5 SERIES 50-11

SKETCHES OF SPECIAL TOOLS BLY
SKETCHES OF SPECIAL TOOLS

k Komatsu does not take responsibility for special tools that made with these diagrams.
B: Adapter
50-12 107E-5 SERIES

BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
ENGINE SYSTEM
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
NOTICE
• The shape, quantity, and installation position of the parts can be different by the machine model. Do
the check about them before you start the work.
• Before you disassemble the engine, fully clean all the engine parts to examine for cracks and dam-
age, and to do the inspection correctly, and to disassemble and assemble quickly.
• Fully seal or remove all openings, electrical parts, and wiring connectors to prevent water contami-
nation before cleaning.
• Clean each part and make sure that there is no dent, scratch, or cast nest. Make sure that the oil and
water paths operate correctly before the assembly.
Special tools to be used when you disassemble and assemble the engine generally
790-501-2001 1
A Repair stand
795-799-1150 1
1 Adapter (for repair stand) 790T-901-6020 1
B Adapter (for Cummins re-
2 795-799-7210 1
pair stand)
795-102-2103 1 Removal and installation of
C Spring pusher
795-799-8800 1 air intake and exhaust valve

D Piston ring tool 795-100-2800 1
piston ring
E Piston holder 795-921-1100 1 Installation of piston
F Puller 795-799-6700 1 Removal of injector
G Seal puller 795-799-6700 1
rear oil seal
H Seal puller 795-799-6400 1
front oil seal
1 Wrench (angle) 790-331-1120 1
J Angle tightening of bolt
2 Angle gauge 795-799-2240 1
Commercially
K Feeler gauge 1
available
Commercially
L Dial gauge, stand 1
available
M Remover 795-799-8150 1
N Support 795-799-6130 1
Commercially gear
P 1/2-inch spinner handle 1
available
107E-5 SERIES 50-13

DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Commercially
Q Bearing puller 1
available
Commercially
R Push puller 1 Removal of gear
available
Commercially
S Center bolt 1
available
T Lifting tool 795-799-9300 1
U Nut 01580-11210 1
Commercially Removal and installation of
V Ratchet 1
available alternator belt
W Bolt 01011-81210 1
X Remover, installer 795-799-2270 1
Y Gear 795-799-1131 1
Z Torque wrench 795-799-7110 1
AA Gauge 795-790-4510 1
DISASSEMBLE ENGINE GENERALLY

Engine as- Preparation Starting motor
sembly work assembly
Exhaust mani- A
Turbocharger
fold
Engine oil
Alternator
cooler
Auto-tensioner
Fan pulley
Engine con-
troller
Supply pump
Exhaust throt-
tle valve
50-14 107E-5 SERIES

Water pump Rocker arm
A Cylinder head B
Engine repair Cylinder head
cover, rocker Crosshead Engine oil pan
stand assembly
housing
Front oil seal C

Thermostat Push rod
dust cover
Wiring har-
Injector as-
ness assem-
sembly
bly
Fuel main fil-

ter assembly
Fuel injection
pipe, fuel
high-pressure
pipe
Common rail
Engine rear oil Flywheel

Flywheel
seal housing
B Piston and
Piston cooling
connecting Crankshaft Tappet Cylinder block
nozzle
rod assembly
C Engine oil
Engine front
pump assem- Camshaft Gear housing
oil seal
bly
Preparation work
1. Set the engine assembly (1) on a rigid and stable stand,
and fix it.
REMARK
The weight is different by the machine model.
Engine assembly: 450kg

2. Drain engine oil.
REMARK
The quantity of oil is different by the machine model.
Engine oil: Approximately 20ℓ
107E-5 SERIES 50-15

Starting motor assembly

3. Remove the bolts (1) (2 pieces) and nut (2), and remove
the starting motor assembly (3) and gasket (4).
Alternator belt
4. Install the ratchet (V) to the part (a) (width across flats
12.7mm) of the auto-tensioner (2).
5. Turn the ratchet (V) in the direction of the arrow to loosen
the tension of the alternator belt (1), and remove the alter-
nator belt (1).
k Securely install the ratchet (V) to the part (a) of the
auto-tensioner (2), and turn it. (The spring of the
auto-tensioner (2) is strong. It is very dangerous to
turn it as the wrench can come off if the ratchet (V)
is not inserted securely.)
k After you remove the alternator belt (1), set the au-
to-tensioner (2) to its initial position slowly and
carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during the work.
Alternator
6. Remove the bolts (1) (3 pieces), and remove the cover (2).
7. Remove the nut (3) and bolts (4) and (5), and remove the
brackets (6) and (7), alternator (8), and spacer (9).
REMARK
• For machines with 85A alternator, be careful not to let
the spacers (9) (2 pieces) fall off when you remove the
nut (3) and bolt (5).
• There is no spacer (9) for machines without 85A alter-
nator.
50-16 107E-5 SERIES

Covers
8. Remove the bolts (1) (4 pieces), and remove the cover (2).
9. Remove the bolts (3) (2 pieces), and remove the brackets

(4) (2 pieces).
Tube, hoses
10. Remove the clip (1).
11. Remove the clamp (2), and remove the blower connector
(3).
12. Remove the joint bolt (4) and sleeve nuts (5) and (6), and
remove the tube (7).
13. Remove the joint bolt (8) and sleeve nut (9), and remove
the tube (10).
107E-5 SERIES 50-17

14. Remove the joint bolt (11), sleeve nuts (12) and (13), and
nut (14), and remove the tube (15).
Wiring harnesses
15. Remove the clips (1) (2 pieces), and disconnect the con-
nector ETV (2).
Brackets
16. Remove the bolt (1).
REMARK
The bolt (1) contains the washers and spacer. Be careful
not to let them fall off.
17. Remove the bolt (2), and remove the bracket (3).
18. Remove the bolts (4) (2 pieces), and remove the bracket
(5).
50-18 107E-5 SERIES

Exhaust throttle valve

19. Remove the clamps (1) (2 pieces), and remove the pipe
(2) and exhaust throttle valve (3).
20. Remove the bolts (4) (2 pieces), and remove the brackets
(5) and (6) together.
Turbocharger
21. Remove the nuts (1) (4 pieces), and remove the turbo-
charger (3), gasket (4), and tube (2) together.
REMARK
• When you pull out the tube (2), be careful that the load
is not applied to the bellows part.
• The O-rings (5) (2 pieces) are attached to the cylinder
block connection part of the tube (2). Remove them
carefully not to let them fall off inside the engine.
107E-5 SERIES 50-19

Exhaust manifold
22. Disconnect the connector EXHAUST PRESSURE (1).
23. Loosen the nut (2), and remove the exhaust manifold pres-
sure sensor (3).
(7).
26. Remove the bolts (8) (8 pieces), and remove the spacers
(9) (8 pieces), exhaust manifold (10), and gaskets (11) (4
pieces).
REMARK
When you remove it, be careful not to let the gasket (11)
fall off.
50-20 107E-5 SERIES

27. Remove the bolts (12) (2 pieces), and remove the cover
(13).
Auto-tensioner
28. Remove the bolt (1), and remove the auto-tensioner (2).
29. Remove the bolts (3) (3 pieces), and remove the coolant
inlet connector (4) and tensioner bracket connector (5).
REMARK
The coolant inlet connector (4) and tensioner bracket con-
nector (5) are tightened together. Be careful not to let them
fall off when you remove them.
Engine oil cooler

30. Remove the bolts (1) (13 pieces) and (2) (2 pieces), and
remove the cover (3), cover gasket (4), engine oil cooler
(5), and engine oil cooler gasket (6).
107E-5 SERIES 50-21

Installation to engine repair stand

31. Install the adapter (B) to the engine assembly (1).
Mounting bolt at engine side: M12×1.75
32. Lift the engine assembly (1), align the adapter (B) with the
repair stand (A), and then install the engine assembly (1).
REMARK
The shape is different by the machine model.
Alternator bracket, lifting bracket

33. Remove the bolts (1) (4 pieces), and remove the alternator
bracket (2) and lifting bracket (3).
REMARK
The alternator bracket (2) and lifting bracket (3) are tight-
ened together. Be careful not to let them fall off when you
remove them.
Thermostat
34. Remove the bolts (1) (3 pieces), and remove the coolant
outlet connector (2).
35. Remove the thermostat (3).
50-22 107E-5 SERIES

Accessory pulley, idler pulley

36. Remove the bolts (1) (4 pieces), and remove the accesso-
ry pulley (2) and idler pulley (3).
37. Remove the bolts (4) (4 pieces), and remove the support
(5).
Water pump
38. Remove the bolts (1) (2 pieces), and remove the water
pump (2).
107E-5 SERIES 50-23

Crankshaft pulley
39. Fix the flywheel (2) with the plate (a) or such not to let the
crankshaft pulley (1) rotate.
40. Loosen the bolts (3) (6 pieces), and remove the plate (a).
41. Remove the bolts (3) (6 pieces), and remove the plate (4)
and crankshaft pulley (1).
Breather hose
42. Remove the hose clamp (1).
43. Remove the bolts (2) (2 pieces) and (3), and remove the
breather hose (4) and bracket together.
50-24 107E-5 SERIES

Engine oil level gauge

(2).
45. Remove the bolts (3) (3 pieces), and remove the engine oil
level gauge (4).
REMARK
The gasket (5) is installed at the installation part of the en-
gine oil level gauge (4). Be careful not to let it fall off when
you remove it.
Fuel main filter assembly

46. Disconnect the fuel main filter hoses (1) (2 pieces), and re-
move the fuel main filter (2).
NOTICE
• As a general rule, do not use the hose again. The
internal components can have damage.
• When you assemble it again, replace the hose with
a new one.
REMARK
When you disconnect the fuel main filter hose (1), push the
locks (a) from the two sides to pull it out.
107E-5 SERIES 50-25

Bypass tube
47. Remove the bypass tube (1).
REMARK
When you remove the bypass tube, push the connector
lock parts (a) at each end from the two sides to pull it out.
Wiring harness assembly

48. Disconnect the connector CRANK CASE PRESSURE (1).
49. Disconnect the connector COOLANT TEMP (2).
(4).
REMARK
The clamps (5) and (6) are tightened together with the
bracket (4).
51. Remove the clamp (7).

(9).
REMARK
The clamp (10) is tightened together with the bracket (10).
53. Disconnect the connector OIL PRESSURE SWITCH (11).
54. Disconnect the connector EPS BACKUP(CAM) (12).
55. Remove the nuts (13) (2 pieces), and remove the bracket
(14).
56. Disconnect the connector EPS MAIN(CRANK) (15).
57. Remove the nuts (16) (2 pieces), and remove the bracket
(17).
58. Remove the bolt (18).
59. Disconnect the connector ECM J1 (19).
60. Remove the clamp (20).

(22).
REMARK
The clamp (23) is tightened together with the bracket (22).
50-26 107E-5 SERIES

62. Remove the clip (24).

63. Disconnect the connector IMV (25).
(27) and clamp (28).
65. Disconnect the connector TMAP (29).
66. Disconnect the connector INJECTOR CYL1&2 (30).

68. Disconnect the connector INJECTOR CYL3&4 (33).
70. Disconnect the connector FUEL RAIL PRESS (36).
Oil filler
(2).
72. Remove the nuts (3) (2 pieces) and bolts (4) (2 pieces),
and remove the oil filler (5).
Lifting bracket
73. Remove the bolts (1) (2 pieces), and remove the lifting
bracket (2).
107E-5 SERIES 50-27

Air intake connector assembly

74. Remove the bolts (1) (2 pieces) and (2) (2 pieces), and re-
move the air intake connector assembly (3) and gasket (4).
Fuel injection pipe, fuel high-pressure pipe, common rail

75. Remove the fuel spray prevention caps (1) (10 pieces).
76. Remove the fuel injection pipes (2), (3), (4), and (5).
77. Remove the joint bolts (6), (7), and (8), and remove the
spill tube (9).
78. Remove the clamps (10) (2 pieces), and remove the fuel
high-pressure pipe (11).
50-28 107E-5 SERIES

79. Remove the bolt (12) and bolts (13) (2 pieces), and re-
move the common rail (14).
Air intake manifold cover

80. Remove the bolts (1) (5 pieces), (2) (2 pieces), and (3),
and remove the air intake manifold cover (4).
Cylinder head cover, rocker housing

81. Remove the nuts (1) (4 pieces), and remove the spacers
(2) (4 pieces), isolators (3) (4 pieces), and cylinder head
cover (4).
82. Remove the gasket (5) from the cylinder head cover (4).
83. Remove the nut (6) of the wiring harness from the injector.
Installation position of wiring harness
Color of wiring harness Cylinder No.
White 1, 3
Black 2, 4
107E-5 SERIES 50-29

NOTICE
Do not remove the injector wiring harness connector (7) from the rocker housing assembly (8) un-
less it is required.
84. Remove the bolt (9), and remove the rocker housing assembly (8).
Rocker arm assembly, crosshead
85. Loosen the lock nut (4) not to apply tension of the valve
spring on the bolt (1), and then loosen the adjustment
screw (5).
86. Remove the bolt (1), and remove the rocker arm assembly
(2).
87. Remove the crosshead (3).
REMARK
Write down the installation position and hole shape of the
parts (a) and (b). (This is to install them in the same direc-
tions during reassembly.)
a b
G0135352
Push rod
88. Remove the push rod (1).
Injector assembly
89. Remove the retaining nut (5), and remove the inlet con-
nector (1).
REMARK
• Use the remover (M) to remove the inlet connector (1).
• Remove mud around the parts and clean it to prevent
entry of mud into the hole of the inlet connector (1).
90. Remove the bolt (3), and remove the holder (4).
50-30 107E-5 SERIES

91. Remove the injector (2).

REMARK
• Use the puller (F) to pull up the injector (2) to remove it. F
• Do not pry the top of the injector (2) to remove it.

