107e-1 Sen00161-23

SEN00161-23
ENGINE 107E -1 SERIES

SEN00163-23
Engine 1SHOP MANUAL
107E-1 Series
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
107E-1 Series 1
SEN00163-23 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00161-23
00 Index and foreword SEN00162-23

Index SEN00163-23 q
Foreword and general information SEN00164-06
01 Specification SEN00165-16
Specification and technical data SEN00166-16 q
10 Structure, function and maintenance standard SEN00167-07

Structure, function and maintenance standard SEN00168-07 q
20 Standard value table SEN00247-16

Standard service value table SEN00248-16 q
30 Testing and adjusting SEN00249-09

Testing and adjusting SEN00250-09 q
40 Troubleshooting SEN00251-05
General information on troubleshooting SEN00252-04
Troubleshooting of electrical system (E-mode), Part 1 SEN00254-04
Troubleshooting of mechanical system (S-mode) SEN00253-02
50 Disassembly and assembly SEN00256-10

General information on disassembly and assembly SEN00257-06
Disassembly and assembly, Part 1 SEN00258-07
90 Repair and replacement of parts SEN05210-00

Information related to repair and replacement SEN05211-00
Parts related to cylinder head SEN05212-00
Parts related to cylinder block SEN05213-00
2 107E-1 Series
Table of contents 1
00 Index and foreword
Index SEN00163-23
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00164-06

Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00166-16
General.................................................................................................................................... 2
Specifications........................................................................................................................... 3
General view............................................................................................................................ 24
Dimensions table ..................................................................................................................... 64
Engine performance curves..................................................................................................... 65
10 Structure, function and maintenance standard

Structure, function and maintenance standard SEN00168-07
Intake system .............................................................................................................................. 3
Exhaust system........................................................................................................................... 4
Lubricating oil system.................................................................................................................. 6
Cooling system............................................................................................................................ 10
Fuel system................................................................................................................................. 11
Fuel supply pump........................................................................................................................ 12
CRI system.................................................................................................................................. 13
Turbocharger............................................................................................................................... 17
Cylinder head .............................................................................................................................. 18
Cylinder block.............................................................................................................................. 20
Crankshaft................................................................................................................................... 22
Piston, piston ring and piston pin ................................................................................................ 24
Connecting rod............................................................................................................................ 26
Vibration damper ......................................................................................................................... 28
Timing gear ................................................................................................................................. 29
Camshaft ..................................................................................................................................... 30
Valve and valve guide ................................................................................................................. 32
Rocker arm, shaft and tappet ...................................................................................................... 34
Flywheel and flywheel housing ................................................................................................... 36
Oil pump...................................................................................................................................... 38
Water pump drive and fan drive .................................................................................................. 39
Water pump................................................................................................................................. 41
Thermostat .................................................................................................................................. 42
Alternator..................................................................................................................................... 43
Starting motor.............................................................................................................................. 48
Sensor......................................................................................................................................... 52
Engine controller ......................................................................................................................... 58
Control system ............................................................................................................................ 61
107E-1 Series 3
20 Standard value table

Standard service value table SEN00248-16
Standard value table for testing, adjusting and troubleshooting .............................................. 2
Running-in standard and performance test criteria.................................................................. 22
30 Testing and adjusting

Testing and adjusting SEN00250-09
Testing and adjusting tools list..................................................................................................... 2
Sketches of special tools............................................................................................................. 4
Testing boost pressure ................................................................................................................ 5
Adjustment of valve clearance .................................................................................................... 6
Testing compression pressure..................................................................................................... 9
Testing blowby pressure.............................................................................................................. 12
Testing engine oil pressure.......................................................................................................... 13
Handling fuel system parts .......................................................................................................... 14
Releasing remaining pressure in fuel system.............................................................................. 14
Testing fuel pressure ................................................................................................................... 15
Reduced cylinder mode operation............................................................................................... 21
No-injection cranking................................................................................................................... 21
Testing fuel delivery, return and leak amount .............................................................................. 22
Bleeding air from fuel circuit ........................................................................................................ 33
Testing fuel system for leakage ................................................................................................... 34
Handling controller high-voltage circuit ....................................................................................... 35
Replacing the fan belt.................................................................................................................. 35
40 Troubleshooting
General information on troubleshooting SEN00252-04
Points on troubleshooting............................................................................................................ 2
Error and failure code table ......................................................................................................... 3
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 5
Information in troubleshooting table ............................................................................................ 7
Connection table for connector pin numbers............................................................................... 9
T- branch box and T- branch adapter table ................................................................................. 45
E-1 Code [111/CA111] Abnormality in engine controller.............................................................. 3
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor....................................... 3
E-3 Code [122/CA122] Charge pressure sensor high error ........................................................ 4
E-4 Code [123/CA123] Charge pressure sensor low error.......................................................... 6
E-5 Code [131/CA131] Throttle sensor power supply high error................................................. 8
E-6 Code [132/CA132] Throttle sensor power supply low error .................................................. 10
E-7 Code [144/CA144] Coolant temperature sensor high error .................................................. 12
E-8 Code [145/CA145] Coolant temperature sensor low error.................................................... 14
E-9 Code [153/CA153] Charge temperature sensor high error................................................... 16
E-10 Code [154/CA154] Charge temperature sensor low error .................................................. 18
E-11 Code [155/CA155] Derating of speed by charge temperature high error ........................... 20
E-12 Code [187/CA187] Sensor power supply 2 low error.......................................................... 22
E-13 Code [221/CA221] Atompspheric pressure sensor high error ............................................ 24
E-14 Code [222/CA222] Atompspheric pressure sensor low error ............................................. 26
E-15 Code [227/CA227] Sensor power supply 2 high error ........................................................ 28
E-16 Code [234/CA234] Engine overspeed ................................................................................ 28
E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply ................................... 29
E-18 Code [271/CA271] Short circuit in IMV/PCV1..................................................................... 30
E-19 Code [272/CA272] Disconnection in IMV/PCV1 ................................................................. 32
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 ........................................ 34
4 107E-1 Series

E-26 Code [342/CA342] Calibration error in engine controller data ............................................ 46
E-27 Code [351/CA351] Abnormality in injector drive circuit ...................................................... 47
E-28 Code [352/CA352] Sensor power supply 1 low error ......................................................... 48
E-29 Code [386/CA386] Sensor power supply 1 high error ........................................................ 50
E-30 Code [428/CA428] Water-in-fuel sensor high error ............................................................ 52
E-31 Code [429/CA429] Water-in-fuel sensor low error.............................................................. 54
E-32 Code [431/CA431] Abnormality in idle validation switch .................................................... 56
E-33 Code [432/CA432] Abnormality in idle validation processing ............................................. 58
E-34 Code [435/CA435] Abnormality in engine oil pressure switch............................................ 3
E-35 Code [441/CA441] Abnormally low power supply voltage .................................................. 4
E-36 Code [442/CA442] Abnormally high power supply voltage ................................................ 6
E-37 Code [449/CA449] Common rail pressure high error 2 ...................................................... 7
E-38 Code [451/CA451] Common rail pressure sensor high error ............................................. 8
E-39 Code [452/CA452] Common rail pressure sensor low error ............................................... 10
E-40 Code [488/CA488] Derating of torque by charge temperature high error........................... 12
E-41 Code [553/CA553] Common rail pressure high error 1 ...................................................... 12
E-42 Code [559/CA559] No-pressure feed 1 by supply pump .................................................... 13
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor .............................................. 15
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase................................ 17
E-45 Code [757/CA757] Loss of all data in engine controller ..................................................... 18
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor........................................... 19
E-47 Code [1633/CA1633] Abnormality in KOMNET.................................................................. 22
E-48 Code [2185/CA2185] Throttle sensor power supply high error .......................................... 23
E-49 Code [2186/CA2186] Throttle sensor power supply low error............................................ 24
E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump ................................................ 25
E-51 Code [2311/CA2311] Abnormality in IMV solenoid ............................................................. 25
E-52 Code [2555/CA2555] Disconnection in intake air heater relay ........................................... 26
E-53 Code [2556/CA2556] Short circuit in intake air heater relay............................................... 28
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction .......................... 30
E-55 Code [---/B@BAZK] Engine oil level low ............................................................................ 30
E-56 Code [---/B@BCNS] Engine overheat ................................................................................ 31
E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error ............................. 32
E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error .............................. 34
E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error....................................... 36
E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error........................................ 38
E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) ......................................... 40
E-62 Code [b6] Droop Rate Adjustment Volume High Error ...................................................... 44
E-63 Code [b7] Droop Rate Adjustment Volume Low Error ........................................................ 46
E-64 Code [b8] Low Idle Speed Adjustment Volume High Error ................................................. 48
E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error.................................................. 50
E-66 Code [bc] Rated Speed Median Adjustment Volume High Error ........................................ 52
E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error......................................... 54
E-68 Code [bE] Ramp Time Adjustment Volume High Error....................................................... 56
E-69 Code [bF] Ramp Time Adjustment Volume Low Error........................................................ 58
Troubleshooting of mechanical system (S-mode) SEN00253-02
Troubleshooting of mechanical system (S-mode) ....................................................................... 1
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 9
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations ........................................................................................ 13
S-5 Engine does not rotate smoothly ...................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 17
107E-1 Series 5
S-9 Oil becomes contaminated quickly.................................................................................... 18

S-10 Fuel consumption is excessive ....................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 20
S-12 Oil pressure drops........................................................................................................... 21
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 22
S-14 Coolant temperature becomes too high (overheating).................................................... 23
S-15 Abnormal noise is made.................................................................................................. 24
S-16 Vibration is excessive...................................................................................................... 25
50 Disassembly and assembly

General information on disassembly and assembly SEN00257-06
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tools list........................................................................................................................... 7

General disassembly of engine ................................................................................................... 2

General assembly of engine........................................................................................................ 2
90 Repair and replacement of parts

Information related to repair and replacement SEN05211-00
Special tool table ......................................................................................................................... 2
Parts related to cylinder head SEN05212-00

Repair of cylinder head ............................................................................................................... 2
Check of valve guide ................................................................................................................... 3
Replacement of valve seat insert ................................................................................................ 4
Vacuum test of valve seat insert.................................................................................................. 6
Grinding of valve ......................................................................................................................... 7
Parts related to cylinder block SEN05213-00

Repair of cylinder block ............................................................................................................... 2
Repair of crankshaft .................................................................................................................... 12
Replacement of connecting rod bushing ..................................................................................... 15
6 107E-1 Series
107E-1 Series 7
SEN00163-23
KOMATSU 107E-1 Series Diesel engine
Form No. SEN00163-23
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12
8
SEN00164-06
Engine 1SHOP MANUAL
107E-1 Series
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
107E-1 Series 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
107E-1 Series 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 107E-1 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
107E-1 Series 25
Precautions when carrying out operation 1