2
• Be careful not to let dirt or foreign material go into the
mounting part of the injector (2).
G0135355
Cylinder head assembly

92. Remove the bolts (1) (18 pieces), and remove the cylinder
head assembly (2).
Cylinder head assembly: 50kg
93. Compress the valve spring (3) with the spring pusher (C),
and remove the valve cotter (4).
94. Remove the upper seat (5) and valve spring (3).
95. Raise the cylinder head assembly, pull out the valve (6),
and remove the valve seal (7).
REMARK
Make marks on the valve (6) to let you know the combina-
tion with the cylinder head.
107E-5 SERIES 50-31

Engine controller
96. Remove the bolts (1) (4 pieces), and remove the engine
controller (2).
REMARK
The ground (3) is tightened together.
97. Remove the bolts (4) (2 pieces) and bolt (5), and remove
the engine controller mount bracket (6).
Supply pump assembly

98. Remove the nuts (1) (3 pieces), and remove the supply
pump assembly (2).
REMARK
The supply pump assembly (2) comes off together with the
gear. The gear is not machined on its teeth (missing tooth)
to align the mark for 1.4TOP.
99. When you remove the gear from the supply pump assem-
bly, remove it as follows. N
1) Fix the gear with the support (N) and 1/2 inch spinner
handle (P), and loosen the nut (3).
REMARK
Do not remove the nut (3) from the shaft.
P
3
G0135364
50-32 107E-5 SERIES

2) Install the bearing puller (Q) between the flange and

gear (4).
G0135365
3) Install the push puller (R) on the bearing puller (Q)

and shaft.
4) Tighten the center bolt (S) until the gear comes off S
from the shaft.
5) Remove the push puller (R) and bearing puller (Q).
R
G0135366
6) Remove the nut (3), lock washer (5), and gear (4)
from the shaft (6).
6
4
5
3
G0135367
Engine oil pan

100. Move the engine repair stand, and set the bolt (1) to the
position where it can be removed easily.
101. Remove the bolts (1) (24 pieces), and remove the engine
oil pan (2).
REMARK
There is a paint mark on the bolt at the position of (d) to
set the position when you adjust the valve clearance.
102. Remove the bolts (3) (2 pieces) and (4), and remove the
engine oil suction pipe (5).
107E-5 SERIES 50-33

103. Remove the bolts (6) (7 pieces), and remove the plate (7).
Front oil seal dust cover

104. Remove the engine front oil seal (1) as follows.
1) Remove the dust seal (2).
2) Install the seal puller (H) to the crankshaft.

3) Tighten the tapping screw (3) of the seal puller (H) to 1
the seal carrier part of the front oil seal (1).
4) Turn the handle in the direction of the arrow, and re- 3
move the engine front oil seal (1).
REMARK
Be careful not to cause damage to the crankshaft
when you remove it.
H G0135372
105. Remove the bolt (4), and remove the Bkup (camshaft)
speed sensor (5).
NOTICE
If the front oil seal dust cover (7) is removed while the
Bkup (camshaft) speed sensor (5) is installed, the front
end of the camshaft can have damage.
106. Remove the bolts (6) (13 pieces), and remove the front oil
seal dust cover (7).
50-34 107E-5 SERIES

Engine oil pump assembly

107. Remove the bolts (1) (4 pieces), and remove the engine oil
pump assembly (2).
Flywheel
108. Fix the flywheel (2) with a tool that is not deformed by the
tightening torque (such as plate (a)) not to let the flywheel
(2) rotate.
110. Remove the bolts (1) (2 pieces), and install the guide bolt.
111. Lift the flywheel (2), and hold it.
112. Remove the remaining bolts (1) (6 pieces), lift the flywheel
(2), and remove it.
k Be careful not to get your fingers caught. It can fall
off suddenly as the spigot joint part of the flywheel
(2) is shallow.
k When you pull out the flywheel (2), be careful not to
let the guide bolt fall out.
Flywheel (2): 50kg
107E-5 SERIES 50-35


113. Install the seal puller (G) to the crankshaft.
114. Tighten the tapping screw (2) of the seal puller (G) to the
seal carrier part of the engine rear oil seal (1).
115. Turn the handle in the direction of the arrow, and remove
G
the engine rear oil seal (1).
REMARK
Be careful not to cause damage to the crankshaft when
you remove it. 2
G0135378
Flywheel housing
116. Remove the bolts (1) (20 pieces), and remove the flywheel
housing (2).
Camshaft
117. Rotate the crankshaft, and align the timing mark (a) part of
the camshaft gear (1) with the chamfered tooth of the
crankshaft gear (4). 1
REMARK a
This is not to interfere with the connecting rod when you

4
remove the camshaft.
G0135381
50-36 107E-5 SERIES

118. Remove the bolts (5) (6 pieces), and remove the camshaft
gear (1).
119. Remove the bolts (6) (2 pieces), and remove the thrust
plate (2).
120. Remove the camshaft (3).
REMARK
Turn the camshaft (3) to pull it out.
Gear housing
121. Remove the bolts (1) (8 pieces), and remove the gear
housing (2).
Piston cooling nozzle

122. Rotate the crankshaft to the position where the piston cool-
ing nozzle (1) can be removed easily.
123. Remove the bolt (2), and remove the piston cooling nozzle
(1).
107E-5 SERIES 50-37

Piston and connecting rod assembly

124. Rotate the crankshaft until the piston to be removed is at the bottom dead center.
125. Remove the carbon on the upper wall of the cylinder bore with the fine paper file.
126. Align the cylinder with each connecting rod cap (1) to
make a mark on the installation position.
REMARK
Before you remove the piston and connecting rod assem-
bly, measure the side clearance between the connecting
rod and crankshaft with the clearance gauge (K).
127. Remove the bolts (2) (2 pieces).

128. Tap the connecting rod cap (1) lightly with a plastic ham-
mer, and remove the connecting rod cap (1) and connect-
ing rod bearing together.
NOTICE
Store the connecting rod and connecting rod cap not
to cause damage to the contact surface. If it has dam-
age, replace the connecting rod and connecting rod
cap.
129. Push the piston and connecting rod assembly from the en-
gine oil pan side, and remove it while you support the pis-
ton (6) not to fall off at the cylinder head side.
REMARK
• Be careful not to cause damage to the inner surface of
the cylinder at the corner of the connecting rod.
• Make a mark of the cylinder number on the piston (6).
130. Remove the remaining piston and connecting rod assem-
bly in the same procedure.
NOTICE
Be careful not to cause damage to the sliding part of
the piston and bearing.
131. Disassemble the piston and connecting rod assembly as
follows.
1) Remove the snap ring (3).
2) Support the connecting rod (4) with your hand, pull out
the piston pin (5), and disconnect the piston (6) and
connecting rod (4).
3) Remove the snap ring at the opposite side.
50-38 107E-5 SERIES

4) Remove the piston ring (7) with the piston ring tool
(D).
REMARK
Store the piston (6), connecting rod (4), connecting
rod bearing, piston ring (7), and piston pin (5) for each
cylinder.
Crankshaft
132. Before you remove the crankshaft, measure the end play
(a) of the crankshaft (4) with the dial gauge, and write it a
down.
G0135392
133. Remove the bolts (2) (2 pieces).

134. Insert the bolt (2) into the bolt hole of the main bearing cap
(1), and shake the main bearing cap (1) to remove it.
REMARK
• There is an installation position number mark on the
main bearing cap (1). No.1 starts at the front side of the
cylinder block.
• Make sure that there is a number on the position num-
ber (b) part of the main bearing cap (1) and it is set to
the engine oil cooler side.
135. Remove the lower main bearing (3) from the main bearing
cap (1).
REMARK
• Write down the installation position number on the latch
part (c) of the removed lower main bearing (3). (Do not
write it on the sliding surface of the lower main bearing
(3).)
• Write down the installation position on the main bearing
cap (1).
107E-5 SERIES 50-39

136. Lift the crankshaft (4), and remove it.
REMARK
• When you lift the crankshaft (4), remove it carefully not
to let it contact to the cylinder block (8) and cause dam-
age to it.
• Store the crankshaft (4) to a safe area not to cause
damage to its sliding surface.
Crankshaft (4): 45kg
137. Remove the thrust bearing (5) and upper main bearing (6).
REMARK
• Write down the installation position number on the latch
part (d) of the removed upper main bearing (6) and
thrust bearing (5). (Do not write it on the sliding surface
of the upper main bearing (6).)
• Organize the main bearing cap (1), lower main bearing
(3), upper main bearing (6), and thrust bearing (5) for
each installation position, and store them not to cause
damage.
Tappet
138. Remove the tappet (1), and put a mark on the installation
position.
REMARK
When you use the tappet again, install it to its initial posi-
tion.
Cylinder block
139. Remove the cylinder block (1) from the repair stand (A)
and adapter (B).
Cylinder block (1): 100kg
50-40 107E-5 SERIES

ASSEMBLE ENGINE GENERALLY

Piston and A
Piston cooling
Cylinder block Tappet Crankshaft connecting rod
nozzle
assembly
Engine oil B
Engine front oil
Gear housing Camshaft pump assem-
seal
bly
Rocker arm Water pump
A Cylinder head C
Cylinder head Engine repair
Engine oil pan Crosshead cover, rocker
assembly stand
housing
Front oil seal

B Push rod Thermostat
dust cover
Injector as- Wiring harness

sembly assembly
Fuel main filter

assembly
Fuel injection
pipe, fuel high-
pressure pipe
Common rail
Flywheel Engine rear oil

Flywheel
housing seal
Starting motor Preparation Engine assem-

assembly work bly
C Exhaust
Turbocharger
manifold
Engine oil
Alternator
cooler
Auto-tensioner
Fan pulley
Engine con-
troller
Supply pump
107E-5 SERIES 50-41

Preparation work
1. Install the adapter (B) to the repair stand (A).
2. Install the cylinder block (1) to the adapter (B).
Cylinder block (1): 100kg
Tappet
3. Apply engine oil on the tappet (1).
Tappet (1): Engine oil
G0135401
4. Install the tappet (1).

REMARK
• When you use the tappet (1) again, install it to its initial
position.
• When you assemble it, the tappet (1) comes off the
mounting hole. Do not turn over the cylinder block 90°
or more.
50-42 107E-5 SERIES

Crankshaft
5. Install the upper main bearing (6) and thrust bearing (5).
REMARK
• Align the protrusions of the upper main bearing (6) and
thrust bearing (5) with the notches (d) of the cylinder
block (8), and install them.
• Make sure that there is no foreign material on the back
surface of the upper main bearing (6) and thrust bear-
ing (5), and then install it.
• Apply engine oil on the inner surfaces of the upper
main bearing (6) and thrust bearing (5). Do not apply it
to the rear surface at this time.
• When you use the upper main bearing (6) and thrust
bearing (5) again, make sure that there is the mark at
the time of disassembly, and install it to its initial posi-
tion.
Inner surface of upper main bearing (6) and thrust
bearing (5): Engine oil
6. Lift the crankshaft (4), and install it.
NOTICE
Be careful not to cause damage to the thrust bearing
(5) when you install it.
Crankshaft (4): 45kg

7. Align the protrusion of the lower main bearing (3) with the
notch (e) of the main bearing cap (1), and install it.
REMARK
Make sure that the dowel ring (7) is installed to the main
bearing cap (1).
8. Apply engine oil to the journal part (f) of the crankshaft (4).
Journal part (f): Engine oil
107E-5 SERIES 50-43

9. Make sure that the position number (b) of the main bearing
cap (1) is correct before the assembly.
REMARK
• Install the cylinder blocks (8) in the sequence shown in
the figure from the front side.
• Set the position number (b) part to the engine oil cooler
side, and install it.
• Tap it with a plastic hammer or rubber hammer to push
it in.
10. Before you tighten the bolt (2), measure the stem length
(g) of the bolt (2) with the gauge (AA), and make sure that
it is in the range of the allowable limit.
Allowable limit length of bolt (2): Below 120.0mm
NOTICE
If the bolt (2) becomes longer than the allowable limit,
do not use it again but replace it. g
G0135404
11. Tighten the bolts (2) in the sequence of (a) to (k).

REMARK
Apply engine oil on the threaded part and seat surface of 2 2 J
the bolt (2).
Bolt (2): Engine oil
G0137349
• When you use the bolt again

1st time: 60±5Nm{6.1±0.5kgfm}
2nd time: 80±5Nm{8.2±0.5kgfm}
3rd time: 90±5° (with wrench (J))
• For new bolts
1st time: 120±10Nm{12.2±1.02kgfm}
2nd time: 360° (loosen)
3rd time: 60±5Nm{6.1±0.5kgfm}
4th time: 85±5Nm{8.7±0.5kgfm}
5th time: 120±5° (with wrench (J))
50-44 107E-5 SERIES

• When you do not use the wrench (J)

Make marks on the main bearing cap (1) and bolt (2)
with paint, and then retighten the bolt (2).
h
Retightening angle (h): 90±5° (when the bolt
is used again)
Retightening angle (h): 120±5° (for new bolt)
12. When you use the bolt again, put a punch mark on the bolt
head.
REMARK G0135407
For new bolts, do not put a punch mark on the bolt head.
13. After you tighten the bolt (2), rotate the crankshaft (4) to make sure that it rotates smoothly.
14. Measure the end play of the crankshaft (4) with the dial
gauge. a
End play (a): 0.24±0.175mm
G0135408
Piston and connecting rod assembly

15. Install the piston ring (7) to the piston with the piston ring
tool (D).
16. Install the oil ring (9) as follows.

1) Set the ring end of the oil ring (9) at 180° from the end 9
of the expander (8).
8
180°
G0135410
107E-5 SERIES 50-45

2) Install the second ring (10) with the “TOP” mark near
the ring end up. 120°
3) Install the top ring (11) with the “Dot” mark near the 11
ring end up.
10
4) Set each ring end in the direction other than the thrust,
anti-thrust, and piston axial, and install each ring.
9
120°
G0135411
17. Install the piston (6) and connecting rod (4) as follows.
4
REMARK
Set the “FRONT” mark at the head of the piston (6) to up,
and make sure that the connecting rod (4) is set in the di-
rection as shown in the figure.
6
G0135412
1) Apply engine oil to the piston pin hole of the connect-

ing rod (4) and piston pin (5).
Piston pin hole of connecting rod (4): Engine
oil
Piston pin (5): Engine oil
G0135413
2) Insert the piston pin (5), and install the piston (6) to
the connecting rod (4).
3) Install the snap rings (3) on the two sides.
18. Install the connecting rod bearing (13) to the connecting

rod (4) and connecting rod cap (2).
50-46 107E-5 SERIES

REMARK
• When you disassemble the connecting rod (4) and connecting rod cap (2), be careful not to cause a
dent or other damage to the contact surface. If it has damage, replace the connecting rod (4) and con-
necting rod cap (2).
• Make sure that there is no foreign material on the back surface of the connecting rod bearing (13).
• Align the protrusions of the connecting rod bearing (13) with the connecting rod (4) and notch (a) of the
connecting rod cap (2), and install it.
19. Set the crankshaft of the cylinder to be installed to the bot-
tom dead center, and apply engine oil on the piston ring
(7), piston skirt (b), and cylinder inner surface (c).
Piston ring (7): Engine oil
Piston skirt part (b): Engine oil
Inner surface of cylinder (c): Engine oil
20. Set the “FRONT” mark of the piston (6) at the front side of
the cylinder block, and insert the piston and connecting rod
assembly.
REMARK
• Make sure again that direction of the ring end of the
piston ring (7) is correct.
• When you insert the connecting rod, be careful not to
cause damage to the wall surface of the cylinder.
• Compress the piston ring (7) with the piston holder (E),
and push in the head part of the piston (6) with a wood
bar or such.
21. Tighten the bolt (1) as follows to install the connecting rod
1
cap (2).
2
REMARK
Apply engine oil on the threaded part of the bolt (1) and in-
ner surface of the connecting rod bearing.
Threaded part of bolt (1): Engine oil
Inner surface of connecting rod bearing: Engine oil
G0135418
107E-5 SERIES 50-47

• Do the angle tightening with the wrench (J).

1 J
Bolt (1) (Tighten the bolts at 2 ends in one and then
the other):
1st time: 30±3Nm{3.06±0.31kgfm}
2nd time: 60±5Nm{6.12±0.51kgfm}
3rd time: 60±5° (with wrench (J))
G0135419
• If the wrench (J) is not available, put paint marks on

the connecting rod cap (2) and bolt (1), and then re-
tighten the bolt (1). d
Retightening angle (d): 90±5°
22. After you install the piston and connecting rod assembly,
rotate the crankshaft to make sure that it rotates smoothly
and correctly.
G0135420
23. Measure the side clearance between the connecting rod

and crankshaft with the feeler gauge (K).
Side clearance: 0.10 to 0.33mm
Piston cooling nozzle

24. Rotate the crankshaft to the position where the piston cooling nozzle (1) can be installed easily.
25. Install the piston cooling nozzle (1) with the bolt (2).
Bolt (1): 15±2Nm{1.5±0.2kgfm}
50-48 107E-5 SERIES

Gear housing
26. Apply liquid gasket on the mounting face (a) of the gear
c
housing (2). 2
REMARK
• Apply liquid gasket 1 to 2mm in diameter. b
• Be sure not to apply too much liquid gasket to the area

around the groove (b) of the blowby oil. If you apply too a
much liquid gasket, the groove can be blocked. c
Gear housing: Liquid gasket (LG-7)

G0137350
27. Make sure that the dowel rings of the gear housing (2) are
securely inserted into the dowel holes of the cylinder
blocks at the top and bottom 2 places (c).
NOTICE
If the bolt is tightened while the dowel ring is not inserted correctly, the dowel ring can have dam-
age.
28. Push the gear housing (2) to let the contact surface to the cylinder block contact fully.
29. Lightly tighten the gear housing (2) with the bolts (1) (8
pieces).
REMARK
Do not apply torque to the bolt (1) if it does not contact
fully.
30. Tighten the bolts (1) in the sequence shown in the figure. 6 8 7
Bolt M12 (no mark): 77±7Nm{7.9±0.7kgfm} 9
5 10
Bolt M10 (□ mark: ℓ=30, ○ mark: ℓ=50):
47±5Nm{4.8±0.5kgfm}
1
Bolt M8 (△ mark): 24±4Nm{2.5±0.4kgfm} 2
4
3
G0135422
Camshaft
31. Rotate the crankshaft, and set the No.1 cylinder to the top dead center (TDC).
32. Apply engine oil to all the camshaft bores (b), camshaft
journals (c), and lobe surfaces (d).
Camshaft bore (b): Engine oil
Camshaft journal (c): Engine oil
Lobe surface (d): Engine oil
107E-5 SERIES 50-49

33. Lightly push in the camshaft (3), and turn it to install.

REMARK
Be careful not to cause damage to the cam bushing when
you install the camshaft (3).
34. Install the thrust plate (2) with the bolts (6) (2 pieces).
Bolt (6): 24±4Nm{2.4±0.4kgfm}
35. Align the timing mark (a) of the camshaft gear (1) with the
chamfered teeth (1 place) of the crankshaft gear (4), and
install it. 1
G0135381
36. Install the camshaft gear (1) with the bolts (5) (6 pieces).
Bolt (5): 36±4Nm{3.7±0.4kgfm}
37. Measure the end play and backlash of the camshaft with
the dial gauge.
REMARK
The end play quantity is set by the thickness of the thrust
plate and groove of the camshaft.
End play: 0.23±0.13mm
Backlash: 0.178±0.102mm
G0135424
50-50 107E-5 SERIES

Flywheel housing
38. Apply liquid gasket on the mounting flange surface of the
flywheel housing (2) and around the mounting bolt holes.
REMARK
Apply liquid gasket 1 to 2mm in diameter.
Flywheel housing: Liquid gasket (LG-7)
39. Install the flywheel housing (2) with the bolts (1) (20
pieces).
REMARK
• Tighten the bolts (1) in the sequence shown in the fig- 7 8 14 6
15
ure. 13
16 5
• There are 5 types of the bolts (1). Install them carefully.
17 12
Bolt (1) M12 (▲ mark: ℓ=80, ■ mark: ℓ=110):
18 11
85±10Nm{8.7±1.0kgfm}
19
Bolt (1) M10 (○ mark: ℓ=40, □ mark: ℓ=80, △
mark: ℓ=110): 49±5Nm{5.0±0.5kgfm} 20
2
3
1
4 9 10 G0135425
Measure radial runout

40. Install the dial gauge (L) to the end surface of the crank-
shaft.
41. Set the probe of the dial gauge (L) at a right angle to the
spigot joint part of the flywheel housing.
42. Set the scale of the dial gauge (L) to “0”, rotate the crank-
shaft by 1 turn, and measure the difference between the
maximum value and minimum value that the pointer of the
dial gauge shows.
REMARK L G0135426
• Radial runout: 0.20mm or below
• When you rotate the crankshaft by 1 turn, make sure
that the pointer of the dial gauge (L) is at the start posi-
tion.
Measure facial runout
43. Similarly to the measurement of the radial runout, set the
probe of the dial gauge (L) to the end face of the flywheel L
housing at a right angle.
REMARK
When you measure the facial runout, move the crankshaft
to the front or rear side to prevent the error caused by the
end play.
44. Set the scale of the dial gauge (L) to “0”, rotate the crank-
shaft by 1 turn, and measure the difference between the G0135427
maximum value and minimum value that the pointer of the
dial gauge (L) shows.
REMARK
Facial runout: 0.20mm or below
107E-5 SERIES 50-51


NOTICE
• Do not remove the pilot (3) installed to the engine rear 3
oil seal (1) until the engine rear oil seal is inserted to
the crankshaft.
• Before you install the engine rear oil seal, remove
grease, clean, and dry the seal contact surface and seal
lip surface of the crankshaft to prevent oil leakage.
1
G0135428
45. Insert the pilot (3) into the crankshaft (4), and push in the
1 5
engine rear oil seal (1) to the flywheel housing (5).
46. Push in the engine rear oil seal (1) more, and pull out the
pilot (3).
4 G0135429
47. Install the engine rear oil seal (1) to the correct depth of
the flywheel housing (5) with the seal puller (G).
REMARK
G
• Make sure that there is no bent on the engine rear oil
seal (1), and push it in.
• Protrusion (c) of engine rear oil seal (1) from flywheel
housing (3): 0.38mm or below
• Radial runout (d) between flywheel housing (3) and 5
crankshaft: 0.25mm or below G0135430
d c
G0137358
Flywheel
48. Install the guide bolt.
49. Lift the flywheel (2), and set it to the installation position.
50. Lightly tighten the flywheel (2) with the bolts (1) (8 pieces).
Flywheel (2): 50kg
50-52 107E-5 SERIES

(2) rotate.
52. Tighten the bolts (1) in the sequence shown in the figure.
Bolt (1): 137±7Nm{14.0±0.7kgfm}
53. Make sure that the bolts (1) (8 pieces) are tightened, and
remove the plate (a).
Measure radial runout

54. Install the dial gauge (L) to the flywheel housing.
55. Set the probe of the dial gauge (L) to the spigot joint part
(a) or outer circumference of the flywheel at a right angle.
56. Rotate the flywheel by 1 turn, and measure the difference a
b
between the lowest and highest values that the pointer of
the dial gauge (L) shows.
L L
REMARK
• Radial runout: 0.13mm or below
G0135433
• After you rotated the flywheel by 1 turn, make sure that
the pointer of the dial gauge (L) is at the start position.
Measure facial runout
57. Similarly to the measurement of the radial runout, set the probe of the dial gauge (L) to the end face (b)
near the outside perimeter of the flywheel at a right angle.
REMARK
When you measure the facial runout, move the crankshaft to the front or rear side to prevent the error
caused by the end play.
58. Rotate the flywheel by 1 turn, and measure the difference between the lowest and highest values that the
pointer of the dial gauge (L) shows.
REMARK
107E-5 SERIES 50-53

Engine oil pump assembly

59. Fill the space of the oil pump rotor and idler shaft bore with
engine oil, and rotate it by 2 turns.
Space of oil pump rotor: Engine oil
Idler shaft bore: Engine oil
G0135434
60. Install the engine oil pump assembly (2) with the bolts (1)
(4 pieces).
REMARK
Tighten the bolts (1) in the sequence shown in the figure. 1 3 2 3
1st time: 8±1Nm{0.8±0.1kgfm} (figure (a))
2nd time: 24±4Nm{2.4±0.4kgfm} (figure (b))
61. Stop the movement of one of the gears, and measure the
backlash (c) of the pump and idler gear.
Backlash (c): 0.2±0.05mm
a c b
4 2 4 1
G0135436
50-54 107E-5 SERIES

Front oil seal dust cover

62. Apply liquid gasket on the mounting face (a) of the front oil
P 7
seal dust cover (7).
REMARK
• Apply liquid gasket 1 to 2mm in diameter.
a
• Be careful that liquid gasket does not go into the oil cir-
cuit (b) when you apply it.
Front oil seal dust cover (7): Liquid gasket (LG-7)
a b
P
G0135437
63. Install the front oil seal dust cover (7) with the bolts (6) (13
pieces).
REMARK
Tighten the bolts (6) in the sequence of (a) to (p).
Bolt (6): 24±4Nm{2.4±0.4kgfm}
64. Install the Bkup (camshaft) speed sensor (5) with the bolt
(4).
Bolt (4): 8±2Nm{0.8±0.2kgfm}
107E-5 SERIES 50-55

65. Install the engine front oil seal (1) with the seal puller (H).
REMARK
• Before you install the engine front oil seal (1), make
sure that there is no scratches, burrs, sharp edges, or
rusts or such on the end surface corner and lip sliding
surface of the crankshaft.
• When you install the engine front oil seal (1), do not ap-
ply oil or grease on the crankshaft or seal lip. Fully
wipe off oil on the crankshaft in advance. 1 H G0135439
• The deviation of the engine front oil seal (1) against the
front oil seal dust cover (7) is as follows.
7
Protrusion (x): 0.38mm or below
Facial runout (y): 0.25mm or below
x 1
G0135440
66. Install the dust seal (2).

REMARK
Make sure that the installed dimension (c) is correct.
Installed dimension (c): 12+0.1/0mm
Engine oil pan

67. Install the plate (7) with the bolts (6) (7 pieces).
Bolt (6): 43±6Nm{4.4±0.6kgfm}
68. Install the engine oil suction pipe (5) with the bolts (3) (2
pieces) and bolt (4).
Bolt (3): 24±4Nm{2.4±0.4kgfm}
Bolt (4): 43±6Nm{4.4±0.6kgfm}
50-56 107E-5 SERIES

69. Remove liquid gasket that comes out between the cylinder
block and gear housing and between the cylinder block
and front cover (a) (4 places) with the scraper.
REMARK
When you install or remove only the engine oil pan, also
remove the used liquid gasket that is clogged inside the
border line (a) (4 places) with a scraper.
70. Apply liquid between the cylinder block and gear housing
and between the cylinder block and front cover (a) (4 pla-
ces) with the scraper.
Engine oil pan (a): Liquid gasket (LG-7)
Application diameter of liquid gasket: 3mm
71. Install the gasket (8) to the mounting face.
REMARK
• Do not apply oil when you install the gasket.
• Set the silicon bead (c) of the gasket to the engine oil
pan side, and install it.
• Apply liquid gasket to the clinch parts (b) (4 places) on
the two sides of the gasket.
(b) part on two sides of gasket: Liquid gasket
(LG-7)
72. Lightly tighten the engine oil pan (2) with the bolts (1) (24
pieces).
• When you use the bolt again
Install the painted bolt to the position (d).
• If you use a new bolt or paint goes out
Paint the bolt to be installed to the position (d).
REMARK
(d) is the position to be aligned when you adjust the
valve clearance.
73. Tighten the bolts (1) (24 pieces) in the sequence shown in
the figure.
REMARK
The lengths of the bolts (with ○ mark) (6 pieces) are differ-
ent. Be careful when you handle them.
Bolt (1): 28±2Nm{2.9±0.2kgfm}
107E-5 SERIES 50-57

Crankshaft pulley
tightening torque (such as plate (a)) not to let the crank-
shaft pulley (1) rotate.
75. Install the crankshaft pulley (1) with its dowel hole aligned
with the dowel pin (b) of the crankshaft.
76. Install the plate (4) and crankshaft pulley (1) with the bolts
(3) (6 pieces).
Tightening procedure of bolt (3)
1st time: 55±5Nm{5.61±0.51kgfm} (Tighten them
diagonally.)
2nd time: Loosen by 180°
3rd time: 55±5Nm{5.61±0.51kgfm} (Tighten them
diagonally.)
4th time: 90±5° (Retighten them diagonally.)
REMARK
Do the angle tightening with the wrench (J).
G0135479
50-58 107E-5 SERIES

When you do not use the wrench (J)

Make marks on the crankshaft pulley (1) and bolt (3) with a
marker, and then retighten the bolt (3).
c
Retightening angle (c): 90±5°
G0135483
Engine controller
78. Install the engine controller mount bracket (6) with the
bolts (4) (2 pieces) and bolt (5).
Bolt (4), (5): 24±4Nm{2.4±0.4kgfm}
79. Install the engine controller (2) and ground (3) with the
bolts (1) (4 pieces).
Bolt (1): 24±4Nm{2.4±0.4kgfm}
Cylinder head assembly

80. Assemble the cylinder head assembly as follows.
1) Install the valve seal (7).
107E-5 SERIES 50-59

2) Apply engine oil on the stem part (a) of the valve (6)
and inner surface (b) of the valve guide.
Stem part (a) of valve (6): Engine oil
Inner surface (b) of valve guide: Engine oil
3) Install the valve (6).
4) Raise the cylinder head, and install the valve spring

(3) and upper seat (5).
5) Compress the valve spring (3) with the spring pusher

(C), and install the valve cotter (4).
REMARK
Tap the valve stem part with a plastic hammer to make
sure that the valve cotter is securely engaged into the
groove of the valve stem.
81. Before you tighten the cylinder head mounting bolts,

measure the stem length (c) of all the mounting bolts to
make sure that they are below the allowable limit.
Allowable limit of bolt length: Below 132.1mm
NOTICE
If a bolt is longer than the allowable limit, do not use it
again but replace it. c
G0135447
50-60 107E-5 SERIES

82. Make sure that there is no dirt or foreign material on the

mounting face of the cylinder head and inside the cylinder,
and then install the cylinder head gasket (8).
REMARK
Make sure that the cylinder head gasket (8) is aligned with
the hole of the cylinder head mounting face.
83. Install the cylinder head assembly (2) to the cylinder block.
Cylinder head assembly (2): 50kg
84. Tighten the bolt (1) 3 to 4 threads by hand.