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

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

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

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

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

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

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

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

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

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 107E-1 Series
2. Table of tightening torques for split flange bolts

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

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

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

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

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

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

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

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

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 107E-1 Series
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
107E-1 Series 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 107E-1 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
107E-1 Series 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 107E-1 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
107E-1 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 107E-1 Series
107E-1 Series 41
SEN00164-06
42
SEN00166-16
Engine 1SHOP MANUAL
107E-1 Series
01 Specification 1
Specification and technical data
General ........................................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
General view ................................................................................................................................................. 24
Dimensions table .......................................................................................................................................... 64
Engine performance curves .......................................................................................................................... 65
107E-1 Series 1
SEN00166-16 01 Specification
General 1
1. Applicable machine
Engine Serial No. Applicable machine

PC200-8, PC200LC-8
PC200-8M0, PC200LC-8M0
PC220-8, PC220LC-8
PC220-8M0, PC220LC-8M0,
PC240LC-8M0 Hydraulic excavator
PC270-8
PC228US-3E0, PC228USLC-3E0
PC228US-8, PC228USLC-8
SAA6D107E-1 PC308USLC-3E0
WA250-6, WA250PZ-6
WA320-6, WA320PZ-6 Wheel loader
WA380-6,WA380Z-6
BR380JG-1E0 Mobile crusher
GD555-5
Motor grader
GD655-5, GD675-5
A6D107E-GD-1 Portable generator
PC160LC-7E0, PC160LC-8
PC200LC-8E0
Hydraulic excavator
HB205-1, HB215LC-1
SAA4D107E-1 HB205-1M0, HB215LC-1M0
WA200-6, WA200PZ-6 Wheel loader
D39EX-22, D39PX-22 Bulldozer
2 107E-1 Series
Specifications 1
Engine SAA6D107E-1
Applicable model PC200-8, PC200LC-8

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

Overall height (excluding exhaust pipe) mm —
Overall height (including exhaust pipe) mm 1,409
kW{HP}/ 116 {155}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 624 {63.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
Max. speed with no load
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
Min. speed with no load
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
Fuel consumption ratio at rated point 223 {170}
{g/HPh}
Dry weight kg 553
Fuel injection system HPCR
—
Fuel injection system control Electronic control type
Lubricating oil amount (refill capacity) l 25.4 (23.1)
Coolant amount l 8.4
Alternator — 24V, 35A
Starting motor — 24V, 4.5kW
Battery — 12V, 110Ah × 2
Turbocharger — HOLSET HX35W
Air compressor — —
Others — —
107E-1 Series 3
Engine SAA6D107E-1
Applicable model PC200-8M0, PC200LC-8M0

Dimensions

kW{HP}/ 109.7 {147.1}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 602 {61.4}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 541
—
Alternator — 24V, 35A, 60A
Starting motor — 24V, 4.5kW, 5.5kW
Others — —
4 107E-1 Series
Engine SAA6D107E-1
Applicable model PC220-8, PC220LC-8

Dimensions

kW{HP}/ 134 {179}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 710 {72.4}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,160 ± 50{2,160 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
107E-1 Series 5
Engine SAA6D107E-1
Applicable model PC220-8M0, PC220LC-8M0, PC240LC-8M0

Dimensions

kW{HP}/ 129.3 {173.3}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 690 {70.4}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,160 ± 50{2,160 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Alternator — 24V, 35A, 60 A
Starting motor — 24V, 4.5kW, 5.5 kW
Others — —
6 107E-1 Series
Engine SAA6D107E-1
Applicable model PC270-8

Dimensions

kW{HP}/ 149 {200}/2,050{2,050}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 771 {78.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,180 ± 50{2,180 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
107E-1 Series 7
Engine SAA6D107E-1
Applicable model PC228US-3E0, PC228USLC-3E0

Dimensions

kW{HP}/ 116 {155}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 624 {63.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
8 107E-1 Series
Engine SAA6D107E-1
Applicable model PC228US-8, PC228USLC-8

Dimensions

kW{HP}/ 116 {155}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 624 {63.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Battery — 12V, 88Ah × 2, 110Ah × 2
Others — —
107E-1 Series 9
Engine SAA6D107E-1
Applicable model PC308USLC-3E0

Dimensions

kW{HP}/ 149 {200}/2,050{2,050}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 771 {78.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,180 ± 50{2,180 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
10 107E-1 Series
Engine SAA6D107E-1
Applicable model WA250-6, WA250PZ-6

Dimensions

kW{HP}/ 104.1 {140}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 627 {64.0}/1,400{1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,250 ± 50{2,250 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25{825 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 590
—
Others — —
107E-1 Series 11
Engine SAA6D107E-1

Dimensions

kW{HP}/ 127.3 {171}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 672 {68.5}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,250 ± 50{2,250 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25{825 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 650
—
Others — —
12 107E-1 Series
Engine SAA6D107E-1
Applicable model WA380-6, WA380Z-6

Dimensions

kW{HP}/ 143.4 {192}/2,100{2,100}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 941 {96.0}/1,450{1,450}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,250 ± 50{2,250 ± 50}
(High idle speed)
min-1{rpm} 850 ± 25{850 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 570
—
Others — —
107E-1 Series 13
Engine SAA6D107E-1
Applicable model BR380JG-1E0

Dimensions

kW{HP}/ 149 {200}/2,050{2,050}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 771 {78.6}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,330 ± 50{2,330 ± 50}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 553
—
Others — —
14 107E-1 Series
Engine SAA6D107E-1
Applicable model GD555-5

Dimensions

kW{HP}/ 146.2 {196}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 880 {89.7}/1,450{1,450}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 ± 50{2,200 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25{825 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 585
—
Alternator — 24V, 60A (90A (if equipped))
Others — —
107E-1 Series 15
Engine SAA6D107E-1
Applicable model GD655-5, GD675-5

Dimensions

kW{HP}/ 164.8 {221}/2,100{2,100}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 941 {96.0}/1,450{1,450}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,200 ± 25{2,200 ± 25}
(High idle speed)
min-1{rpm} 825 ± 25{825 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 585
—
Alternator — 24V, 60A (90A (if equipped))
Others — —
16 107E-1 Series
Engine SAA6D107E-1
Applicable model A6D107E-GD-1

Dimensions

kW{HP}/ 115 {155}/1,500{1,500}
50Hz rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 139 {186}/1,800{1,800}
60Hz rated horsepower
Performance
min-1{rpm} (Gross)
min-1{rpm} Max. 1,890{Max. 1,890}
(High idle speed)
min-1{rpm} 650 ± 25{650 ± 25}
(Low idle speed)
Fuel consumption ratio at rated point g/kWh
221/223 {165/166}
(50 Hz/60 Hz) {g/HPh}
Dry weight kg 675
—
Others — —
107E-1 Series 17
Engine SAA4D107E-1
Applicable model PC160LC-7E0, PC160LC-8

Firing order — 1–3–4–2
Dimensions

kW{HP}/ 90.0 {121}/2,200{2,200}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 471 {48.0}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,320 ± 30{2,320 ± 30}
(High idle speed)
min-1{rpm} 1,050 ± 25{1,050 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 430
—
Lubricating oil amount (refill capacity) l 18 (16)
Coolant amount l 7
Turbocharger — HOLSET HE221W
Others — —
18 107E-1 Series
Engine SAA4D107E-1
Applicable model PC200LC-8E0

Dimensions

kW{HP}/ 106.6 {143}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 593.9 {60.6}/1,700{1,700}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 700 ± 25{700 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 414 (Excluding muffler)
—
Coolant amount l 7
Others — —
107E-1 Series 19
Engine SAA4D107E-1
Applicable model HB205-1, HB215LC-1

Dimensions

kW{HP}/ 110.3 {148}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 593.9 {60.6}/1,700{1,700}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 700 ± 25{700 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
—
Coolant amount l 7
Alternator — 24V, 35A,60A
Battery — 12V, 88Ah × 2,140Ah × 2
Others — —
20 107E-1 Series
Engine SAA4D107E-1
Applicable model HB205-1M0, HB215LC-1M0

Dimensions

kW{HP}/ 110.3 {148}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 593.9 {60.6}/1,700{1,700}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,060 ± 50{2,060 ± 50}
(High idle speed)
min-1{rpm} 700 ± 25{700 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
—
Coolant amount l 7
Battery — 12V, 88Ah × 2, 140Ah × 2
Others — —
107E-1 Series 21
Engine SAA4D107E-1

Overall length mm 853
Dimensions

kW{HP}/ 95.2 {128}/2,000{2,000}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 586 {59.8}/1,400{1,400}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,250 ± 50{2,250 ± 50}
(High idle speed)
min-1{rpm} 825 ± 25{825 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 465
—
Coolant amount l 7
Others — —
22 107E-1 Series
Engine SAA4D107E-1
Applicable model D39EX-22, D39PX-22

Overall length mm 924
Dimensions

Overall height (excluding exhaust pipe) mm 1,233
Overall height (including exhaust pipe) mm —
kW{HP}/ 80.0 {107}/2,200{2,200}
Rated horsepower
min-1{rpm} (Gross)
Nm{kgm}/ 476 {48.5}/1,500{1,500}
Max. torque
Performance
min-1{rpm} (Gross)
min-1{rpm} 2,400 ± 50{2,400 ± 50}
(High idle speed)
min-1{rpm} 975 ± 25{975 ± 25}
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 455
—
Coolant amount l 7
Alternator — 24V, 35A, 60A (if equipped)
Others — —
107E-1 Series 23
General view 1
SAA6D107E-1 (Left side view of engine)
Machine model: PC200-8, PC200LC-8,PC220-8, PC228US-3E0, PC228US-8,
PC228USLC-8, PC270-8, BR380JG-1E0
a The shape may differ according to the machine model.
1. Crankshaft center
2. Flywheel housing rear surface
24 107E-1 Series
1
SAA6D107E-1 (Right side view of engine)
PC228USLC-8, PC270-8, BR380JG-1E0
107E-1 Series 25
SAA6D107E-1 (Front view of engine)

PC228USLC-8, PC270-8, BR380JG-1E0
2. Cylinder center
26 107E-1 Series
SAA6D107E-1 (Rear view of engine)

PC228USLC-8, PC270-8, BR380JG-1E0
2. Cylinder center
107E-1 Series 27

Machine model:
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0, PC240LC-8M0
28 107E-1 Series

Machine model:
107E-1 Series 29

Machine model:
2. Cylinder center
30 107E-1 Series

Machine model:
2. Cylinder center
107E-1 Series 31

Machine model: WA380-6, WA380Z-6
32 107E-1 Series

107E-1 Series 33

2. Cylinder center
34 107E-1 Series

2. Cylinder center
107E-1 Series 35

Machine model: GD555-5, GD655-5, GD675-5
36 107E-1 Series

107E-1 Series 37

2. Cylinder center
38 107E-1 Series

2. Cylinder center
107E-1 Series 39

Machine model: A6D107E-GD-1 (Portable generator)
2. Flywheel rear surface
40 107E-1 Series

2. Flywheel rear surface
107E-1 Series 41

2. Cylinder center
42 107E-1 Series

2. Cylinder center
107E-1 Series 43

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

107E-1 Series 45

2. Cylinder center
46 107E-1 Series

2. Cylinder center
107E-1 Series 47

Machine model: PC200LC-8E0
48 107E-1 Series

107E-1 Series 49

2. Cylinder center
50 107E-1 Series

2. Cylinder center
107E-1 Series 51

Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0
52 107E-1 Series

107E-1 Series 53

2. Cylinder center
54 107E-1 Series

2. Cylinder center
107E-1 Series 55

Machine model: WA200-6,WA200PZ-6
56 107E-1 Series

107E-1 Series 57

2. Cylinder center
58 107E-1 Series

2. Cylinder center
107E-1 Series 59

Machine model: D39EX-22, D39PX-22
60 107E-1 Series

107E-1 Series 61

2. Cylinder center
62 107E-1 Series

2. Cylinder center
107E-1 Series 63
Dimensions table 1
Unit: mm
Dimension of each part
Engine Machine model
A B C D
PC200-8,PC200LC-8 1,355 1,409 427 790
PC200-8M0,
1,352 1,413 429 689
PC200LC-8M0
PC220-8 1,355 1,409 427 790
PC220-8M0,
PC220LC-8M0, 1,352 1,413 429 689
PC240LC-8M0
PC270-8 1,355 1,409 427 790
PC228US-3E0 1,355 1,409 427 790
PC228US-8,
SAA6D107E-1 PC228USLC-8 1,355 1,409 427 790
PC308USLC-3E0 1,355 1,409 427 790

WA250-6, WA250PZ-6 1,067 1,612 427 819
WA320-6, WA320PZ-6 1,044 1,475 479 817
WA380-6, WA380Z-6 1,101 1,592 407 882
BR380JG-1E0 1,355 1,409 427 790
GD555-5
1,068 1,593 408 849
GD655-5, GD675-5
A6D107E-GD-1
1,501 1,254 391 764
(Portable generator)
PC160LC-7E0,
1,104 1,333 382 717
PC160LC-8
PC200LC-8E0 1,187 1,417 433 726
HB205-1, HB215LC-1 1,187 1,417 433 726
SAA4D107E-1
HB205-1M0,
1,187 1,421 437 726
HB215LC-1M0
WA200-6, WA200PZ-6 853 1,612 427 819
D39EX-22, D39PX-22 885 1,220 295 619
a These dimensions are given for reference when the engine is set on a test bench.
64 107E-1 Series
Engine performance curves 1

SAA6D107E-1
(Machine model: PC200-8, PC200LC-8, PC228US-3E0, PC228USLC-3E0,
PC228US-8, PC228USLC-8) 1
Rated horsepower: 116 kW {155 HP}/2,000 min-1{2,000 rpm}(Gross)
Max. torque: 624 Nm {63.6 kgm}/1,500 min-1{1,500 rpm}(Gross)
107E-1 Series 65
SAA6D107E-1 (Machine model: PC200-8M0, PC200LC-8M0) 1

1
Rated horsepower: 109.7 kW {147.1 HP}/2,000 min-1{2,000 rpm}(Gross)
Max. torque: 602 Nm {61.4 kgm}/1,500 min-1{1,500 rpm}(Gross)
66 107E-1 Series
SAA6D107E-1 (Machine model: PC220-8, PC220LC-8) 1
Rated horsepower: 134 kW {179 HP}/2,000 min-1{2,000 rpm} (Gross)

Max. torque: 710 Nm {72.4 kgm}/1,500 min-1{1,500 rpm} (Gross)
107E-1 Series 67
SAA6D107E-1 (Machine model: PC220-8M0, PC220LC-8M0, PC240LC-

8M0) 1
Rated horsepower: 129.3 kW {173.3 HP}/2,000 min-1{2,000 rpm} (Gross)

68 107E-1 Series
SAA6D107E-1 (Machine model: PC270-8, PC308USLC-3E0) 1

107E-1 Series 69
SAA6D107E-1 (Machine model: WA250-6, WA250PZ-6) 1
Rated horsepower: 104.1 kW {140 HP}/2,000 min-1{2,000 rpm} (Gross)

70 107E-1 Series

107E-1 Series 71
SAA6D107E-1 (Machine model: WA380-6, WA380Z-6) 1

72 107E-1 Series
SAA6D107E-1 (Machine model: BR380JG-1E0) 1

107E-1 Series 73
SAA6D107E-1 (Machine model: GD555-5) 1

74 107E-1 Series
SAA6D107E-1 (Machine model: GD655-5, GD675-5) 1

107E-1 Series 75
SAA6D107E-1 (Machine model: A6D107E-GD-1 (Portable generator) 1
60Hz Rated horsepower: 139 kW {186 HP}/1,800 min-1{1,800 rpm} (Gross)

50Hz Rated horsepower: 115 kW {155 HP}/1,500 min-1{1,500 rpm} (Gross)
76 107E-1 Series
SAA4D107E-1 (Machine model: PC160LC-7E0, PC160LC-8) 1

107E-1 Series 77
SAA4D107E-1 (Machine model: PC200LC-8E0) 1

Max. torque: 593.9 Nm {60.6 kgm}/1,700 min-1{1,700 rpm} (Gross)
78 107E-1 Series
SAA4D107E-1 (Machine model: HB205-1, HB215LC-1, HB205-1M0,

HB215LC-1M0 ) 1

Max. torque: 593.9 Nm {60.6 kgm}/1,700 min-1{1,700 rpm} (Gross)
107E-1 Series 79

80 107E-1 Series
SAA4D107E-1 (Machine model: D39EX-22, D39PX-22) 1

107E-1 Series 81
© 2012 KOMATSU
All Rights Reserved
82 107E-1 Series
SEN00168-07
Engine 1SHOP MANUAL
107E-1 Series
10 Structure, function and

maintenance standard
Intake system.................................................................................................................................................. 3
Exhaust system............................................................................................................................................... 4
Lubricating oil system ..................................................................................................................................... 6
Cooling system ............................................................................................................................................. 10
Fuel system....................................................................................................................................................11
Fuel supply pump.......................................................................................................................................... 12
CRI system ................................................................................................................................................... 13
Turbocharger................................................................................................................................................. 17
Cylinder head................................................................................................................................................ 18
Cylinder block ............................................................................................................................................... 20
Crankshaft..................................................................................................................................................... 22
Piston, piston ring and piston pin .................................................................................................................. 24
Connecting rod.............................................................................................................................................. 26
Vibration damper........................................................................................................................................... 28
Timing gear ................................................................................................................................................... 29
Camshaft....................................................................................................................................................... 30
Valve and valve guide ................................................................................................................................... 32
Rocker arm, shaft and tappet........................................................................................................................ 34
Flywheel and flywheel housing ..................................................................................................................... 36
Oil pump........................................................................................................................................................ 38
107E-1 Series 1
SEN00168-07 10 Structure, function and maintenance standard
Water pump drive and fan drive .................................................................................................................... 39

Water pump................................................................................................................................................... 41
Thermostat .................................................................................................................................................... 42
Alternator....................................................................................................................................................... 43
Starting motor................................................................................................................................................ 48
Sensor........................................................................................................................................................... 52
Engine controller ........................................................................................................................................... 58
Control system .............................................................................................................................................. 61
2 107E-1 Series
Intake system 1
General Information
1. Intake air inlet to turbocharger Air is drawn through the air cleaner into the com-
2. Turbocharger air to charge air cooler pressor side of the turbocharger. It is then forced
3. Charge air cooler through the charge air cooler piping to the charge
4. Intake manifold air cooler, the intake air heater (if applicable), and
(integral part of the cylinder head) into the intake manifold. From the intake manifold,
5. Intake valve air is forced into the cylinders and used for combus-
tion.
107E-1 Series 3
Exhaust system 1
General Information
1. Exhaust valve
2. Exhaust manifold
3. Turbocharger
4. Turbocharger exhaust outlet
The turbocharger uses exhaust gas energy to turn

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

mon shaft (referred to as a rotor assembly), which
is supported by two rotating bearings in the bearing
housing.
Passages in the bearing housing direct filtered,
pressurized engine oil to the shaft bearings and
thrust bearings. The oil is used to lubricate and cool
the rotating components. Oil then drains from the
bearing housing to the engine sump through the oil
drain line.
4 107E-1 Series
Lubricating Oil Consumption and Leaks

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

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

engines with a catalyst, check the exhaust restric-
tion during the repair.
107E-1 Series 5
Lubricating oil system 1

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

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

2. Turbocharger lubricating oil drain
6 107E-1 Series
Lubrication for the power components
1. From lubricating oil cooler

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

2. Rocker lever support
3. Transfer slot
4. Rocker lever shaft
5. Rocker lever bore
6. Rocker lever
8 107E-1 Series
Lubrication for the accessory drive
1. Oil feed from block

2. Oil supply to accessory drive
NOTE:
Oil returns to pan through the gear housing.
107E-1 Series 9
Cooling system 1
General Information
1. Coolant inlet
2. Pump impeller
3. Coolant flow past lubricating oil cooler
4. Coolant flow past cylinders
5. Coolant flow from cylinder block to cylinder
head
6. Coolant flow between cylinders
7. Coolant flow to thermostat housing
8. Coolant bypass passage
9. Coolant flow back to radiator
10. Bypass open
11. Coolant bypass in cylinder head
12. Coolant flow to water pump inlet
10 107E-1 Series
Fuel system 1
General Information (Flow Diagram)
1. Fuel supply tank

2. Hand primer
3. Prefilter (water/fuel separator)
a not mounted on engine
4. Clear bowl
5. Gear pump (low pressure fuel pump)
6. Fuel supply pump (high-pressure fuel pump)
7. Fuel main filter
8. Fuel rail (common rail)
a: Injector drain
107E-1 Series 11
Fuel supply pump 1
a Shape may change according to model.
A: Fuel inlet (from prefilter)

B: Fuel outlet (to main filter)
C: Fuel inlet (from main filter)
D: Fuel outlet (to common rail)
E: Drain (to fuel tank)

2. Fuel supply pump (high pressure fuel pump)
3. Connector of IMA solenoid
Specification
q Type: Rotary type with plunger pressure feed
q Lubrication method: Fuel lubrication
12 107E-1 Series
CRI system 1
a CRI means common rail injection.
a Shape may change according to model.
1. Fuel connector (No. 1)