REMARK
Apply engine oil on the threaded part of the bolt (1) and
the seat surface at the head part of the bolt (1).
Threaded part of bolt (1): Engine oil
Seat surface at head of bolt (1): Engine oil
85. Tighten the bolts (1) in the sequence shown in the figure 12 4 5 13
as follows. 16 8 1 9 17
3rd time: 90±5° (angle tightening with wrench (J))
15 7 2 10 18
11 3 6 14
G0135449
G0135479
REMARK
If the wrench (J) is not available, put paint marks on the
cylinder head assembly (2) and bolt (1), and then retighten d
the bolt (1).
Retightening angle (d): 90±5°
G0135484
107E-5 SERIES 50-61

Injector assembly
86. Install the gasket (6) and O-ring (7) to the injector (2).
NOTICE
When you replace the injector (2) with a new one, re-
place the inlet connector (1) with a new one, too.
REMARK
Make sure that there is no scratch or dirt on the injector
sleeve part (f).
87. Apply engine oil on the O-ring (7) and cylinder head side of
the injector (2).
O-ring (7) and cylinder head side of injector: En-
gine oil
88. Set the fuel inlet hole of the injector assembly (2) to the air
intake manifold side, and insert it into the cylinder head.
89. Install the holder (4), and tighten the bolt (3) 3 to 4 threads
by hand.
90. Examine the inlet connector (1) for the items that follow. If
a problem is found, replace the inlet connector (1).
• When there is burr or wear scratch on the front end (a)
or rear end (b) of the inlet connector (1) b
c
• When there is a foreign material on the edge filter at
the rear end (c) of the inlet connector (1)
• When there is a crack or deterioration on the O-ring at
the top (d) of the inlet connector (1) a d
• When there is wear or rough contact with the seat sur- G0135452
face (e) at the front end of the inlet connector (1)
REMARK
If high-pressure fuel leaks into the inlet connector (1), the
sheet surface can have a corrosion and it causes the fine
lines or scratches.
G0135453
50-62 107E-5 SERIES

91. Apply engine oil on the O-ring (8) and cylinder head side of
the inlet connector (1). 2 4 1 5
O-ring (8) and cylinder head side of inlet connec- 3
tor (1): Engine oil
92. Insert the inlet connector (1) into the mounting hole of the
injector (2), and tighten the retaining nut (5) lightly.
NOTICE
• After you tighten it lightly, it must be tightened to
the specified torque. Be sure to tighten each one to 8 G0137353
the specified torque. If the tightening torque is not
sufficient or too much, it will cause fuel leakage in-
to the engine.
• Install the inlet connector (1) with its positioning
ball at the head side guide groove part.
Retaining nut (5) (tighten lightly):
15±5Nm{1.53±0.51kgfm}
93. Tighten the bolts (3) in one and then the other.
Bolt (3): 8±0.8Nm{0.82±0.08kgfm}
94. Tighten the retaining nut (5) of the inlet connector (1).
Retaining nut (5) (tighten to specified torque): 50±5Nm{5.1±0.5kgfm}
Push rod
95. Apply engine oil on the socket part of the push rod (1).
Socket part of push rod (1): Engine oil
96. Install the push rod (1).
REMARK
Make sure that the push rod (1) is in the tappet.
107E-5 SERIES 50-63

Rocker arm assembly, crosshead

97. Install the crosshead (3).
98. Install the rocker arm assembly (2) with the bolt (1).
NOTICE
• Make sure that the ball part (c) on the adjustment
screw (4) of the rocker arm assembly (2) is secure-
ly inserted into the socket of the push rod, and
then tighten the bolt (1).
• The hole shapes of the parts (a) and (b) on the
crosshead (3) are different. When you use them
again, install them in the same direction with the
same intake and exhaust valve. a b
Bolt (1): 36±5Nm{3.7±0.5kgfm}
G0135352
Adjustment of valve clearance

99. Remove the plug (1) at the bottom of the starting motor,
and install the gear (Y).
50-64 107E-5 SERIES

100. Make sure that there is paint on the part (a) of the crank-
shaft pulley (6) and the mounting bolt (7) of the engine oil
pan.
REMARK
If you cannot see the paint, paint the parts (a) (10th slit
from the wide slit (b)) of the crankshaft pulley (6) and
mounting bolt (7) of the engine oil pan.
101. Use the gear (Y) to rotate the crankshaft in the normal di-
rection, and set the part (a) of the crankshaft pulley (6) and
mounting bolt (7) of the engine oil pan in straight.
NOTICE
When you do this positioning, the position of the No.1
cylinder or No.4 cylinder is not at the compression top
dead center (TDC). (The position is 76 to 88° in front of
the compression top dead center.)
102. Adjust the valve clearance as follows.

Valve layout drawing
REMARK
• If the rocker arm of the intake valve (IN side) moves by
hand for the quantity of the valve clearance, adjust the
valve shown by ○ in the valve layout drawing.
• If the rocker arm of the exhaust valve (EX side) moves
by hand for the quantity of the valve clearance, adjust
the valve shown by ● in the valve layout drawing.
G0135461
1) Loosen the lock nut (4) while the adjustment screw (5)
is fixed.
2) Insert the feeler gauge (K) into the clearance between
the rocker arm (2) and crosshead (3).
3) Adjust the valve clearance with the adjustment screw
(5).
107E-5 SERIES 50-65

REMARK
• While the feeler gauge (K) is inserted, turn the adjustment screw (5) to adjust the feeler gauge (K)
approximately to the degree that it moves lightly.
• Adjust the valve clearance to the target values as follows.
Intake valve: 0.25±0.05mm
Exhaust valve: 0.51±0.05mm
4) Tighten the lock nut (4) while the adjustment screw (5) is fixed.
Lock nut (4): 24±4Nm{2.45±0.41kgfm}
REMARK
• Tighten the lock nut (4), and then examine the valve clearance again.
• Do this procedure continuously until the value is adjusted to the target range.
103. After you adjust the valve clearances at the 4 places, rotate the crankshaft in the normal direction with the
gear (Y) 1 turn, and set the positions of the (a) part of the crankshaft pulley (6) and mounting bolt (7) of the
engine oil pan in straight.
104. Adjust the valve clearance at the remaining 4 places.
REMARK
If you adjusted the positions with the mark ○ in the valve layout drawing in the previous step, adjust the
remaining positions with the mark ●. If you adjusted the positions with the ● mark, adjust the positions with
the ○ mark.
105. When the adjustment of the valve clearance is completed,
remove the gear (Y), and install the plug (1).
Bolt for plug (1): 24±4Nm{2.45±0.41kgfm}
50-66 107E-5 SERIES

Rocker housing, head cover

106. Install the rocker housing assembly (8) with the bolts (9) (5
pieces).
Bolt (9): 24±4Nm{2.45±0.41kgfm}
107. Install the nut (6) of the injector wiring harness.
Installation position of wiring harness
Color of wiring harness Cylinder No.
White 1, 3
Black 2, 4
Nut (6): 1.5±0.25Nm{0.15±0.03kgfm} 7

REMARK
10
• Make sure that the injector wiring harness does not in-
terfere with the rocker arm.
• When you removed the injector wiring harness connec-
tor (7), apply liquid gasket on the O-ring (10) and 11
flange surface (11) of the injector wiring harness con-
nector (7) before you install it.
G0135464
• When you apply liquid gasket on the O-ring part (10),
apply it 3mm in diameter until the O-ring groove is filled
fully.
• If the O-ring (10) has damage, replace the wiring har-
ness assembly.
O-ring (10) of injector wiring harness connector (7): Liquid gasket (LG-7)
Flange surface (11) of injector wiring harness connector (7): Liquid gasket (LG-7)
108. Install the injector wiring harness (7) with the bolt (12).
Bolt (12): 10±2Nm{1±0.2kgfm}
109. Install the gasket (5) to the cylinder head cover (4).
110. Install the cylinder head cover (4), isolator (3), and spacer
(2) with the nuts (1) (4 pieces).
Nut (1): 24±4Nm{2.45±0.41kgfm}
107E-5 SERIES 50-67


111. Install the gear (4) to the supply pump as follows.
REMARK
6
Clean dirt and foreign material on the contact surface of 4
the shaft (6) and gear (4), and dry them. 3
5
1) Install the gear (4) to the shaft (6).

2) Install the lock washer (5) and nut (3), and tighten
them lightly by hand.
G0135367
3) Fix the gear with the support (N) and 1/2 inch spinner
handle (P), and tighten the nut (3). N
Nut (1): 105±5Nm{10.7±0.51kgfm}
P
3
G0135364
112. Install the supply pump assembly (2) with the mounting
nuts (1) (3 pieces).
REMARK
• Do not apply too much grease to the O-ring (7). It can
leak outside. (Apply it to the O-ring groove area of the
part (a).)
• When you replace the stud bolt (8), apply liquid adhe-
sive to the threaded part at the cylinder block side of
the stud bolt (8).
Stud bolt (8): Liquid adhesive (LT-2)
Stud bolt (8): 12±2Nm{1.2±0.2kgfm}
• When you install the nut (1), the nut at the cylinder
block side cannot be installed easily. Be careful not to
let the nut (1) fall off or cause damage to the nut (1).
Nut (1): 24±4Nm{2.45±0.41kgfm}
G0135283
50-68 107E-5 SERIES

Air intake manifold cover

113. Install the gasket (6).
REMARK
Install the gasket (6) with its part number tag (a) at the rear
side.
114. Install the air intake manifold cover (4) with the bolts (1) (5
pieces), bolts (2) (2 pieces), and bolt (3).
Bolt (1), (2), (3): 24±4Nm{2.45±0.41kgfm}
Common rail pressure sensor, pressure limiter

REMARK
Do this only when you replace the common rail pressure sensor (2) and pressure limiter (3).
115. Replace the common rail pressure sensor (2) as follows.
1) Fully remove dirt around the area and clean it before
you remove the common rail pressure sensor (2).
2) Remove the common rail pressure sensor (2).
NOTICE
• Do not remove the common rail pressure sen-
sor (2) from the common rail (1). You can re-
move it only at the time of replacement.
• Be sure to replace the common rail pressure
sensor (2) with a new one when you remove it
from the common rail (1).
3) Examine the connector of the common rail pressure sensor (2) for cracks, breakage, damage to the
seal, foreign material on the pin, corrosion, bending, and breakage of the pin.
4) Install the new common rail pressure sensor (2).
Threaded part of common rail pressure sensor (2): Gear oil (#90)
Common rail pressure sensor (2): 70±5Nm{7.1±0.5kgfm}
116. Replace the pressure limiter (3) as follows.
1) Fully remove dirt around the area and clean it before you remove the pressure limiter (3).
2) Remove the pressure limiter (3).
NOTICE
Do not use the pressure limiter (3) again if the leakage rate exceeds the specified value.
107E-5 SERIES 50-69

3) Make sure that there is no damage on the pressure

a
limiter (3) and high-pressure seal surface (a) of the
common rail.
4) Install the pressure limiter (3).
REMARK
Excessive tightening can cause leakage. Be careful
not to tighten it too much.
Threaded part of pressure limiter (3): Gear oil
3
(#90) G0135468
Pressure limiter (3): 100±4Nm{10.2±0.4kgfm}

Fuel injection pipe, fuel high-pressure pipe, common rail
k Make sure that the fuel injection pipe and fuel high-
b
pressure pipe are as follows, and then install them. If a
problem is found, replace the fuel injection pipe and
fuel high-pressure pipe. If it is not done, the fuel leak-
age can be caused.
k Do not bend the fuel injection pipe or fuel high-pres-
sure pipe to use. a c
k Be sure to use genuine parts for the fuel injection pipe
d G0135469
and fuel high-pressure pipe fixing clamp, and obey the
tightening torque.
k Keep a distance of 10mm or more between the fuel in-
jection pipe, fuel high-pressure pipe, and wiring har-
ness when you install them.
k Visually examine that there is no longitudinal slits (b)
or spotted dent (c) on the taper seal part ((a): 2mm from
the front end) of the connection part.
k Make sure that there is no fatigue or step part (d) (taper
seal end part where 2mm from the front end) you can
feel by your fingernails.
117. Lightly tighten the common rail (14) and bracket (15) with
the bolts (12) (2 pieces) and (13) (2 pieces).
REMARK
When you install the common rail, apply liquid gasket on
the threaded part of the bolt (12) at the engine side.
Threaded part of bolt (12): Liquid gasket (LG-7)
Bolt (12) (tighten lightly): 0.2 to 0.8Nm{0.02 to
0.08kgfm}
50-70 107E-5 SERIES

118. Tighten the fuel injection pipes (2), (3), (4), and (5) and fuel
high-pressure pipe (11) lightly.
Sleeve nut (tighten lightly): 0.2 to 0.8Nm{0.02 to
0.08kgfm}
119. Tighten the fuel injection pipes (2), (3), (4), and (5) as fol-
lows.
1) Fuel injection pipe ((2): connector side) -> ((3): con-
nector side) -> ((2): common rail side) -> ((3): common
rail side)
2) Fuel injection pipe ((4): connector side) -> ((5): con-
nector side) -> ((4): common rail side) -> ((5): common
rail side)
Sleeve nut: 35±3.5Nm{3.57±0.36kgfm}
120. Install the clamp (10), and tighten it lightly.
121. Tighten the high-pressure pipes (11) at the supply pump
side first, and then at the common rail side.
122. Tighten the bolts (12) (2 pieces) and bolts (13) (2 pieces).
Bolt (12), (13): 24±4Nm{2.45±0.41kgfm}