7. Common rail (fuel rail)
8. Fuel main filter
10. Fuel supply pump (high pressure fuel pump)
11. Fuel high pressure tube (No. 1)
107E-1 Series 13
Injectors and fuel lines - overview

General Information
q The fuel system is a high-pressure common (PS) that monitors the fuel pressure provided
rail electronically controlled fuel system. The to the common rail (7) from the fuel supply
high-pressure common rail system consists of pump (10).
4 main components: gear pump (9), fuel sup- Fuel pressure measured by the common rail
ply pump (high-pressure pump) (10), common pressure sensor (PS) is used by the engine
rail (7), and injectors. The fuel supply pump controller to adjust the fuel output of the fuel
(high-pressure pump) (10) supplies high-pres- supply pump (10). The common rail (7) also
sure fuel to the common rail (7) independent of contains a common rail pressure relief valve
engine speed. The high-pressure fuel is then (RV). The common rail pressure relief valve
accumulated in the common rail (7). High-pres- (RV) is a safety valve used to bleed off excess
sure fuel is constantly supplied to the injectors pressure if the rail pressure exceeds a preset
by the common rail (7). The engine controller threshold. Fuel bled off by the common rail
controls the fueling and timing of the engine by pressure relief valve (RV) is returned to the
actuating the injectors. fuel tank through a fuel drain line connected to
q Prefilter is located off of the engine and has the common rail (7).
fuel/water separating function. Fuel passed
through prefilter flows to the gear pump (9). By
gear pump pressure (approximately 0.3 – 1.3
MPa {3.0 – 13.3 kg/cm2}), fuel is filtered using
an on-engine fuel main filter (8) prior to enter-
ing the supply pump (high-pressure fuel pump)
(10).
$(
q The fuel that enters the fuel supply pump (10)

is pressurized between 25 and 180 MPa [255
to 1,837 kg/cm 2 ] by three radial pumping
chambers. The inlet valve to the 3 radial pump-
ing chambers regulates the volume of fuel that
is allowed to enter the pumping chambers. By
regulating the volume of fuel that is pressur-
ized, the valve maintain the pressure in the
common rail (7) at a desired level. Fuel that is
not allowed to enter the 3 radial pumping
chambers is directed through the Cascade
Overflow Valve. The Cascade Overflow Valve
directs a certain amount of pressure to the lube
channels of the fuel supply (10) pump and then
returns the fuel to the fuel tank.
q The common rail (7) acts as a fuel manifold
accumulating and distributing fuel to each of
the injector supply lines. Within the common
rail (7), there is a common rail pressure sensor
14 107E-1 Series
q High-pressure common rail fuel systems use q High-pressure fuel is supplied to the injector
solenoid-actuated injectors. High-pressure fuel (17) from the common rail (7) by fuel high pres-
flows into the side of the injector. When the sure tube (11) and a fuel connector (1). The
solenoid is activated, an internal needle lifts fuel connector (1) pushes against the injector
and fuel is injected. (17) body when the fuel connector nut (18) is
q The engine controller (EC) controls the fueling tightened. The fuel high pressure tube (11) is
and timing of the engine by actuating the sole- then connected to the fuel connector (1).
noids on each injector (17). An electronic pulse q The torque on this fuel connector (1) and the
is sent to the solenoids to lift the needle and fuel high pressure tube (11) is critical. If the nut
start the injection event. By electronically con- (18) is undertightened, the surfaces will not
trolling each injector (17), there is a more pre- seal and a high-pressure fuel leak will result. If
cise and accurate control of fueling quantity the nut (18) is overtightened, the connector (1)
and timing. Also, multiple injection events can and injector (17) will deform and cause a high-
be achieved by electronically controlling each pressure fuel leak. This leak will be inside the
injector (17). head and will not be visible. The result will be a
fault code, low power, or no-start.
7. Common rail
10. Fuel supply pump
17. Injector
EC: Engine controller
PS: Common rail pressure sensor
The clearances in the nozzle bore are

extremely small and any dirt or contaminants
will cause the injector to stick. This is why it is
important to clean around all fuel connections
before servicing the fuel system. Also, cap or
cover any open fuel connections before a fuel
system repair is performed.
107E-1 Series 15
q The fuel connector contains an edge filter that

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

contained within the cylinder head. Any excess
fuel is returned to the tank via this drilling in the
cylinder head and return line attached to the
rear of the cylinder head. A back-pressure
valve is located on the back of the cylinder
head where the drain line attaches. The fuel
drain lines may have either a quick-disconnect
fitting or a banjo fitting at ends of the fuel drain
lines.
Each of the fuel drain lines combine together at
the fuel return manifold.
16 107E-1 Series
Turbocharger 1
Unit: mm
No. Check item Criteria Remedy

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

3 Tighten
bolt 26 {2.6}
107E-1 Series 17
Cylinder head 1
18 107E-1 Series
Unit: mm

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

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

4
mounting bolt 8 {0.8}
Tighten
Tightening torque for head cover mount-
5 24 {2.4}
ing bolt
107E-1 Series 19
Cylinder block 1
20 107E-1 Series
Unit: mm

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

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

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

8
bolt 28 {2.8}
Procedure Target (Nm {kgm}) Tighten
Tightening torque for crankshaft pulley
9 1st stage 50 {5.1}
mounting bolt
2nd stage Rotate 90 degrees clockwise
Inside diameter of cylinder 106.990 to 107.010
Correct by over-
10 Roundness of inside of cylinder Repair limit: 0.038 size or replace
cylinder block
Taper of inside of cylinder Repair limit: 0.076
107E-1 Series 21
Crankshaft 1
22 107E-1 Series
Unit: mm

Replace thrust
1 End play (A) 0.065 to 0.432 bearing metal or
use oversize metal
Outside diameter of main journal 82.962 to 83.013
Use undersize
Roundness of main journal Repair limit: 0.050
journal or replace
2 Taper of main journal Repair limit: 0.013
Replace main
Clearance of main journal 0.04 to 0.12
bearing metal
Outside diameter of crank pin journal 68.962 to 69.013 Use undersize
Roundness of crank pin journal Repair limit: 0.050 journal or replace
3
Replace connect-
Clearance of crank pin journal 0.04 to 0.12 ing rod bearing
metal
Outside diameter of crankshaft gear
4 70.59 to 70.61 Use undersize
journal
crankshaft or
Inside diameter of crankshaft gear jour- replace
5 70.51 to 70.55
nal
107E-1 Series 23
Piston, piston ring and piston pin 1
Unit: mm

Outside diameter of piston
1 106.878 to 106.892 Replace piston
(at right angles to boss)
Top ring 0.33 to 0.43
2 Clearance at piston ring end gap 2nd ring 0.55 to 0.85
Replace piston
Oil ring 0.25 to 0.50
ring or piston
2nd ring 0.040 to 0.110
3 Clearance of piston ring
Oil ring 0.040 to 0.085
4 Outside diameter of piston pin 39.997 to 40.003 Peplace piston or
5 Inside diameter of piston pin bore 40.006 to 40.012 piston pin
24 107E-1 Series
107E-1 Series 25
Connecting rod 1
26 107E-1 Series
Unit: mm
Replace bushing
Inside diameter of connecting rod
1 40.019 to 40.042 (spare part is
bushing (when bushing is installed)
semi-finished part)
Inside diameter of connecting rod
2 69.05 to 69.10 Replace connect-
bearing
ing rod bearing
3 Thickness of connecting rod bearing 1.955 to 1.968
Inside diameter of connecting rod Replace connect-
4 72.99 to 73.01
bearing mounting hole ing rod
Tightening torque for connecting rod 1st stage 30 {3.1} Tighten and
5 cap mounting bolt
2nd stage 60 {6.1} retighten
(Coat thread of bolt nut with engine oil)
3rd stage Rotate 60 degrees clockwise
Replace connect-
6 Side clearance of connecting rod 0.10 to 0.33
ing rod
107E-1 Series 27
Vibration damper 1
Unit: mm

Tighten and
1 Tightening torque of vibration damper 1st stage 50 {5.1}
retighten
2nd stage Retighten 90 degrees
28 107E-1 Series
Timing gear 1
Unit: mm

Backlash of oil pump
A 0.170 to 0.300
gear
Backlash of camshaft
B 0.076 to 0.280
gear
– Backlash of each gear Replace
Backlash of oil pump idler
C 0.170 to 0.300
gear
Backlash of fuel injection
D 0.022 to 0.146
pump gear
107E-1 Series 29
Camshaft 1
Unit: mm

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

5
plate mounting bolt 24 {2.4}
Tighten
Tightening torque of camshaft gear
6 36 {3.7}
mounting bolt
30 107E-1 Series
107E-1 Series 31
Valve and valve guide 1
32 107E-1 Series
Unit: mm

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

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

Replace
5 Diameter of valve guide bore 7.027 to 7.077
Clearance between valve guide and Replace valve or
6 0.017 to 0.117
valve stem valve guide
Depth of valve insert bore
7 34.847 to 34.863 Replace
(standard insert)
107E-1 Series 33
Rocker arm, shaft and tappet 1
34 107E-1 Series
Unit: mm

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

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

9 Tighten
mounting bolt 36 {3.7}
107E-1 Series 35
Flywheel and flywheel housing 1
36 107E-1 Series
Unit: mm

Repair limit: 0.20 <All engine except for generator>
1 Face runout of flywheel housing
0.28 <A6D107E-GD-1 (Protable generator)> Reassemble,
Repair limit: 0.20 <All engine except for generator> correct
2 Radial runout of flywheel housing
0.50 <A6D107E-GD-1 (Protable generator)>
Target (Nm {kgm})
Tightening torque of flywheel housing
3 M10: 49 {5.0} Tighten
mounting bolt
M12: 85 {8.7}
Flywheel Repair limit
For clutch 0.013 / ø25.4
4 Face runout of flywheel Reassemble,
For torque correct
Diameter (actual measurement) × 0.0005
converter
5 Radial runout of flywheel Repair limit: 0.13
Tightening torque of flywheel mounting Target (Nm {kgm}) Tigthen and

6
bolt(Coat bolt thread with engine oil) 137 {14.0} retighten
107E-1 Series 37
Oil pump 1
Unit: mm

1 Clearance of rotor in axial direction Max. 0.127
Clearance between outer rotor and Replace oil pump
2 Max. 0.178
inner rotor
Tightening torque of oil pump mounting Tigthen and
3 1st stage 8 {0.8}
bolt retighten
2nd stage 24 {2.4}
38 107E-1 Series
Water pump drive and fan drive 1
a The shape is subject to machine models.