123. Tighten the bolts (2 pieces) of the clamp (10).
Bolt for clamp (10): 24±4Nm{2.45±0.41kgfm}

124. Install the spill tube (9) with the joint bolts (6), (7), and (8).
Joint bolt (6), (7), (8): 24±4Nm{2.45±0.41kgfm}
125. Install the fuel spray prevention cap (1).
k Install the fuel spray prevention cap (1) with its slits
to outside and down.
107E-5 SERIES 50-71

Air intake connector assembly

126. Install the air intake connector assembly (3) and gasket (4)
with the bolts (1) (2 pieces) and (2) (2 pieces).
Bolt (1), (2): 24±4Nm{2.45±0.41kgfm}
Lifting bracket
127. Install the lifting bracket (2) with the bolts (1) (2 pieces).
Bolt (1): 77±12Nm{7.85±1.22kgfm}
Oil filler
128. Install the oil filler (5) with the nuts (3) (2 pieces) and bolts
(4) (2 pieces).
Nut (3): 24±4Nm{2.45±0.41kgfm}
Bolt (4): 77±12Nm{7.85±1.22kgfm}
129. Install the bracket (2) with the bolts (1) (2 pieces).
Bolt (1): 24±4Nm{2.45±0.41kgfm}
50-72 107E-5 SERIES

Wiring harness assembly

130. Install the connector FUEL RAIL PRESS (36).
131. Install the bracket (35) with the bolt (34).
Bolt (34): 24±4Nm{2.45±0.41kgfm}

132. Install the connector INJECTOR CYL3&4 (33).
133. Install the connector INJECTOR CYL1&2 (30).
134. Install the connector TMAP (29).
135. Install the bracket (27) and clamp (28) with the bolt (26).
Bolt (26): 24±4Nm{2.45±0.41kgfm}

136. Install the connector IMV (25).
137. Install the clamp (24).
138. Install the bracket (22) and clamp (23) with the bolts (21)
(3 pieces).
Bolt (21): 24±4Nm{2.45±0.41kgfm}
140. Install the connector ECM J1 (19).

141. Install the bolt (18).
REMARK
The bolt (18) has a hexagonal socket head (4mm).
Bolt (18): 9±1Nm{0.92±0.1kgfm}
142. Install the bracket (17) with the nuts (16) (2 pieces).
Nut (16): 10±2Nm{1.0±0.2kgfm}

143. Install the connector EPS MAIN(CRANK) (15).
REMARK
After you install it, insert the fall-off prevention stopper, and make sure that the connector is fully connected.
144. Install the bracket (14) with the nuts (13) (2 pieces).
Nut (13): 10±2Nm{1.0±0.2kgfm}
107E-5 SERIES 50-73

145. Install the connector EPS BACKUP(CAM) (12).
REMARK
After you install it, insert the fall-off prevention stopper, and
make sure that the connector is fully connected.
146. Disconnect the connector OIL PRESSURE SWITCH (11).
REMARK
147. Install the bracket (9) and clamp (10) with the bolts (8) (3
pieces).
Bolt (8): 24±4Nm{2.45±0.41kgfm}

149. Install the bracket (4) and clamps (5) and (6) with the bolts
(3) (4 pieces).
Bolt (3): 24±4Nm{2.45±0.41kgfm}
150. Install the connector COOLANT TEMP (2).
151. Install the connector CRANK CASE PRESSURE (1).
Bypass tube
152. Install the bypass tube (1).
REMARK
When you install the bypass tube (1), insert it straight while
you push the connector lock parts (a) at the two ends.
50-74 107E-5 SERIES

Fuel main filter assembly

153. Connect the fuel main filter hoses (1) (2 pieces), and install
the fuel main filter (2).
NOTICE
• As a general rule, do not use the hose again. The
internal components can have damage.
• When you assemble it again, replace the hose with
a new one.
REMARK
Insert the fuel main filter hose (1) straight while you push
the lock (a). Do not pry or shake it to the right and left.
Engine oil level gauge

154. Install the engine oil level gauge (4) and gasket (5) with
the bolts (3) (3 pieces).
Bolt (3): 24±4Nm{2.45±0.41kgfm}
Bolt (1): 24±4Nm{2.45±0.41kgfm}
107E-5 SERIES 50-75

Breather hose
156. Install the breather hose (4) and bracket together with the
bolts (2) and (3).
Bolt (2), (3): 24±4Nm{2.45±0.41kgfm}

158. Connect the breather hose (4), and install the hose clamp
(1).
Hose clamp (1): 5±1Nm{0.51±0.1kgfm}
Water pump
159. Install the seal ring (3) to the water pump (2).
160. Lightly tighten the water pump (2) with the bolts (1) (2
pieces).
161. Tighten the bolt (1) as follows.

50-76 107E-5 SERIES

Accessory pulley, idler pulley

162. Install the support (5) with the bolts (4) (4 pieces).
Bolt (4): 43±6Nm{4.38±0.61kgfm}
163. Install the accessory pulley (2) and idler pulley (3) with the
bolts (1) (4 pieces).
Bolt (1): 43±6Nm{4.38±0.61kgfm}
Thermostat
164. Install the thermostat (3).
165. Install the coolant outlet connector (2) with the bolts (1) (3
pieces).
Bolt (1): 8±1Nm{0.8±0.1kgfm}
107E-5 SERIES 50-77

Alternator bracket, lifting bracket

166. Install the alternator bracket (2) and lifting bracket (3) with
the bolts (1) (4 pieces).
Bolt (1): 43±6Nm{4.38±0.61kgfm}
Remove from the engine repair stand

167. Lift the engine assembly (1) with the lifting tool (T), and
disconnect it from the repair stand (A).

168. Remove the adapter (B) from the engine assembly (1).
169. Set the engine assembly (1) on a rigid and stable stand,
and fix it.
REMARK
After you install all the tubes, install the alternator.
Engine oil cooler

170. Install the cover (3), cover gasket (4), engine oil cooler (5),
and engine oil cooler gasket (6) with the bolts (1) (13
pieces) and (2) (2 pieces).
50-78 107E-5 SERIES

REMARK
Tighten the bolts (1) and (2) in the sequence shown in the
figure.
No mark: Bolt (1)
▲ mark: Bolt (2)
Coolant inlet connector, auto-tensioner

171. Install the coolant inlet connector (4) and tensioner bracket
connector (5) with the bolts (3) (3 pieces).
Bolt (3): 43±6Nm{4.38±0.61kgfm}
172. Install the auto-tensioner (2) with the bolt (1).
REMARK
After you install the auto-tensioner (2), visually examine
the auto-tensioner pulley and crankshaft pulley, or use a
ruler to make sure that the belt mounting parts are parallel.
Bolt (1): 43±6Nm{4.38±0.61kgfm}
Exhaust manifold
173. Install the cover (13) with the bolts (12) (2 pieces).
Bolt (12): 24±4Nm{2.45±0.41kgfm}
107E-5 SERIES 50-79

174. Lightly tighten the gasket (11), exhaust manifold (10), and
spacer (9) with the bolts (8) (8 pieces).
175. Tighten the bolts (8) (8 pieces) to the specified torque in

the sequence shown in the figure.
1st time: 53±5Nm{5.4±0.5kgfm} (Tighten them in
the sequence of (1) to (8) shown in the figure.)
2nd time: 53±5Nm{5.4±0.5kgfm} (Retighten only
(1) to (4) shown in the figure.)
176. Install the exhaust manifold pressure sensor (3) with the
nut (2).
Nut (2): 18±3Nm{1.84±0.31kgfm}
177. Install the bracket (5) with the bolt (4).
Bolt (4): 24±4Nm{2.45±0.41kgfm}
Bolt (6): 59 to 74Nm{6.02 to 7.55kgfm}
50-80 107E-5 SERIES

179. Install the connector EXHAUST PRESSURE (1).
REMARK
Turbocharger
180. Install the turbocharger (3), gasket (4), and tube (2) togeth-
er with the nuts (1) (4 pieces).
REMARK
• Install them while you take care not to apply an exces-
sive force to bellows part of the tube (2).
• The O-rings (5) (2 pieces) are installed to the cylinder
block connection part of the tube (2). Install them care-
fully not to let them fall off inside the engine.
• Tighten the nuts (1) diagonally.
Nut (1): 55±6Nm{5.61±0.61kgfm}
Exhaust throttle valve

181. Install the bolts (4) (2 pieces), and install the brackets (5)
and (6) together.
107E-5 SERIES 50-81

182. Install the pipe (2) and exhaust throttle valve (3) with the
clamps (1) (2 pieces).
REMARK
A pin is inserted in the circumferential direction on the con-
nection surface at the turbocharger side of the exhaust
throttle valve (3). Align the pin with the hole of the turbo-
charger, and install it.
Clamp (1): 10±2Nm{1.02±0.2kgfm}
Brackets
183. Install the bracket (5), and tighten the bolts (4) (2 pieces)
lightly.
184. Install the bracket (3), and tighten the bolt (2) lightly.
185. Tighten the bolt (1).
REMARK
The bolt (1) contains the washers and spacer. Be careful
not to let them fall off.
Bolt (1): 28 to 29.4Nm{2.86 to 3.0kgfm}
186. Tighten the bolt (2).
Bolt (2): Approximately 10Nm{1.0kgfm}

187. Tighten the bolts (4) (2 pieces) to the specified torque.
Bolt (4): 59 to 74Nm{6.02 to 7.55kgfm}

188. Loosen the bolt (2), and then tighten it again.
REMARK
After you tighten the bolts (1), (2), and (4), make sure that
there is no space in the parts (a) and (b).
Bolt (2): 43±6Nm{4.38±0.61kgfm}
50-82 107E-5 SERIES

Wiring harnesses
189. Install the connector ETV (2).
190. Install the clips (1) (2 pieces).
Tube, hoses
191. Install the tube (15) with the joint bolt (11), sleeve nuts (12)
and (13), and nut (14).
REMARK
• When you tighten the sleeve nut (12), fix the nipples at
the exhaust throttle valve side not to rotate together.
• When you remove the elbow of the sleeve nut (13) and
assemble it again, tighten the elbow nut to the torque
as follows.
Joint bolt (11): 24±4Nm{2.45±0.41kgfm}
Sleeve nut (12): 14 to 16Nm{1.43 to 1.63kgfm}
Sleeve nut (13): 35±5Nm{3.57±0.51kgfm}
Elbow for sleeve nut (13) (when assembled
again): 75±7Nm{7.65±0.71kgfm}
Nut (14): 10±2Nm{1.02±0.2kgfm}
192. Install the tube (10) with the joint bolt (8) and sleeve nut
(9).
REMARK
When you remove the elbow of the sleeve nut (9) and as-
semble it again, tighten the elbow nut to the torque as fol-
lows.
Elbow for sleeve nut (9) (when assembled again):
24±4Nm{2.45±0.41kgfm}
193. Install the tube (7) with the joint bolt (4) and sleeve nuts (5)
and (6).
REMARK
When you tighten the sleeve nut (5), fix the nipples at the
exhaust throttle valve side not to rotate together.
Sleeve nut (5): 14 to 16Nm{1.43 to 1.63kgfm}
107E-5 SERIES 50-83


194. Install the blower connector (3) with the clamp (2).
Clamp (2): 10±2Nm{1.02±0.2kgfm}

195. Install the clip (1).
Bolt for clip (1): 28 to 29.4Nm{2.86 to 3kgfm}
Covers
196. Install the brackets (4) (2 pieces), and tighten the bolts (3)
(2 pieces) lightly.
Bolt (1): 28 to 29.4Nm{2.86 to 3kgfm}

198. Tighten the bolts (3) (2 pieces) of the brackets (4) (2
pieces) to the specified torque.
Bolt (3): 59 to 74Nm{6.02 to 7.55kgfm}
Alternator
199. Install the brackets (6) and (7), alternator (8), and spacer
(9), and tighten the nut (3) and bolts (4) and (5) lightly.
REMARK
• For machines with 85A alternator, be sure to install the
spacers (9) (2 pieces) when you install the nut (3) and
bolt (5).
• There is no spacer (9) for machines without 85A alter-
nator.
• Install the brackets (6), (7), and (10) loosely, install the
cover (2), fix it at the position, and then install it.
50-84 107E-5 SERIES

Bolt (1): 24±4Nm{2.45±0.41kgfm}

201. Tighten the nut (3) and bolts (4) and (5) to the specified
torque.
Bolt (3), (4): 98 to 123Nm{10 to 12.5kgfm}
Alternator belt
202. Install the ratchet (V) to the part (a) (width across flats
203. Turn the ratchet (V) in the direction of the arrow to loosen
the tension of the alternator belt (1), and install the alterna-
tor belt (1).
k Securely install the ratchet (V) to the part (a) of the
auto-tensioner (2), and turn it. (The spring of the
auto-tensioner (2) is strong. It is very dangerous to
turn it as the ratchet (V) comes off if the wrench is
not inserted securely.)
k After you install the alternator belt (1), set the auto-
tensioner (2) to its initial position slowly and care-
fully.
k After the alternator belt (1) is installed, make sure
that the rib threads of the belt are engaged with the
grooves at the pulley side correctly.
Starting motor assembly
204. Install the gasket (4) and starting motor assembly (3) with
the bolts (1) (2 pieces) and nut (2).
Bolt (1): 43±6Nm{4.4±0.6kgfm}
Nut (2): 24±4Nm{2.45±0.41kgfm}
Tightening torque of sensor

205. When you remove, install, or replace the sensor, tighten it to the torque as follows.
Sensor name Tightening torque

Coolant temperature sensor 20±3Nm{2.04±0.31kgfm}
Engine oil pressure switch 8±2Nm{0.82±0.2kgfm}
Ne (crankshaft) speed sensor 8±2Nm{0.82±0.2kgfm}
Crankcase pressure sensor 8±2Nm{0.82±0.2kgfm}
Charge (boost) pressure and temperature sensor 8±2Nm{0.82±0.2kgfm}
Exhaust manifold pressure sensor 20±3Nm{2.04±0.31kgfm}
107E-5 SERIES 50-85