A: To radiator 1. Poly V-belt 5. Alternator
B: From radiator 2. Crankshaft pulley 6. Fan pulley
3. Tension pulley
a, b, c, d, e: Outside diameter of pulley 4. Water pump
107E-1 Series 39
Outside diameter of pulley

Unit: mm
Engine Applicable machines a (Water pump) b (Alternator) c (Tension) d (Crank) e (Fan)
PC200-8 88 78 73 174 200
PC200-8M0
PC200LC-8M0
PC220-8
88 78 73 174 183
PC220-8M0
PC220LC-8M0
PC240LC-8M0
PC270-8 88 78 73 174 169
PC228US-3E0
88 78 73 174 182
SAA6D107E-1 PC228USLC-3E0
PC228US-8
88 78 73 174 182
PC228USLC-8
WA320-6 88 78 73 174 158
WA380-6 88 78 73 174 129
WA380Z-6 88 80 73 174 73
BR380JG-1E0 88 78 73 174 158
A6D107E-GD-1
88 78 73 174 158
PC160LC-7E0
88 78 73 174 169
PC160LC-8
PC200-8E0 88 78 73 174 189
HB205-1
88 78 73 174 182
HB215LC-1
SAA4D107E-1
HB205-1M0
88 78 73 174 190
HB215LC-1M0
WA200-6 88 78 73 174 158
D39EX-22
88 78 73 174 －
D39PX-22
*1: Air conditioner compressor

*2: Idler pulley (for machine without air conditioner)
40 107E-1 Series
Water pump 1
1. Impeller
2. Water seal
3. Pump body
4. Pulley
5. Drive shaft
Specification
Type: centrifugal type, poly V-belt drive
107E-1 Series 41
Thermostat 1
1. Thermostat
A: To radiator
42 107E-1 Series
Alternator 1
Alternator with built-in regulator (open type, 35 A)
1. Alternator (body) 4B. Regulator

2. Alternator pulley 4C. Terminal L load
3. Terminal B 4D. Starting switch
4. Internal electrical circuit diagram 4E. Battery
4A. Alternator assembly
107E-1 Series 43
Pulley
Engine Applicable machines Type Specification Outside diameter Weight (kg)
Number of ribs
(mm)
PC200-8
PC200-8M0
PC200LC-8M0
PC220-8
PC220LC-8
PC220-8M0
PC220LC-8M0
PC240LC-8M0
SAA6D107E-1
PC270-8
PC228US-3E0
PC228USLC-3E0 Open type,
PC228US-8 Poly V-ribbed
manufactured 24 V, 35 A 77.5 5.4
PC228USLC-8 with 8 ribs
by DENSO
BR380JG-1E0
A6D107E-GD-1
PC200-8E0
HB205-1
HB215LC-1
SAA4D107E-1 HB205-1M0
HB215LC-1M0
D39EX-22
D39PX-22
44 107E-1 Series
1.Alternator (body) 6.Internal electrical circuit diagram

2.Alternator pulley 6A.Field coil
3.Terminal E 6B.Initial energizing resistance
4.Terminal B 6C.Regulator
5.Terminal R
Pulley
Number of ribs
(mm)
Open type,
manufactured
Poly V-ribbed
SAA6D107E-1 WA380Z-6 by Nikko Elec- 24 V, 60 A 80 11.0
with 8 ribs
tric Industry
Co.
107E-1 Series 45
1. Alternator (body) 4B. Regulator

2. Alternator pulley 4C. Terminal L load
3. Terminal B 4D. Starting switch
4. Internal electrical circuit diagram 4E. Battery
4A. Alternator assembly
46 107E-1 Series
Pulley
Number of ribs
(mm)
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC240LC-8M0
PC228US-8
PC228USLC-8
PC308USLC-3E0
SAA6D107E-1
WA250-6
WA250PZ-6
WA320-6
WA320PZ-6
WA380-6 Open type,
Poly V-ribbed
WA380Z-6 manufactured 24 V, 60 A 77.5 6.3
with 8 ribs
GD655-5 by DENSO
GD675-5
PC160LC-7E0
PC160LC-8
HB205-1
HB215LC-1
HB205-1M0
SAA4D107E-1
HB215LC-1M0
WA200-6
WA200PZ-6
D39EX-22
D39PX-22
107E-1 Series 47
Starting motor 1
For 4.5 kW

1. Pinion gear 8. Internal electrical circuit diagram
2. Magnetic switch 8A. Relay
3. Starting motor assembly 8B. Starting switch
4. Jump start prohibition warning plate 8C. Battery
5. Jump start prevention cover 8D. 30 (terminal B)
6. 50 (terminal C) 8E. 50 (terminal C)
7. 30 (terminal B)
48 107E-1 Series
Number of pinion
Engine Applicable machines Type Specification Weight (kg)
teeth
PC200-8
PC200LC-8
PC200-8M0
PC200LC-8M0
PC220-8
PC220LC-8
PC220-8M0
PC220LC-8M0
PC240LC-8M0
PC270-8
SAA6D107E-1
PC228US-3E0
PC228USLC-3E0 Drip proof, oil proof type, manu-
PC228US-8 24 V, 4.5 kW 10 8.4
factured by DENSO
PC228USLC-8
WA250-6
WA250PZ-6
WA320-6
WA320PZ-6
A6D107E-GD-1
HB205-1M0
HB215LC-1M0
SAA4D107E-1
WA200-6
WA200PZ-6
107E-1 Series 49
For 5.5 kW
1. Pinion gear 8. Internal electrical circuit diagram

2. Magnetic switch 8 A.Relay
3. Starting motor assembly 8B.Starting switch
4. Jump start prohibition warning plate 8C.Battery
5. Jump start prevention cover 8D.30 (terminal B)
6. 50 (terminal C) 8E.50 (terminal C)
7. 30 (terminal B)
50 107E-1 Series
Number of pinion
Engine Applicable machines Type Specification Weight (kg)
teeth
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC240LC-8M0
PC228US-3E0
PC228USLC-3E0
SAA6D107E-1 PC228US-8
PC228USLC-8
PC308USLC-3E0
WA380-6
WA380Z-6
BR380JG-1E0 Drip proof, oil proof type, manu-
24 V, 5.5 kW 10 10.5
GD655-5 factured by DENSO
GD675-5
PC160LC-7E0
PC160LC-8
PC200-8E0
PC200LC-8E0
HB205-1
SAA4D107E-1
HB215LC-1
HB205-1M0
HB215LC-1M0
D39EX-22
D39PX-22
107E-1 Series 51
Sensor 1
1. Coolant temperature sensor

2. Charge (boost) temperature & pressure sensor
3. Ambient pressure sensor
4. Common rail pressure sensor
5. Engine oil pressure sensor (oil pressure switch)
6. NE speed sensor (crankshaft sensor)
7. Bkup speed sensor (CAM sensor)
8. Engine controller
9. Ground of engine controller
52 107E-1 Series
Various sensors 1) Coolant temperature sensor

1. Temperature sensor
The temperature sensor detects temperature
using a thermistor (TH) of which resistance
changes according to the temperature.
The temperature sensor itself has no polarity.
(The wiring harness has polarities naturally.)
a The temperature characteristics depend on
each sensor.
q When the temperature increases, the resis-

tance of the thermistor (TH) decreases.
q Connector label: COOLANT TEMP

q The coolant temperature sensor detects
the coolant temperature.
q Temperature characteristics of resistance
0°C Resistance 30 to 37 kz
25°C Resistance 9.3 to 10.7 kz
q The thermistor signal (Sig) is connected to the 80°C Resistance 1.0 to 1.3 kz
resistor (R) inside the engine controller. The 95°C Resistance 700 to 800 kz
engine controller detects the thermistor voltage
(VTH) by applying a voltage of 5 V to the resis-
tor (R) and thermistor (TH) in series. The
engine controller calculates the temperature
from the thermistor voltage (VTH).
a If the circuit is open because of a disconnec-
tion of the temperature sensor connector (CN)
etc., no current flows and thus the voltage
does not decrease through the resistor (R) in
th e eng in e c o ntr ol le r. As a re s ult , V T H
becomes 5 V and the failure code "**** Temp
Sensor High Error" is displayed on the
machine monitor to notify the abnormality. If
short circuit occurs between (A) and (B) or the
thermistor signal (Sig) has a ground fault, the
failure code "**** Temp Sensor Low Error" is
displayed to notify the abnormality.
107E-1 Series 53
2) Charge (Boost) temperature and pres- 1) Charge (Boost) temperature and pres-
sure sensor sure sensor
Connector label: BOOST PRESS & IMT
a Integrated with the charge (boost) temper-
ature sensor (See the figure at left).
- The charge pressure sensor detects the
intake air (boost) pressure.
Connector label: BOOST PRESS & IMT

a Integrated with the charge (boost) pres-
sure sensor.
q The charge temperature sensor detects
the intake air (boost) temperature.
2) Ambient pressure sensor

q Temperature characteristics of resistance
-40°C Resistance 41 to 48 kz
-20°C Resistance 14 to 16 kz
60°C Resistance 560 to 600 z
2. Pressure sensor Connector label: AMB. AIR PRESSURE

The pressure sensor inputs power of 5 V and a The engine controller detects the altitude
outputs pressure signals as voltage. The out- from the ambient pressure and calculates
put (pressure - voltage) characteristics depend the oxygen concentration.
on each sensor.
a The 5 V power supply and GND for the
sensor are used partly in common when
viewed from the engine controller.
a Since semiconductors are used in the
sensor, it is impossible to use the resis-
tance to judge if the sensor itself is defec-
tive.
54 107E-1 Series
3) Common rail pressure sensor 4) Engine oil pressure sensor

Connector label: OIL PRESSURE SWITCH
a This is an ON/OFF switch which operates
as follows.
When no oil pressure is applied because of
stop of the engine etc.:
ON, there is continuity (CLOSE)
When the engine is in operation: OFF, there is
no continuity (OPEN)
q The hysteresis characteristics are shown
in the following figure.
Connector label: FUEL RAIL PRESS

q The common rail pressure sensor is
installed in the common rail and detects
the fuel pressure.
a Similarly to the temperature sensor, the

sensor output voltage is connected to 5 V
po we r i ns i d e t he e ng i ne c on tr ol l er.
Accordingly, if the circuit is open (if the
connector is disconnected), SIG voltage of
the common rail pressure sensor
becomes 5 V and the failure code "Com-
mon Rail Press Sensor High Error" is dis-
played.
a When the common rail pressure sensor
needs to be replaced, the whole common
rail must be replaced.
a A characteristics graph cannot be
obtained.
107E-1 Series 55
3. Speed sensor 1) Bkup speed sensor (CAM sensor)

Connector label: CAM SENSOR
q The Bkup speed sensor (CAM sensor)
detects groove (B) of the camshaft ring.
There are 2 speed sensors; One is the Bkup

speed sensor (CAM sensor) and the other is
the NE speed sensor (crankshaft sensor). Both
of them receive power of 5 V and output the
speed signals as pulse voltages of 0 to 5 V. 2) NE speed sensor (Crankshaft sensor)
There are the hall element and the waveform Connector label: CRANK SENSOR
shaping circuit in each speed sensor. If the q The NE speed sensor (Crankshaft sensor)
magnetic line of force changes, the output of detects a hole (WS) of the wheel that is
the hall element sensor changes linearly and it installed inside the crankshaft damper.
is converted into pulse of 0 to 5 V by the wave- There is paint mark (M1) on the damper
form shaping circuit. which is aligned with a hole (WS) of the
a The speed sensor functions only when wheel.
combined with a rotary mating part.
a Since semiconductors (not coils) are used
in the speed sensor, it is impossible to use
the resistance to judge if the sensor itself
is defective.
a The engine controller can detect the TOP
of the No. 1 cylinder by the two speed
sensors of the Bkup speed sensor (CAM
sensor) and NE speed sensor (crankshaft
sensor).
56 107E-1 Series
4. Engine oil level sensor
1) Connector q This sensor is installed to the oil pan.