Examine for fuel leakage

• When you install or remove the supply pump (1), com-
mon rail (2), fuel injection pipe, and fuel high-pressure
pipe, examine the fuel leakage as follows after the en-
gine assembly is completed.
• Before you examine for fuel leakage, clean the engine
and the area around it, and remove grease.
206. Spray the color checker (developer) over the connecting
part of the supply pump (1), common rail (2), injector, fuel
injection pipe, and fuel high-pressure pipe.
207. Start the engine, and keep the engine speed in 1000 min-1{1000 rpm} or below. When the engine speed
becomes stable, stop it.
REMARK
For some models, the speed must be 1500 min-1{1500 rpm}.
208. Examine the fuel piping and component for fuel leakage.
• Examine for fuel leakage from the high-pressure circuit, mainly for the area sprayed with the color
checker.
• If fuel leakage is found, do the inspection again after it is repaired.
209. Start the engine, and keep it at low idle.
REMARK
checker.
211. Start the engine, and keep it at high idle.
REMARK
checker.
213. Start the engine, and keep the engine speed at high idle to apply load to the engine.
REMARK
When you do this work while it is installed to the machine, do the torque converter stall or main pump relief,
or such.
REMARK
checker.
• When no fuel leakage is found, the inspection is completed.
50-86 107E-5 SERIES

BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

Special tools to be used when you remove and install the supply pump assembly
A Support 795-799-6130 1
Commercially gear
B 1/2-inch spinner handle 1
available
Commercially
C Bearing puller 1
available
Commercially
1 Push puller 1 Removal of gear
available
D
Commercially
2 Center bolt 1
available
REMOVE SUPPLY PUMP ASSEMBLY

Fuel main filter, fuel filter hose, wiring harness connector
1. Disconnect the fuel filter hoses (2) and (3) from the supply
pump assembly (1), and remove the fuel main filter (4).
REMARK
Pull out the hose in the direction of (a) while you push the
locks (L) at 2 sides.
2. Disconnect the connector IMV (5).
107E-5 SERIES 50-87

REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY
Fuel high-pressure pipe

3. Remove the fuel spray prevention cap (1).
4. Remove the clamp (2), and remove the fuel high-pressure

pipe (3).
Spill tube
5. Remove the joint bolts (1), (2), and (3), and remove the
spill tube (4).
50-88 107E-5 SERIES


6. Remove the nuts (1) (3 pieces), and remove the supply
pump assembly (2).
REMARK
The supply pump assembly (2) comes off together with the
gear. The gear is not machined on its teeth (missing tooth)
to align the mark for 1.4TOP.
Gear
7. When you remove the gear from the supply pump assembly, obey the procedure that follows.
1) Fix the gear with the support (A) and 1/2 inch spinner
handle (B), and loosen the nut (1).
A
REMARK
Do not remove the nut (1) from the shaft.
B
1 G0137334
2) Install the bearing puller (C) between the flange and

gear (2).
G0137335
107E-5 SERIES 50-89

3) Install the push puller (D1) on the top of the bearing

puller (C) and shaft.
4) Tighten the center bolt (D2) until the gear is removed D2
from the shaft.
5) Remove the push puller (D1) and bearing puller (C).
D1
G0137336
6) Remove the nut (1), lock washer (3), and gear (2)
from the shaft (4).
4
2
3
1
G0137337
INSTALL SUPPLY PUMP ASSEMBLY

Gear
1. Clean dirt and unwanted material on the contact surface of
the shaft (4) and gear (2), and dry them.
2. 4
Install the gear (2) to the shaft (4).
2
3. Tighten the lock washer (3) and nut (1) by hand until they 3
1
are seated.
G0137337
4. Fix the gear with the support (A) and 1/2 inch spinner han-
dle (B), and tighten the nut (1). A
Nut (1): 105±5Nm{10.7±0.51kgfm}
1 G0137338
50-90 107E-5 SERIES


5. Install the supply pump assembly (2) with the nuts (1) (3
2
pieces).
G0137339
REMARK
• Do not apply too much grease to the O-ring (3). It can leak outside. (Apply it on the O-ring groove area
(a).)
• When you replace the stud bolt (4), apply liquid adhesive to the threaded part at the cylinder block side
of the stud bolt (4).
Stud bolt (4): Liquid adhesive (LT-2)
Stud bolt (4): 12±2Nm{1.2±0.2kgfm}
• The nut at the cylinder block side cannot be installed easily. Install the nut (1) carefully not to let the nut
(1) fall off or be damaged.
Nut (1): 24±4Nm{2.45±0.41kgfm}
Spill tube
6. Install the spill tube (4) with the joint bolts (1), (2), and (3).
Joint bolt (1), (2), (3): 24±4Nm{2.45±0.41kgfm}
107E-5 SERIES 50-91

Fuel high-pressure pipe

7. Tighten the sleeve nut of the fuel high-pressure pipe (3) by
hand. (At 2 sides)
8. Tighten the sleeve nuts of the high-pressure pipe (3) at the
supply pump side first, and then at the common rail side.
9. Install the clamps (2) (2 pieces).
Clamp (2): 24±4Nm{2.45±0.41kgfm}
10. Install the fuel spray prevention cap (1).

REMARK
• Set the fuel spray prevention cap with its slit outside or
down.
• The fuel spray prevention cap is installed not to let fuel
spout over the hot part of the engine if it leaks, and to
prevent fire.
Fuel main filter, fuel filter hose, wiring harness connector

11. Install the connector IMV (5).
12. Install the fuel filter hoses (2) and (3) to the supply pump
assembly (1), and install the fuel main filter (4).
NOTICE
• Insert the hose in the direction of (b) while you
push the locks (L) at 2 sides.
• The internal components of the fittings for the dis-
connected hose and tube can be damaged during
removal. Do not use them again.
Use a new one for installation.
• Make sure that no mud or dirt is attached on the
hose connection part in advance.
• Do not pry or shake the connector, and insert it
straight in the direction of (b). If it cannot be inser-
ted easily, do not insert it by force. Pull it out, and
then make sure that there is no problem on the
convex and concave surfaces or no mud is attach-
ed on that part.
50-92 107E-5 SERIES

BLY REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE FRONT OIL SEAL

Special tools to be used when you remove and install the engine front oil seal
Commercially
A Ratchet 1 Removal and installation of
available
alternator belt
B Seal puller 795-799-6400 1
1 Wrench (angle) 790-331-1120 1 Removal and installation of
C
2 Angle gauge 795-799-2240 1 engine front oil seal
REMOVE ENGINE FRONT OIL SEAL

Alternator belt
1. Install the ratchet (A) to the part (a) (width across flats
2. Turn the ratchet (A) in the direction of the arrow to loosen
the tension of the alternator belt (1), and remove the alter-
nator belt (1).
k Securely set the ratchet (A) on the part (a) of the
auto-tensioner (2), and then turn it. (The spring of
the auto-tensioner (2) is strong. It is very danger-
ous to turn it as the ratchet (A) comes off if the
wrench is not inserted securely.)
k After you remove the alternator belt (1), set the au-
to-tensioner (2) to its initial position slowly and
carefully.
Crankshaft pulley
5. Remove the bolts (3) (6 pieces), and remove the plate (4)
and crankshaft pulley (1).
107E-5 SERIES 50-93

REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY
Engine front oil seal

6. Remove the engine front oil seal (1) as follows.
1) Remove the dust seal (2).
2) Install the seal puller (B) to the crankshaft (5).

3) Screw in the tapping screw (3) of the seal puller (B) to 1
the seal carrier part of the engine front oil seal (1).
4) Turn the handle in the direction of the arrow to remove 3
the engine front oil seal (1).
REMARK
Be careful not to damage the crankshaft (5) while you
remove it.
B G0137308
50-94 107E-5 SERIES

INSTALL ENGINE FRONT OIL SEAL

Engine front oil seal
1. Install the engine front oil seal (1) with the seal puller (B).
REMARK
• Before you install the engine front oil seal (1), make
sure that there is no damage, burrs, sharp edge, or rust
on the end surface corner and lip sliding surface of the
crankshaft.
• When you install the engine front oil seal (1), do not ap-
ply oil or grease to the crankshaft and seal lip. Fully
wipe off oil on the crankshaft in advance. 1 B G0137310
• Measure the protrusion and facial runout from the front
oil seal dust cover (6) of the engine front oil seal (1). 6
Facial runout (y): 0.25mm or below
x 1 G0137311
2. Install the dust seal (2).

REMARK
Check the installed dimension (a).
Installed dimension (a): 12+0.1/0mm
Crankshaft pulley
107E-5 SERIES 50-95

REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY
4. Install the crankshaft pulley (1) with its dowel hole aligned
with the dowel pin (b) of the crankshaft.
5. Install the plate (4) and crankshaft pulley (1) with the bolts
(3) (6 pieces).
Tightening procedure of bolt (3)
1st time: 55±5Nm{5.61±0.51kgfm} (Tighten them
in the diagonal sequence.)
2nd time: Loosen them by 180°.
3rd time: 55±5Nm{5.61±0.51kgfm} (Tighten them
in the diagonal sequence.)
4th time: 90±5° (Retighten them in the diagonal
sequence.)
REMARK
Do the angle tightening with the wrench (C).
C
When wrench (C) is not available
Make marks on the crankshaft pulley and bolt with a mark-
er, and retighten the bolt.
Retightening angle (b): 90±5°
remove the plate (a). G0137314
G0137315
Alternator belt
7. Install the ratchet (A) to the part (a) (width across flats
8. Turn the ratchet (A) in the direction of the arrow to loosen
the tension of the alternator belt (1), and install the alterna-
tor belt (1).
50-96 107E-5 SERIES

k Securely set the ratchet (A) on the part (a) of the auto-tensioner (2), and then turn it. (The spring
of the auto-tensioner (2) is strong. It is very dangerous to turn it as the ratchet (A) comes off if
the wrench is not inserted securely.)
k After you install the alternator belt (1), set the auto-tensioner (2) to its initial position slowly and
carefully.
k Be careful not to get your fingers caught between the pulley and alternator belt (1) during the
work.
k After the alternator belt (1) is installed, make sure that the rib threads of the belt are engaged
with the grooves at the pulley side correctly.
107E-5 SERIES 50-97

REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY
REMOVE AND INSTALL ENGINE REAR OIL SEAL

Special tools to be used when you remove and install the engine rear oil seal
A Seal puller 795-799-6700 1
Commercially engine rear oil seal
B Dial gauge 1
available
REMOVE ENGINE REAR OIL SEAL

Flywheel
(2) rotate.
3. Remove the bolts (1) (2 pieces), and install the guide bolt.
4. Lift the flywheel (2), and hold it.
5. Remove the remaining bolts (1) (6 pieces), lift the flywheel
(2), and remove it.
Flywheel (2): 50kg

k Be careful not to get your fingers caught. It can fall
off suddenly as the spigot joint part of the flywheel
(2) is shallow.
k Be careful not to let the guide bolt fall out when
you pull out the flywheel (2).
6. Remove the engine rear oil seal (1) as follows.
50-98 107E-5 SERIES

BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL
1) Install the seal puller (A) to the crankshaft (3).

2) Screw in the tapping screw (2) of the seal puller (A) to
the seal carrier part of the engine rear oil seal (1).
3) Turn the handle in the direction of the arrow to remove
A
the engine rear oil seal (1).
REMARK
Be careful not to damage the crankshaft (3) while you
remove it. 2
G0137318
INSTALL ENGINE REAR OIL SEAL

NOTICE
4
• Do not remove the pilot (4) installed to the engine rear
oil seal (1) until the engine rear oil seal is inserted to
the crankshaft.
• Before you install the engine rear oil seal, remove
grease, clean, and dry the seal contact surface and seal
lip surface of the crankshaft to prevent oil leakage.
1
G0137320
1. Insert the pilot (4) into the crankshaft (3), and push in the 1 5
engine rear oil seal (1) to the flywheel housing (5).
2. Push in the engine rear oil seal (1) more, and pull out the
pilot (4).
3 G0137321
107E-5 SERIES 50-99

REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY
3. Install the engine rear oil seal (1) to the correct depth on
the flywheel housing (5) with the seal puller (A).
REMARK
• Make sure that there is no bent on the engine rear oil A
seal (1), and push it in.
• Measure the protrusion of the engine rear oil seal (1)
from the flywheel housing (5).
5
G0137322
G0137323
Flywheel
4. Install the guide bolt.
5. Lift the flywheel (2), and set it to the installation position.
6. Install the flywheel (2) with the bolts (1) (8 pieces).
Flywheel (2): 50kg
(2) rotate.
8. Tighten the bolts (1) in the sequence shown in the figure.