2) Bracket q Float (3) moves up and down according to the
3) Float change of the engine oil level, and it turns switch
(4) ON and OFF.
4) Switch
5. Water-in-fuel sensor
q This sensor is installed to the bottom of the prefil-

1) Connector
ter.
2) Electrode q If water is accumulated at the bottom of the prefil-
ter, the resistance between elect rodes (2)
3) Sensor
changes. Sensor (3) detects this change of the
4) O-ring resistance.
107E-1 Series 57
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller

q Engine controller CM850 developed by the
cooperation between KOMATSU and CUM-
MINS is employed.
(Employment in 107, 114, 125, 140, 170 and
12V 140 engines)
3 Lock screws (L1) and (L2) (at wiring harness

side) of connector ECM (DRC26-60) and
machine wiring harness connector (DRC26-
50): 3±1 Nm (Use 4 mm hexagonal wrench)
a If lock screws (L1) and (L2) (at wiring har-
ness side) are tightened excessively, the
female screws will be broken and the
engine controller will have to be replaced.
Take care.
58 107E-1 Series
Input/Output signal
q The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
Connector ECM (DRC26-60P)

Signal Signal
Pin No. Signal name classifi- Pin No. Signal name classifica-
cation tion
1 NC (*) – 31 NC (*) –
2 IMA power supply D 32 IMA return C
3 Ambient pressure sensor B 33 Sensor power supply (5 V) A,D
4 NC (*) – 34 NC (*) –
5 NC (*) – 35 NC (*) –
6 CAN (-) E 36 NC (*) –
7 NC (*) – 37 Sensor power supply (5 V) A,D
8 CAN (+) E 38 GND C
9 NC (*) – 39 NC (*) –
10 NC (*) – 40 NC (*) –
11 NC (*) – 41 NC (*) –
12 NC (*) – 42 NC (*) –
13 NC (*) – 43 NC (*) –
14 Water-in-fuel sensor B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
16 Sensor power supply (5 V) A,D 46 Injector #5 (+) D
17 Engine oil pressure switch B 47 Sensor GND C
18 NC (*) – 48 Crankshaft speed sensor (-) C
19 NC (*) – 49 NC (*) –
20 NC (*) – 50 NC (*) –
21 NC (*) – 51 Injector #2 (–) C
22 NC (*) – 52 Injector #3 (–) C
23 Intake air temperature sensor B 53 Injector #1 (–) C
24 NC (*) – 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 Camshaft speed sensor (+) B 56 Injector #4 (+) D
27 Crankshaft speed sensor (+) B 57 Injector #6 (+) D
28 NC (*) – 58 Injector #4 (–) C
29 NC (*) – 59 Injector #6 (–) C
30 NC (*) – 60 Injector #5 (–) C
*: Never connect any cable to NC, or malfunctions or failures will occur.
107E-1 Series 59
Connector for machine wiring harness (DRC26-50P)

a Connector lable changes according to model
Signal
Signal
Pin No. Signal name classifi- Pin No. Signal name
category
cation
1 Idle validation 2 B 26 NC (*) –
2 NC (*) – 27 NC (*) –
3 NC (*) – 28 NC (*) –
4 NC (*) – 29 IVS P (-) C
5 NC (*) – 30 NC (*) –
6 NC (*) – 31 NC (*) –
7 NC (*) – 32 OEM sensor (-) C
8 NC (*) – 33 DIS_SEL0 (GND) C
9 Fuel control dial (+) B 34 NC (*) –
10 NC (*) – 35 NC (*) –
11 Idle validation 1 B 36 NC (*) –
12 NC (*) – 37 NC (*) –
13 NC (*) – 38 NC (*) –
14 NC (*) – 39 Starting switch ACC signal A,B
Electrical intake air heater relay
15 NC (*) – 40 D
drive
16 NC (*) – 41 NC (*) –
Electrical intake air heater relay
17 NC (*) – 42 C
return
18 NC (*) – 43 NC (*) –
19 NC (*) – 44 NC (*) –
20 NC (*) – 45 NC (*) –
21 OEM sensor supply (+5V) A,D 46 CAN (+) E
22 Fuel control dial (5 V) A,D 47 CAN (-) E
23 Fuel control dial (–) C 48 NC (*) –
24 NC (*) – 49 Engine controller power cutoff relay D
25 NC (*) – 50 NC (*) –
*: Never connect any cable to NC, or malfunctions or failures will occur.
Connector for power supply (DTP-4P)

a Connector lable changes according to model
Signal
Pin No. Signal name
classification
1 GND C
2 GND C
3 Continuous power supply (24 V) A,B
4 Continuous power supply (24 V) A,B
60 107E-1 Series
Control system 1
q The CRI* system checks the condition of the

engine (engine speed, accelerator angle, cool-
ant temperature, etc.) with sensors.
q The engine controller of the CRI system con-
trols the fuel injection rate, fuel injection timing,
fuel injection pressure, etc. totally to operate
the engine under the best condition.
q The CRI system has a diagnosis function
which engine controller checks the main com-
ponent parts and notifies the operator of
detected failures.
q In addition, the CRI system has a failsafe func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues the operation by changing the control
method in such a case.
*: CRI means common rail injection.
107E-1 Series 61
1.Fuel injection rate control function

q The fuel injection rate control function is
employed instead of the function of the con-
ventional governor. It controls the fuel injection
for each injector according to the signals of
engine speed and accelerator angle so that the
fuel injection rate will be most proper.
62 107E-1 Series
2.Fuel injection timing control function

q The fuel injection timing control function is
employed instead of the function of the con-
ventional timer. It controls the fuel injection
timing most properly from the engine speed
and fuel injection rate.
107E-1 Series 63
3.Fuel injection pressure control func-

tion
(Common rail fuel pressure control function)
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
feeding it back to the engine controller to con-
trol the delivery of the fuel supply pump.
q This function performs pressure feedback con-
trol so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
64 107E-1 Series
107E-1 Series 65
*: Label of power supply connector (DTP-4) and machine wiring harness connector (DRC26-50) changes
according to model.
a Power supply wiring harness and pin name of machine wiring harness connector (DRC26-50) are an
example of PC200-8
a Engine wiring harness is common to all model.
66 107E-1 Series
107E-1 Series 67
SEN00168-07
a Exclusive for generator
68
107E-1 Series 69
© 2012 KOMATSU
All Rights Reserved
70 107E-1 Series
SEN00248-16
Engine 1SHOP MANUAL
107E-1 Series
20 Standard value table

Standard service value table
Standard value table for testing, adjusting and troubleshooting ..................................................................... 2
Running-in standard and performance test criteria ....................................................................................... 22
107E-1 Series 1
SEN00248-16 20 Standard value table
Standard value table for testing, adjusting and troubleshooting 1

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

Cate-
Standard value for

gory
Item Measurement conditions Unit Repair limit

new machine
Max. speed with no load rpm 2,060 ± 50 2,060 ± 50
Performance
Engine speed
Min. speed with no load rpm 1,050 ± 25 1,050 ± 25
Necessary starting At 0°C rpm — —

speed At –20°C rpm — —
kPa Max. 3.73 7.45
Intake resistance At all speed
{mmH2O} {Max. 380} {760}
Intake pressure kPa Min. 140 113
At rated horsepower
Air intake and exhaust system
(Aftercooler inlet) {mmHg} {Min. 1,050} {850}

Exhaust pressure kPa
At rated horsepower — —
(Turbine inlet press.) {mmHg}
Exhaust temperature
At all speed (at 20°C) °C Max. 650 700
(Turbine outlet temp.)
Opacity
At rated horsepower Max. 12 22
%
Exhaust gas color
Quick acceleration Opacity
Max. 25 35
(Low idle o high idle) %
Intake valve mm 0.25 0.152 to 0.381
Valve clearance
Exhaust valve mm 0.51 0.381 to 0.762
Oil temperature: 40 to 60°C
MPa Min. 2.41 1.69
Compression pressure Engine speed: 250 to 280
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
Blowby pressure At rated horsepower
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
(Oil temperature: Min. 80°C)
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
Oil temperature °C 80 to 110 120
(Oil in oil pan)
At continuous rated horse-
Oil consumption ratio power % Max. 0.15 0.3
(Ratio to fuel consumption)
Radiator pressure Opening pressure kPa
— —
Cooling system
valve (Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm 1,740 1,740
Fan and alternator belt Deflects when pushed with a

mm Auto-tensioner Auto-tensioner
tension finger force of 98 N {10 kg}
2 107E-1 Series
1
Engine SAA6D107E-1
Applicable machine PC200-8M0, PC200LC-8M0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 3
Engine SAA6D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

4 107E-1 Series
Engine SAA6D107E-1
Applicable machine PC220-8M0, PC220LC-8M0, PC240LC-8M0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 5
Engine SAA6D107E-1
Applicable machine PC270-8

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

6 107E-1 Series
Engine SAA6D107E-1
Applicable machine PC228US-3E0, PC228USLC-3E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 7
Engine SAA6D107E-1
Applicable machine PC228US-8, PC228USLC-8

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

8 107E-1 Series
Engine SAA6D107E-1
Applicable machine PC308USLC-3E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 9
Engine SAA6D107E-1
Applicable machine WA250-6, WA250PZ-6

Cate-
Standard value for

gory

new machine
Performance
Engine speed
Min. speed with no load rpm 825 ± 25 825 ± 25

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
(Aftercooler inlet) {mmHg} {Min. 900} {700}

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system
Fan speed At rated engine speed rpm Hydraulically driven on machine side

10 107E-1 Series
Engine SAA6D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 11
Engine SAA6D107E-1
Applicable machine WA380-6, WA380Z-6

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

12 107E-1 Series
Engine SAA6D107E-1
Applicable machine BR380JG-1E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 13
Engine SAA6D107E-1
Applicable machine GD555-5

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

14 107E-1 Series
Engine SAA6D107E-1
Applicable machine GD655-5, GD675-5

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower
(Aftercooler inlet) {mmHg} {Min. 1,200} {1,000}

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 15
Engine SAA6D107E-1
A6D107E-GD-1
Applicable machine
Cate-
Standard value for

gory

new machine
Max. speed with no load rpm Max. 1,890 Max. 1,890
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
Oil temperature: 40 to 60°C MPa Min. 2.41 1.69
Compression pressure
{kg/cm2} {Min. 24.6} {17.2}
Body
Engine speed: 250 to 280 rpm

kPa Max. 1.18 1.96
{mmH2O} {Max. 120} {200}
At rated horsepower (At 60 Hz)
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
At continuous rated horsepower
Oil consumption ratio % Max. 0.15 0.3
Radiator pressure Opening pressure kPa 49 49
Cooling system
valve (Differential pressure) {kg/cm2} {0.5} {0.5}

At rated engine speed
Fan speed rpm 1,980 1,980
(At 60 Hz)
16 107E-1 Series
Engine SAA4D107E-1
Applicable machine PC160LC-7E0, PC160LC-8

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 17
Engine SAA4D107E-1
Applicable machine PC200LC-8E0

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

18 107E-1 Series
Engine SAA4D107E-1
HB205-1, HB215LC-1
Applicable machine
HB205-1M0, HB215LC-1M0
Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 19
Engine SAA4D107E-1

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

20 107E-1 Series
Engine SAA4D107E-1
Applicable machine D39EX-22, D39PX-22

Cate-
Standard value for

gory

new machine
Performance
Engine speed

kPa Max. 3.73 7.45
{mmH2O} {Max. 380} {760}
At rated horsepower

Exhaust temperature
Opacity
%
Exhaust gas color
Max. 25 35
Valve clearance
MPa Min. 2.41 1.69
{kg/cm2} {Min. 24.6} {17.2}
Body
rpm
kPa Max. 0.98 1.96
{mmH2O} {Max. 100} {200}
At rated horsepower
MPa Min. 0.29 0.25
{kg/cm2} {Min. 3.0} {2.5}
SAE15W-40
Lubrication system
Oil pressure
At low idle
MPa Min. 0.10 0.07
{kg/cm2} {Min. 1.0} {0.7}
SAE15W-40
At all speed
(Oil in oil pan)
— —
Cooling system

107E-1 Series 21
Running-in standard and performance test criteria 1

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

Engine SAA6D107E-1
Max. speed Min. speed
Test item Rated horsepower Max. torque
with no load with no load
116 ± 5.81 kW/ 624+19.6/–39.2 Nm/
Specification value 2,000 rpm 1,500 ± 100 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {155 ± 8 HP/ {63.6+2/–4 kgm/
2,000 rpm} 1,500 ± 100 rpm}
Engine speed rpm 2,000 1,500 ± 100 2,060 ± 50 1,050 ± 25
N 771 871
Dynamometer load — —
{kg} {78.6} {88.8}
kW 116
Output (Gross) — — —
{HP} {155}
Nm 624
Torque (Gross) — — —
{kgm} {63.6}
sec/
Fuel consumption 35 — — —
300cc
Coolant temperature °C 75 to 94 75 to 94 75 to 94 75 to 94
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9
pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values using the JIS correction factor.
a The output and torque values in the table are the standard values with the fan removed, so they are dif-
ferent from the specification values.
a This table shows the standard values when an air cleaner and a muffler are installed, and no load is
applied to the alternator.
a The dynamometer load shows the value for an arm length of 716 mm.
a Use ASTM D975 diesel oil as the fuel.
a Use SAE15W-40 as the lubricating oil.
22 107E-1 Series
1
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 109.7 {147.1}

Engine SAA6D107E-1
109.7 ± 5.5 kW/ 602 ± 30 Nm/
Specification value 2,000 rpm 1,500 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {147.1 ± 7.4 HP/ {61.4 ± 3.1 kgm/
2,000 rpm} 1,500 rpm}
Engine speed rpm 2,000 1,500 2,060 ± 50 1,050 ± 25
N 732 841
{kg} {74.6} {85.8}
kW 109.7
{HP} {147.1}
Nm 602
{kgm} {61.4}
sec/
300cc
Lubricating oil
°C 80 to110 80 to 110 80 to 110 80 to 110
temperature
Exhaust temperature
(Turbine outlet °C Max. 550 Max. 590 — —
temperature)
107E-1 Series 23
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Dynamometer load N {kg} 0 {0} 98 {10} 245 {25} 440 {45} 892 {91}
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 134 {179}

Engine SAA6D107E-1
Specification value 134±6.69 kW/2,000 rpm 710±34.3 Nm/1,500±100 rpm
— 2,160 ± 50 rpm 1,050 ± 25 rpm
(Gross) {179±9 HP/2,000 rpm} {72.4±3.5 kgm/1,500±100 rpm}
Engine speed rpm 2,000 1,500 ± 100 2,160 ± 50 1,050 ± 25
N 892 991
{kg} {91} {101.0}
kW 134
{HP} {179}
Nm 710
{kgm} {72.4}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
24 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Applicable machine PC220-8M0, PC220LC-8M0, PC240LC-8M0
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 129.3 {173.3}

Engine SAA6D107E-1
Applicable machine PC220-8M0, PC220LC-8M0,PC240LC-8M0
Specification value 129.6±6.4 kW/2,000 rpm 690±34.3 Nm/1,500±100 rpm
— 2,160 ± 50 rpm 1,050 ± 25 rpm
(Gross) {173.3 ± 8.6 HP/2,000 rpm} {70.4±3.5 kgm/1,500±100 rpm}
Engine speed rpm 2,000 1,500 ± 100 2,160 ± 50 1,050 ± 25
N 863 964
{kg} {88} {98.3}
kW 129.3
{HP} {173.3}
Nm 690
{kgm} {70.4}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Exhaust temperature
(Turbine outlet °C Max. 550 Max. 590 — —
temperature)
107E-1 Series 25
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
— 2,180 ± 50 rpm 1,050 ± 25 rpm
Engine speed rpm 2,050 1,500 ± 100 2,180 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 to110 80 to 110 80 to 110 80 to 110
temperature
26 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 116 {155}

Engine SAA6D107E-1
116 ± 5.81 kW/ 624+19.6/–39.2 Nm/
Specification value 2,000 rpm 1,500 ± 100 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {155 ± 8 HP/ {63.6+2/–4 kgm/
2,000 rpm} 1,500 ± 100 rpm}
Engine speed rpm 2,000 1,500 ± 100 2,060 ± 50 1,050 ± 25
N 771 871
{kg} {78.6} {88.8}
kW 116
{HP} {155}
Nm 624
{kgm} {63.6}
sec/
300cc
Lubricating oil
°C 80 to110 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 27
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 116 {155}

Engine SAA6D107E-1
Max. speed Min. speed with
with no load no load
116 ± 5.81 kW/ 623.7 ± 31.2 Nm/
Specification value 2,000 rpm 1,500 ±100 rpm
— 2,060 ± 50 rpm 1,050 ± 25 rpm
(Gross) {155 ± 8 HP/ {63.6 ± 3.2 kgm/
2,000 rpm} 1,500 ± 100 rpm}
Engine speed rpm 2,000 1,500 ± 100 2,060 ± 50 1,050 ± 25
N 771 871
{kg} {78.6} {88.8}
kW 116
{HP} {155}
Nm 624
{kgm} {63.6}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
28 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
— 2,180 ± 50 rpm 1,050 ± 25 rpm
Engine speed rpm 2,050 1,500 ± 100 2,180 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 29
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 104.1 {140}

Engine SAA6D107E-1
Specification value 104.1 ± 5.2 kW/2,000 rpm 627 ± 31 Nm/1,400 ± 100 rpm
— 2,250 ± 50 rpm 825 ± 25 rpm
(Gross) {140 ± 7.1 HP/2,000 rpm} {64 ± 3.2 kgm/1,400 ± 100rpm}
Engine speed rpm 2,000 1,400 ± 100 2,250 ± 50 825 ± 25
N 694 875
{kg} {71} {89.4}
kW 104.1
{HP} {140}
Nm 627
{kgm} {64.0}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 294 Min. 98
30 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,100
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 127.3 {171}

Engine SAA6D107E-1
Specification value 127.3 ± 6.4kW/2,000 rpm 672 ± 34 Nm/1,500 rpm
— 2,250 ± 50 rpm 825 ± 25 rpm
(Gross) {171 ± 8.6 HP/2,000 rpm} {68.5 ± 3.5 kgm/1,500 rpm}
Engine speed rpm 2,000 1,500 2,250 ± 50 825 ± 25
N 853 938
{kg} {87} {95.7}
kW 127.3
{HP} {171}
Nm 672
{kgm} {68.5}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Lubricating oil kPa Min. 261.8 Min. 193.2 Min. 294 Min. 98
107E-1 Series 31
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,100
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 143.4 {192}

Engine SAA6D107E-1
Specification value 143.4 ± 7.21kW/2,100rpm 941 ± 47 Nm/1,450 ± 100 rpm
— 2,250 ± 50 rpm 850 ± 25 rpm
(Gross) {192 ± 9.7 HP/2,100 rpm} {96.0± 4.8kgm/1,450 ± 100rpm}
Engine speed rpm 2,100 1,450 ± 100 2,250 ± 50 850 ± 25
N 911 1,315
{kg} {93} {134.1}
kW 143.4
{HP} {192}
Nm 941
{kgm} {96.0}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Lubricating oil kPa Min. 294 Min. 193.2 Min. 294 Min. 98
32 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 149 {200}

Engine SAA6D107E-1
— 2,330 ± 50 rpm 1,050 ± 25 rpm
Engine speed rpm 2,050 1,500 ± 100 2,330 ± 50 1,050 ± 25
N 971 1,077
{kg} {99} {109.8}
kW 149
{HP} {200}
Nm 771
{kgm} {78.6}
sec/
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 33
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 825 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 146.2 {196}

Engine SAA6D107E-1
Specification value 146.2 ± 7.3 kW/2,000 rpm 880 ± 44 Nm/1,450 rpm
— 2,200 ± 50 rpm 825 ± 25 rpm
Engine speed rpm 2,000 1,450 2,200 ± 50 825 ± 25
N 973 1,229
{kg} {99.2} {125.3}
kW 146.2
{HP} {196}
Nm 880
{kgm} {89.7}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 120 80 to 120 80 to 120
temperature
34 107E-1 Series
Running-in standard
Engine SAA6D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 825 1,000 1,200 1,600 2,100
Dynamometer load N {kg} 0 {0} 98 {10} 245 {25} 440 {45} 1,047 {106.7}
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 53 {71} 164.8 {221}