Bolt (1): 137±7Nm{14.0±0.71kgfm}
50-100 107E-5 SERIES

BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL
Measure the radial runout

10. After you install the flywheel (2), measure the radial runout
with the dial gauge (B).
Radial runout: 0.13mm or below
11. Install the dial gauge (B) to the flywheel housing. a
b
12. Set the probe of the dial gauge to the spigot joint part (a)
or outside perimeter of the flywheel at a right angle.
B B
13. Rotate the flywheel by 1 turn, and measure the difference
between the lowest and highest values that the pointer of
the dial gauge shows. G0137325
REMARK
After you rotated the flywheel by 1 turn, make sure that the
pointer of the dial gauge is at the start position.
Measure the facial runout
14. Similarly to the measurement of the radial runout, set the probe of the dial gauge to the end face (b) near
the outside perimeter of the flywheel at a right angle.
REMARK
When you measure the facial runout, move the crankshaft to the front or rear side to prevent the error
caused by the end play.
15. Rotate the flywheel by 1 turn, and measure the difference between the lowest and highest values that the
pointer of the dial gauge shows.
107E-5 SERIES 50-101

60 MAINTENANCE STANDARD
107E-5 SERIES 60-1

CONTENTS 60 MAINTENANCE STANDARD
CONTENTS
ENGINE SYSTEM ......................................................................................................................................... 60-3
INTAKE AND EXHAUST SYSTEM PARTS ............................................................................................. 60-3
MAINTENANCE STANDARD OF TURBOCHARGER ...................................................................... 60-3
ENGINE MAIN BODY PARTS................................................................................................................. 60-4
MAINTENANCE STANDARD OF CYLINDER HEAD ....................................................................... 60-4
MAINTENANCE STANDARD OF CYLINDER BLOCK ..................................................................... 60-6
MAINTENANCE STANDARD OF CRANKSHAFT ............................................................................ 60-8
MAINTENANCE STANDARD OF PISTON..................................................................................... 60-10
MAINTENANCE STANDARD OF CONROD ...................................................................................60-11
MAINTENANCE STANDARD OF TIMING GEAR........................................................................... 60-13
MAINTENANCE STANDARD OF CAMSHAFT .............................................................................. 60-14
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE....................................................... 60-16
MAINTENANCE STANDARD OF ROCKER ARM .......................................................................... 60-18
MAINTENANCE STANDARD OF TAPPET .................................................................................... 60-19
MAINTENANCE STANDARD OF FLYWHEEL ............................................................................... 60-20
LUBRICATION SYSTEM....................................................................................................................... 60-22
MAINTENANCE STANDARD OF ENGINE OIL PUMP .................................................................. 60-22
60-2 107E-5 SERIES

60 MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM PARTS
ENGINE SYSTEM
INTAKE AND EXHAUST SYSTEM PARTS
MAINTENANCE STANDARD OF TURBOCHARGER
1
A
G0121968
No. Item Judgment criteria Remedy

Replace the
1 Radial play 0.329 to 0.501
bearing parts.
Replace the
2 End play (axial play) 0.038 to 0.093
thrust parts.
107E-5 SERIES 60-3

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD
ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CYLINDER HEAD
1 2 12 4 5 13
EX
16 8 1 9 17
15 7 2 IN 10 18
11 3 6 14
3 4
G0121969
No
Item Judgment criteria Remedy
.
Distortion of cylinder Longitudinal direction Max. 0.305 Repair by
1 head mounting sur- grinding or
face Horizontal direction Max. 0.076 replace.
Tightening torque of Procedure Target
cylinder head
1st time 90±3 Nm {9.2±0.3 kgfm}
mounting bolt Tighten and
2 (Apply molybdenum 2nd time 90±3 Nm {9.2±0.3 kgfm} retighten
disulfide or engine (*)
oil on bottom sur- 3rd time Retighten by 90±5 °
face of screw head)
60-4 107E-5 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS
No
Item Judgment criteria Remedy
.
Repair limit Replace the
Protrusion of injec-
3 nozzle or
tor nozzle 1.63 to 1.98 gasket.
Tightening torque of Target
4 injector holder
mounting bolt 8 Nm {0.8 kgfm}
Tighten
Tightening torque of
5 head cover mount- 24 Nm {2.4 kgfm}
ing bolt
*: Tighten them in the sequence of the number shown in the figure.
107E-5 SERIES 60-5

MAINTENANCE STANDARD OF CYLINDER BLOCK
1 2, 3
4 5, 6
7 8 13 9 5 3 1 7 11 15
7 3 1 5 9
17 21
19 23
20 24
8 4 2 6 10 18 22
14 10 6 2 4 8 12 16
Front
9 10
G0121970
60-6 107E-5 SERIES


Longitudinal direction Max. 0.075 Repair by
Distortion of cylinder head
1 grinding or re-
mounting surface Horizontal direction Max. 0.051 place.
Replace the
Inside diameter of main
2 87.983 to 88.019 main bearing
bearing mounting hole
cap.
Inside diameter of main
3 83.041 to 83.109 Replace the
bearing
main bearing.
4 Thickness of main bearing 2.456 to 2.464
Inside diameter of cam- Repair or re-
5 shaft bushing mounting Max. 59.248 place the cylin-
hole der block.
Correct the cyl-
Inside diameter of cam- inder block,
6 shaft hole (without bush- Max. 54.164 and insert the
ing) camshaft bush-
ing.
Procedure Target
Tightening torque of main 1st time 60 Nm {6.1 kgfm} Tighten and re-
bearing cap (Apply engine tighten
oil on threaded part) 2nd time 80 Nm {8.2 kgfm} (*)
7
3rd time Retighten by 90 °.
Replace the
Usage limit of stem length
Max. 120 main bearing
for main bearing cap bolt
cap bolt.
Tightening torque of en- Target Tighten

8
gine oil pan mounting bolt 28 Nm {2.8 kgfm} (*)
Procedure Target
Tightening torque of crank- Tighten and re-
9 1st time 50 Nm {5.1 kgfm}
shaft pulley mounting bolt tighten
2nd time Retighten by 90 °.
Inside diameter of cylinder
106.990 to 107.030 Over-size re-
bore
10 pair or replace
Roundness of cylinder the block.
Repair limit: 0.038
bore
107E-5 SERIES 60-7

MAINTENANCE STANDARD OF CRANKSHAFT
1 2
A
3 4
G0126780
No
Item Criteria Remedy
.
Replace thrust
1 End play (A) 0.065 to 0.432 bearing or over
size repair
Outside diameter of crankshaft
82.962 to 83.013
main journal
Roundness of crankshaft main Undersize repair or
Repair limit: 0.050
journal replace
2
Taper of crankshaft main jour-
Repair limit: 0.013
nal
Clearance of crankshaft main Replace main
0.04 to 0.12
journal bearing
60-8 107E-5 SERIES

No
.
Outside diameter of crankshaft
68.962 to 69.013
pin journal Undersize repair or
Roundness of crankshaft pin replace
3 Repair limit: 0.050
journal
Clearance of crankshaft pin Replace connect-
0.04 to 0.12
journal ing rod bearing
Outside diameter of front
4 70.59 to 70.61
crankshaft gear journal Undersize repair or
Inside diameter of front crank- replace
5 70.51 to 70.55
shaft gear
107E-5 SERIES 60-9

MAINTENANCE STANDARD OF PISTON
1 3
21.4mm
4 5
G0126781
No
.
Outside diameter of Replace
1 106.881 to 106.899
piston skirt piston
Top ring 0.38 to 0.48
Closed gap of top
2 Second ring 0.85 to 1.15
ring Replace
Oil ring 0.22 to 0.58 piston ring
or piston
Clearance of piston Second ring 0.05 to 0.09
3
ring Oil ring 0.040 to 0.085
4 39.997 to 40.003
piston pin piston pin
Inside diameter of Replace
5 40.006 to 40.012
piston pin bore piston
60-10 107E-5 SERIES

MAINTENANCE STANDARD OF CONROD
1 2, 4
3 5
G0126782
N
o.
Inside diameter of con-
Inside diameter of connecting rod small end
1 necting rod bushing 40.019 to 40.042 bushing
(When installing bushing) (Spare part is half fin-
ished.)
2 69.05 to 69.10
necting rod bearing Replace connecting
Thickness of connecting rod bearing
3 1.955 to 1.968
rod bearing
Replace connecting
4 necting rod bearing 72.99 to 73.11
rod
mounting hole
107E-5 SERIES 60-11

N
o.
Tightening torque of con- 1st stage 30±3 Nm {3.06±0.1 kgfm}
necting rod cap mounting
2nd stage 60±5 Nm {6.12±0.51 kgfm}
bolt
5 Tighten and retighten
(Apply engine oil to nut
seat surface of thread 3rd stage Retighten 60±5 °
part of bolt)
Side clearance of con- Replace connecting
6 0.10 to 0.33
necting rod rod
60-12 107E-5 SERIES

MAINTENANCE STANDARD OF TIMING GEAR
A B
C
D
G0126783
No. Item Criteria Remedy

A Backlash of engine oil pump gear 0.170 to 0.300
B Backlash of camshaft gear 0.076 to 0.280
- Backlash of each gear Replacement
C Backlash of idler gear 0.150 to 0.250
D Backlash of supply pump gear 0.022 to 0.146
107E-5 SERIES 60-13

MAINTENANCE STANDARD OF CAMSHAFT
1 2
A
B B
3 4
5 6
G0126784

Replace
1 End play 0.23±0.13
thrust plate
Outside diameter of
Repair or re-
2 camshaft bearing jour- 53.095 to 54.045
place
nal
Intake side 46.545 to 47.855
3 Camshaft lobe height
Exhaust side 45.002 to 46.312
Replacement
Thickness of camshaft
4 5.25 to 5.35
thrust plate
60-14 107E-5 SERIES


5 camshaft thrust plate 24±4 Nm {2.45±0.41 kgfm}
mounting bolt
Tighten
6 camshaft gear mount- 36±4 Nm {3.67±0.41 kgfm}
ing bolt
107E-5 SERIES 60-15

MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE
1 2
3 4
45°
30°
5 6
G0126785

Intake side 0.584 to 1.092 Replace
1 Valve recess valve or valve
Exhaust side 0.965 to 1.473 seat
Replace
2 Valve rim thickness (B) Min. 0.79
valve
Valve Angle Repair limit
Repair or re-
3 Valve seat angle Intake side 30 ° Judge contact surface state place valve or
by vacuum test valve seat
Exhaust side 45 °
4 6.96 to 7.01
valve stem valve
Valve guide bore diame- Replace
5 7.027 to 7.077
ter valve guide
60-16 107E-5 SERIES


Inside diameter of valve
6 insert bore 34.847 to 34.863 -
(Standard insert)
107E-5 SERIES 60-17

MAINTENANCE STANDARD OF ROCKER ARM
1 2
4, 5 6
G0126786

Replace
Outside diameter of
1 Min. 21.965 rocker arm
rocker arm shaft
shaft
Inside diameter of rock- Replace
2 Max. 22.027
er arm shaft hole rocker arm
Replace
Clearance between
rocker arm or
3 rocker arm shaft and Max. 0.062
rocker arm
rocker arm
shaft
4 rocker arm adjustment Tighten
screw lock nut 24 Nm {2.4 kgfm}
Valve Repair limit Adjustment value

Valve clearance (when
5 Intake side 0.152 to 0.381 0.25±0.05 Adjustment
cooled)
Exhaust side 0.381 to 0.762 0.51 0.05
6 rocker arm mounting Tighten
bolt 36 Nm {3.7 kgfm}
60-18 107E-5 SERIES

MAINTENANCE STANDARD OF TAPPET
1 2
28mm
G0126787

1 Outside diameter of tappet 15.936 to 15.977 Replace tappet
Inside diameter of tappet Cylinder block re-
2 16.000 to 16.055
hole placement
Clearance between tappet Replace tappet or
3 0.023 to 0.119
and tappet hole cylinder block
107E-5 SERIES 60-19

MAINTENANCE STANDARD OF FLYWHEEL
1 1 2
3 15 7 5
6
13
16 14
8 5
17
18
12
19
20 11
1 2
4 3
9 10
3 1
5
8
7
6
2 4
G0126788

Radial runout of flywheel
housing Assemble
Facial runout of flywheel again to repair.
housing
Tightening torque of fly- M10 49±5 Nm {5±0.51 kgfm} Tighten
3 wheel housing mounting
bolt M12 85±10 Nm {8.67±1.38 kgfm} (*)
Allowable value
4 Facial runout of flywheel Assemble
Measured diameter x 0.0005
again to repair.
5 Radial runout of flywheel Repair limit: 0.13
60-20 107E-5 SERIES


Tightening torque of fly-
wheel mounting bolt (Apply Tighten
6 137±7 Nm {14±0.71 kgfm}
engine oil on threaded part (*)
and seat surface)
107E-5 SERIES 60-21

LUBRICATION SYSTEM 60 MAINTENANCE STANDARD
LUBRICATION SYSTEM
MAINTENANCE STANDARD OF ENGINE OIL PUMP
1 2
3
1 3 2 3
4 4
A 2 B 1
G0126789

1 Axial clearance of rotor Max. 0.127
Clearance between Replace the oil
2 outer rotor and inner Max. 0.178 pump.
rotor
8±1 Nm {0.82±0.1 kgfm}
1st time
Tightening torque of oil (Tightening sequence: A) Tighten
3
pump mounting bolt 24±4 Nm {2.45±0.41 kgfm} (*)
2nd time
(Tightening sequence: B)
60-22 107E-5 SERIES

INDEX
INDEX
A Charge (boost) pressure and temperature sensor -
Structure...................................................... 10-97
Abbreviation List................................................. 00-69 Coating materials list.............................................50-5
Actions if fire occurs............................................00-16 Common rail........................................................10-68
AdBlue/DEF - Store............................................ 00-20 Common rail - Function.......................................10-68
AdBlue/DEF hose............................................... 10-22 Common rail - Structure......................................10-68
AdBlue/DEF hose - Function.............................. 10-22 Common rail pressure sensor - Function..........10-101
AdBlue/DEF hose - Structure..............................10-22 Common rail pressure sensor - Structure......... 10-101
AdBlue/DEF injector............................................10-21 Component parts of electrical system.................10-78
AdBlue/DEF injector - Function...........................10-21 Component parts of urea SCR system............... 10-16
AdBlue/DEF injector - Operation.........................10-21 Connecting rod - Maintenance standard............. 60-11
AdBlue/DEF injector - Structure..........................10-21 Connector - Precautions for disconnection and con-
AdBlue/DEF pump.............................................. 10-20 nection......................................................... 00-39
AdBlue/DEF pump - Function............................. 10-20 Connector with housing to rotate - Disconnect/
AdBlue/DEF pump - Structure............................ 10-20 Connect....................................................... 00-49
AdBlue/DEF supply system - Function................. 10-7 Connector with lock to push - Disconnect/Connect......
AdBlue/DEF tank................................................ 10-18 .....................................................................00-47
AdBlue/DEF tank - Structure...............................10-18 Conversion table................................................. 00-64
AdBlue/DEF tank heating valve.......................... 10-23 Coolant temperature sensor - Function.............. 10-98
AdBlue/DEF tank heating valve - Function......... 10-23 Coolant temperature sensor - Structure..............10-98
AdBlue/DEF tank heating valve - Operation....... 10-23 Cooling system................................................... 10-73
AdBlue/DEF tank heating valve - Structure........ 10-23 Cooling system - Circuit diagram........................ 10-74
AdBlue/DEF tank sensor.....................................10-19 Cooling system parts - Layout drawing...............10-73
AdBlue/DEF tank sensor - Function....................10-19 Crankcase pressure sensor - Function............. 10-103
AdBlue/DEF tank sensor - Structure...................10-19 Crankcase pressure sensor - Structure............ 10-103
Air cleaner...........................................................10-28 Crankcase ventilation system............................. 10-47
Air cleaner - Operation........................................10-28 Crankcase ventilation system - Function............ 10-47
Air cleaner - Specifications................................. 10-28 Crankcase ventilation system - System diagram 10-47
Air cleaner - Structure......................................... 10-28 Crankshaft - Maintenance standard......................60-8
Air cleaner clogging sensor - Function..............10-105 Crankshaft pulley................................................ 10-37
Air cleaner clogging sensor - Structure.............10-105 Crankshaft pulley - Structure.............................. 10-37
Alternator............................................................ 10-78 CRI system......................................................... 10-65
Alternator with built-in regulator (open type, 100 A) - CRI system - Control function............................. 10-66
Structure...................................................... 10-80 CRI system - Function........................................ 10-65
Alternator with built-in regulator (open type, 100A) - CRI system - Structure........................................10-65
Specifications...............................................10-80 CRI system - System diagram............................ 10-65
Alternator with built-in regulator (open type, 60 A) - Cylinder block..................................................... 10-32
Specifications...............................................10-78 Cylinder block - Maintenance standard.................60-6
Alternator with built-in regulator (open type, 60 A) - Cylinder block - Specifications............................ 10-33
Structure...................................................... 10-78 Cylinder block - Structure....................................10-32
Alternator with built-in regulator (open type, 85 A) - Cylinder head......................................................10-30
Specifications...............................................10-79 Cylinder head - Maintenance standard................. 60-4
Alternator with built-in regulator (open type, 85 A) - Cylinder head - Specifications............................ 10-31
Structure...................................................... 10-79 Cylinder head - Structure.................................... 10-30
Assembly and disassembly - Related information 50-3
D
B
Deutsch connector - Disconnect/Connect...........00-43
Bkup (cam) speed sensor - Function................ 10-100 Drive pulley......................................................... 10-75
Bkup (cam) speed sensor - Structure............... 10-100 Drive pulley - Structure....................................... 10-75
C E
Camshaft - Maintenance standard......................60-14 Electrical system................................................. 10-78
Charge (boost) pressure and temperature sensor - Engine - Assemble generally.............................. 50-41
Function....................................................... 10-97 Engine - Assemble/Disassemble generally.........50-13
1
INDEX
Engine - Disassemble generally......................... 50-14 Exhaust throttle valve (with built-in position sensor) -
Engine - Standard value table...............................20-3 Function..................................................... 10-108
Engine components - Layout.............................. 10-24 Exhaust throttle valve (with built-in position sensor) -
Engine components - Layout drawing.................10-24 Structure.................................................... 10-108
Engine conformed to Stage V regulation - System di-
agram.............................................................01-5 F
Engine controller................................................. 10-84
Engine controller - Function................................ 10-84 Flywheel - Maintenance standard....................... 60-20
Engine controller - Input and output signals........10-86 Flywheel and flywheel housing........................... 10-42
Engine controller - Structure............................... 10-84 Flywheel and flywheel housing - Specifications..10-43
Engine controller - System diagram....................10-84 Flywheel and flywheel housing - Structure......... 10-42
Engine front oil seal - Install................................50-95 Foreword, Safety, Basic information..................... 00-4
Engine front oil seal - Remove............................50-93 Front cover..........................................................10-39
Engine front oil seal - Remove/Install................. 50-93 Front cover - Structure........................................ 10-39
Engine general view............................................01-10 Fuel main filter.................................................... 10-72
Engine main body parts.............................. 10-30,60-4 Fuel main filter - Structure...................................10-72
Engine oil cooler................................................. 10-58 Fuel main prefilter - Function.............................. 10-72
Engine oil cooler - Function................................ 10-59 Fuel prefilter........................................................ 10-71
Engine oil cooler - Specifications........................ 10-58 Fuel prefilter - Function....................................... 10-71
Engine oil cooler - Structure................................10-58 Fuel prefilter - Structure...................................... 10-71
Engine oil filter.................................................... 10-57 Fuel system.........................................................10-63
Engine oil filter - Function................................... 10-57 Fuel system - Circuit diagram............................. 10-64
Engine oil filter - Structure...................................10-57 Fuel system equipment - Precautions for handling......
Engine oil level sensor - Function..................... 10-104 .....................................................................00-33
Engine oil level sensor - Structure.................... 10-104 Fuel system of CRI system - Function................ 10-66
Engine oil pan..................................................... 10-62 Fuel system parts - Layout drawing.................... 10-63
Engine oil pan - Structure................................... 10-62
Engine oil pressure switch - Function................. 10-96 G
Engine oil pressure switch - Structure................ 10-96
Engine oil pump.................................................. 10-56 General character and precautions for handling.00-19
Engine oil pump - Function................................. 10-56
Engine oil pump - Maintenance standard........... 60-22 H
Engine oil pump - Specifications.........................10-56
How to read electrical wire code......................... 00-50
Engine oil pump - Structure................................ 10-56
How to read this manual....................................... 50-3
Engine oil regulator valve....................................10-60
Engine oil regulator valve - Function...................10-60
Engine oil regulator valve - specafications..........10-60 I
Engine oil regulator valve - suructure................. 10-60 Impactor (filterless)............................................. 10-48
Engine oil safety valve........................................ 10-61 Impactor (filterless) - Operation.......................... 10-48
Engine performance curve..................................01-22 Impactor (filterless) - Structure............................10-48
Engine rear oil seal - Install.................................50-99 Inducement strategy............................................. 10-9
Engine rear oil seal - Remove.............................50-98 Inducement strategy for abnormality recurrence with-
Engine rear oil seal - Remove/Install.................. 50-98 in 40 hours (For European Union)............... 10-15
Engine sensor - Layout drawing......................... 10-92 Inducement strategy when abnormality is found in
Engine shop manual - How to read.......................00-4 AdBlue/DEF quality, AdBlue/DEF injection, and
Engine system.................................. 10-24,50-13,60-3 urea SCR system devices (EU specification).......
Engine technology to conform exhaust gas emission.. ..................................................................... 10-11
.....................................................................00-18 Inducement strategy when abnormality is found in the
Engine wiring harness.........................................10-82 KDPF system by the urea SCR system devices
Engine wiring harness - Structure.......................10-82 (For European Union).................................. 10-12
Exhaust gas regulation - Outline...........................01-3 Inducement strategy when the AdBlue/DEF level in
Exhaust manifold pressure sensor - Function...10-107 the tank becomes low (For European Union) 10-9
Exhaust manifold pressure sensor - Structure..10-107 Injector................................................................ 10-69
Exhaust throttle valve..........................................10-49 Injector - Function............................................... 10-70
Exhaust throttle valve - Function.........................10-49 Injector - Operation............................................. 10-70
Exhaust throttle valve - Operation.......................10-49 Injector - Structure.............................................. 10-69
Exhaust throttle valve - Structure........................10-49 Intake air heater.................................................. 10-29
Intake air heater - Specifications.........................10-29
2
INDEX
Intake air heater - Structure................................ 10-29 Piston ring - Structure......................................... 10-36

Intake and exhaust system - Circuit diagram......10-26 Precautions for adding........................................ 00-19
Intake and exhaust system - Function................ 10-26 Precautions for DEF............................................00-19
Intake and exhaust system parts - Layout drawing...... Precautions for disposing of waste materials......00-17
.....................................................................10-25 Precautions for fire hazard and leakage............. 00-19
Intake and exhaust systems parts.............. 10-25,60-3 Precautions for handling electrical equipment.... 00-31
Intake manifold pressure and temperature sensor - Precautions for handling hydraulic equipment.... 00-21
Function....................................................... 10-95 Precautions for storing........................................ 00-19
Intake manifold pressure and temperature sensor - Precautions to prevent fire.................................. 00-14
Structure...................................................... 10-95 Push-pull type coupler - Disconnect/Connect..... 00-35
Intake system equipment - Precautions for handling...
.....................................................................00-34 R
Regeneration function - Types............................ 10-52
K Rocker arm - Maintenance standard...................60-18
KDPF.................................................................. 10-50 Running-in standard and performance test standard...
KDPF - Function................................................. 10-51 .....................................................................20-12
KDPF - Structure.................................................10-50
KDPF differential pressure and outlet pressure sen- S
sor - Function.............................................10-102
KDPF differential pressure and outlet pressure sen- SAA4D107E-5 (D51EX-24E0, D51EXI-24E0,
sor - Structure............................................ 10-102 D51PX-24E0, D51PXI-24E0) - Engine general
view..............................................................01-10
SAA4D107E-5 (D51EX-24E0, D51EXI-24E0,
L D51PX-24E0, D51PXI-24E0) - Engine perform-
List of applicable machines: 107E-5..................... 01-6 ance curve................................................... 01-22
Lubrication system....................................10-54,60-22 SAA4D107E-5 (D51EX-24E0, D51EXI-24E0,
Lubrication system - Circuit diagram...................10-55 D51PX-24E0, D51PXI-24E0) - Specifications......
Lubrication system parts - Layout drawing......... 10-54 .......................................................................01-7
SAA4D107E-5 (GD535-6) - Engine general view........
M .....................................................................01-14
SAA4D107E-5 (GD535-6) - Engine performance
Main drive parts - Specifications......................... 10-36 curve............................................................ 01-23
Main drive parts - Structure.................................10-34 SAA4D107E-5 (GD535-6) - Specifications........... 01-8
Main moving parts...............................................10-34 SAA4D107E-5 (WA200-8E0) - Engine general view....
Method for disconnecting and connecting connector .....................................................................01-18
with lock to pull............................................ 00-46 SAA4D107E-5 (WA200-8E0) - Engine performance
curve............................................................ 01-24
N SAA4D107E-5 (WA200-8E0) - Specifications.......01-9
Safety notice for operation.................................... 00-6
NE (crankshaft) speed sensor - Function........... 10-99 Safety valve of engine oil.................................... 10-61
NE (crankshaft) speed sensor - Structure...........10-99 Safety valve of engine oil - Specifications...........10-61
Safety valve of engine oil - Structure.................. 10-61
P SCR assembly.................................................... 10-16
SCR assembly - Structure.................................. 10-16
Performance test standard and standard for operation
Sensor.................................................................10-92
of engine for break in period - SAA4D107E-5
Slide lock type connector - Disconnect/Connect.00-44
(D51EX-24E0, D51EXI-24E0, D51PX-24E0,
Special tools - Sketches......................................50-12
D51PXI-24E0)..............................................20-12
Special tools list.................................................. 50-10
Specification................................................. 01-3,01-7
of engine for break in period: SAA4D107E-5
Standard tightening torque table.........................00-57
(GD535-6)....................................................20-14
Standard value table for engine - SAA4D107E-5
(D51EX-24E0, D51EXI-24E0, D51PX-24E0,
of engine for break in period: SAA4D107E-5
D51PXI-24E0)................................................20-3
(WA200-8E0)............................................... 20-16
Piping - Precautions for disconnection and connec-
(GD535-6)......................................................20-6
tion............................................................... 00-24
Piston - Maintenance standard........................... 60-10
(WA200-8E0)................................................. 20-9
Piston ring........................................................... 10-36
3
INDEX
Starter built in safety relay (5.5 kW) - Specifications.... Water-in-fuel sensor - Structure........................ 10-106
.....................................................................10-81
Starter with built-in safety relay (5.5kW) - Structure.....
.....................................................................10-81
Starting motor..................................................... 10-81
Supply pump....................................................... 10-67
Supply pump - Function...................................... 10-67
Supply pump - Specifications..............................10-67
Supply pump - Structure..................................... 10-67
Supply pump assembly - Install.......................... 50-90
Supply pump assembly - Remove...................... 50-87
Supply pump assembly - Remove/Install............50-87
T
Tappet - Maintenance standard.......................... 60-19
Temporary restoration from Inducement (For Europe-
an Union) - Function.................................... 10-14
Terms for maintenance standard - Explanation.. 00-54
The other precautions......................................... 00-19
Thermostat..........................................................10-77
Thermostat - Specifications................................ 10-77
Thermostat - Structure........................................ 10-77
Timing gear......................................................... 10-38
Timing gear - Function........................................ 10-38
Timing gear - Maintenance standard.................. 60-13
Timing gear - Structure....................................... 10-38
Turbocharger.......................................................10-44
Turbocharger - Function......................................10-45
Turbocharger - Maintenance standard..................60-3
Turbocharger - Specifications............................. 10-45
Turbocharger - Structure.....................................10-44
Type 1 push-pull type coupler - Disconnect/Connect...
.....................................................................00-35
.....................................................................00-36
.....................................................................00-37
U
Urea SCR system................................................. 10-4
Urea SCR system - Function................................ 10-7
Urea SCR system - Layout drawing......................10-4
Urea SCR system - System diagram.................... 10-6
V
Valve and valve guide - Maintenance standard.. 60-16
Valve system.......................................................10-40
Valve system - Structure..................................... 10-40
W
Water pump.........................................................10-76
Water pump - Function........................................10-76
Water pump - Specifications............................... 10-76
Water pump - Structure.......................................10-76
Water-in-fuel sensor - Function.........................10-106
4
107E-5 SERIES ENGINE
Form No. SEN06896-03
©2022 KOMATSU
All Rights Reserved
Printed in Japan 05-2022

Gd535 6 Engine Manual

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SEN06896-03

ENGINE 107E -5 SERIES

107E-5 SERIES 00-1

00-2 107E-5 SERIES

COMPONENT PARTS OF ELECTRICAL SYSTEM ....................................................................... 10-78

107E-5 SERIES 00-3

FOREWORD, SAFETY, BASIC INFORMATION

00-4 107E-5 SERIES

Symbol Item Remark

107E-5 SERIES 00-5

SAFETY NOTICE FOR OPERATION

00-6 107E-5 SERIES

• Always wear the protective eyeglasses when hitting parts

Precautions during work

107E-5 SERIES 00-7

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

00-8 107E-5 SERIES

Precautions for slinging work and making signals

107E-5 SERIES 00-9

00-10 107E-5 SERIES

Precautions for using overhead traveling crane

107E-5 SERIES 00-11

Nominal diameter of rope (mm) Allowable load (kN {t} )

Precautions for disconnecting air conditioner piping

00-12 107E-5 SERIES

107E-5 SERIES 00-13

PRECAUTIONS TO PREVENT FIRE

00-14 107E-5 SERIES

107E-5 SERIES 00-15

ACTIONS IF FIRE OCCURS

00-16 107E-5 SERIES

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

107E-5 SERIES 00-17

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION

00-18 107E-5 SERIES

PRECAUTIONS FOR DEF

PRECAUTIONS FOR ADDING

PRECAUTIONS FOR STORING

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

THE OTHER PRECAUTIONS

107E-5 SERIES 00-19

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

00-20 107E-5 SERIES

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

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

Sealing of openings (prevention of flowing out of oil)

107E-5 SERIES 00-21

Preventing intrusion of foreign materials during refilling

Replacing hydraulic oil while its temperature is high

00-22 107E-5 SERIES

107E-5 SERIES 00-23

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00-24 107E-5 SERIES

Hose side Pipe joint side

Hose side Pipe joint side

107E-5 SERIES 00-25

Nomi Bolt pitch (mm) Hose side Tube side

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

00-26 107E-5 SERIES

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

Nominal Plug (1)

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415