Engine SAA6D107E-1
— 2,200 ± 25 rpm 825 ± 25 rpm
(Gross) {221±11.1HP/2,100rpm} {96.0 ± 4.8 kgm/1,450 rpm}
Engine speed rpm 2,100 1,450 2,200 ± 25 825 ± 25
N 1,047 1,314
{kg} {106.7} {134}
kW 164.8
{HP} {221}
Nm 941
{kgm} {96.0}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 120 80 to 120 80 to 120
temperature
107E-1 Series 35
Running-in standard
Engine SAA6D107E-1
Applicable machine A6D107E-GD-1 (Portable generator)
Procedure
Item
1 2 3 4 5
Engine speed rpm 650 1,000 1,200 1,500 1,800
Dynamometer load N {kg} 0 {0} 98 {10} 245 {25} 440 {45} 1,030 {105}
Output kW {HP} 0 {0} 7.4 {10} 22 {29.5} 50 {68} 139 {189}

Engine SAA6D107E-1
Applicable machine A6D107E-GD-1 (Portable generator)
Test item 50 Hz Rated horsepower 60 Hz Rated horsepower
Specification value 115 ± 5.81 kW/1,500 rpm 139 ± 6.99 kW/1,800 rpm
— Max.1,890 rpm 650 ± 25 rpm
(Gross) {155 ± 7.8 HP/1,500 rpm} {186 ± 9.4 HP/1,800 rpm}
Engine speed rpm 1,500 1,800 Max. 1,890 650 ± 25
N 1,027 1,030
{kg} {104.7} {105}
kW 115 139
Output (Gross) — —
{HP} {155} {186}
Nm
Torque (Gross) — — — —
{kgm}
sec/
Fuel consumption 35 29 — —
300cc
Lubricating oil
°C 80 to 110 80 to 110 80 to 110 80 to 110
temperature
Lubricating oil kPa Min. 193.2 Min. 261.8 Min. 261.8 Min. 98
36 107E-1 Series
Running-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,050
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 90 {121}

Engine SAA4D107E-1
Specification value 90.0 ± 4.5 kW/2,200 rpm 471 ± 23.5 Nm/1,500 rpm
— 2,320 ± 30 rpm 1,050 ± 25 rpm
(Gross) {121 ± 6 HP/2,200 rpm} {48.0 ± 2.4 kgm/1,500 rpm}
Engine speed rpm 2,200 1,500 2,320 ± 30 1,050 ± 25
N 545 657
{kg} {55.6} {67.0}
kW 90
{HP} {121}
Nm 471
{kgm} {48.0}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 37
Running-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 700 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 106.6 {143}

Engine SAA4D107E-1
Specification value 106.6 ± 5.4 kW/2,200 rpm 593.9 ± 29 Nm/1,700 rpm
— 2,060 ± 50 rpm 700 ± 25 rpm
Engine speed rpm 2,000 1,700 2,060 ± 50 700 ± 25
N 711 829
{kg} {72.5} {84.6}
kW 106.6
{HP} {143}
Nm 593.9
{kgm} {60.6}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 110 80 to 110 80 to 110
temperature
38 107E-1 Series
Running-in standard
Engine SAA4D107E-1
Applicable machine HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0
Procedure
Item
1 2 3 4 5
Engine speed rpm 700 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 110.3 {148}

Engine SAA4D107E-1
HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0
Applicable machine

Specification value 110.3 ± 5.5 kW/2,200 rpm 593.9 ± 29 Nm/1,700 rpm
— 2,060 ± 50 rpm 700 ± 25 rpm
Engine speed rpm 2,000 1,700 2,060 ± 50 700 ± 25
N 735 829
{kg} {75.0} {84.6}
kW 110.3
{HP} {148}
Nm 593.9
{kgm} {60.6}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 39
Running-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 95.2 {128}

Engine SAA4D107E-1
— 2,250 ± 50 rpm 825 ± 25 rpm
Engine speed rpm 2,000 1,400 2,250 ± 50 825 ± 25
N 635 819
{kg} {64.8} {83.5}
kW 95.2
{HP} {129.5}
Nm 586
{kgm} {59.8}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 110 80 to 110 80 to 110
temperature
40 107E-1 Series
Running-in standard
Engine SAA4D107E-1
Procedure
Item
1 2 3 4 5
Engine speed rpm 1,050 1,000 1,200 1,600 2,200
Output kW {HP} 0 {0} 7.4 {10} 13.2 {18} 29.4 {39} 80 {107}

Engine SAA4D107E-1
Specification value 800 ± 4.0 kW/2,200 rpm 476 ± 23.5 Nm/1,500 rpm
— 2,400 ± 50 rpm 975 ± 25 rpm
(Gross) {108.7 ± 5.3 HP/2,200 rpm} {48.5 ± 2.4 kgm/1,500 rpm}
Engine speed rpm 2,200 1,500 2,400 ± 50 975 ± 25
N 484 664
{kg} {49.4} {67.7}
kW 80.0
{HP} {107}
Nm 476
{kgm} {48.5}
sec/
300cc
Lubricating oil
°C 80 to 120 80 to 110 80 to 110 80 to 110
temperature
107E-1 Series 41
SEN00248-16
© 2012 KOMATSU
All Rights Reserved
42
SEN00250-09
Engine 1SHOP MANUAL
107E-1 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting tools list ........................................................................................................................ 2
Sketches of special tools ................................................................................................................................ 4
Testing boost pressure.................................................................................................................................... 5
Adjustment of valve clearance ........................................................................................................................ 6
Testing compression pressure ........................................................................................................................ 9
Testing blowby pressure ............................................................................................................................... 12
Testing engine oil pressure ........................................................................................................................... 13
Handling fuel system parts............................................................................................................................ 14
Releasing remaining pressure in fuel system ............................................................................................... 14
Testing fuel pressure..................................................................................................................................... 15
Reduced cylinder mode operation ................................................................................................................ 21
No-injection cranking .................................................................................................................................... 21
Testing fuel delivery, return and leak amount................................................................................................ 22
Bleeding air from fuel circuit.......................................................................................................................... 33
Testing fuel system for leakage..................................................................................................................... 34
Handling controller high-voltage circuit ......................................................................................................... 35
Replacing the fan belt ................................................................................................................................... 35
107E-1 Series 1
SEN00250-09 30 Testing and adjusting
Testing and adjusting tools list 1

Testing and Sym-
Part No. Part name Q'ty Remarks
adjusting item bol
Testing boost 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
1 795-799-1131 Gear 1
Adjusting valve
C Commercially
clearance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1
Testing compression 2 795-502-1590 Gauge assembly 1
D
pressure 3 795-790-4410 Adapter 1
4 6754-11-3130 Gasket 1
Testing blowby 1 799-201-1504 Blowby checker 1 0 – 5 kPa {0 – 500 mmH2O}
E
pressure 2 795-790-3300 Blowby tool 1
Pressure gauge: 2.5, 6, 40, 60 MPa
1 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing oil pressure F 2 790-301-1230 Nipple 1
3 799-101-5160 Nipple 1
4 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
6732-81-3170 Adapter 1 10 × 1.0 mm o Rc1/8
Testing fuel pressure G 2 795-790-4430 Adapter 1 10 × 1.0 mm o Rc1/8
6215-81-9710 O-ring 1
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure 795-790-4430 Adapter 1 10 × 1.0 mm o Rc1/8
G 2
(*) 6215-81-9710 O-ring 1
5 799-201-2202 Boost gauge kit 1
6 795-790-5110 Screw 1
1 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
4 Measuring cylinder 1
Testing fuel delivery, available
return and leak H Commercially
amount 5 Stopwatch 1
available
Commercially
6 Hose 1 Inside diameter: ø14 mm
available
Commercially
7 Hose 1 Inside diameter: ø8 mm
available
*: Devices shown with this mark are for testing and adjustment for HB205-1M0 and HB215LC-1M0 .
2 107E-1 Series
Testing and Sym-

Part No. Part name Q'ty Remarks
adjusting item bol
1 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
2
6754-71-5350 Washer 1
3 6164-81-5790 Joint 1
4 6745-71-1130 Seal washer 1
Testing fuel delivery,
return and leak H 5 07206-30812 Joint bolt 1
amount (*) Commercially
6 Stopwatch 1
available
Commercially
7 Measuring cylinder 1
available
Commercially
8 Hose 1
available
Measuring voltage Commercially
— Circuit tester 1
and resistance available
Removal and installa-
tion of booster pres- 3.26 mm Hexlobe (TORX) wrench
— 795-799-6210 Hexlobe (TORX) wrench 1
sure and temperature (KTC Q4T15 or equivalent)
sensors
Removal and installa-
Commercially
tion of engine oil — Deep socket 1 27 mm deep socket
available
pressure sensor
Removal and installa- 21 mm deep socket
tion of engine cool- Commercially (MITOLOY 4ML-21 or equivalent)
— Socket 1
ant temperature available Applicable engine serial No. :
sensor 26500006 - 26530192
19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
— 795T-981-1010 Socket 1
Applicable engine serial No. :
26530193 and up
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-7310 T-adapter 1 SWP (12 poles)
799-601-7070 T-adapter 1 SWP (14 poles)
799-601-4100 T-adapter assembly 1 Connected with engine
Diagnosis sensor and 799-799-5530 T-adapter 1 Engine coolant temperature
—
harness 799-601-4230 T-adapter 1 Boost temperature/pressure sensor
799-601-4130 T-adapter 1 Ne sensor, CAM sensor
799-601-4160 T-adapter 1 Hydraulic pressure sensor
799-601-4211 T-adapter 1 Controller (50 poles)
799-601-4140 T-adapter 1 Atmosperic pressure sensor
799-601-4340 T-adapter 1 Pump actuator
799-601-4190 T-adapter 1 Common rail pressure sensor
*: Devices shown with this mark are for testing and adjustment for HB205-1M0 and HB215LC-1M0 .
107E-1 Series 3
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
4 107E-1 Series
Testing boost pressure 1

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

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

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

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

tools and return the removed parts.
107E-1 Series 5
Adjustment of valve clearance 1

a Valve clearance adjusting tools 5. Remove gasket (4a).
a Take care so that foreign matter does not
Symbol Part No. Part name enter the engine.
1 795-799-1131 Gear a If gasket (4a) is cracked, deteriorated, or
worn, replace it with a new one.
C Commercially
2 Clearance gauge
available
<WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-

8M0, PC220LC-8M0 and PC240LC-8M0 only>
1. Remove three connectors (4) and two bands
(5) from wiring harness (3) and separate wiring
harness (3) from the head cover.
2. Remove five head cover mounting bolts (6).
a After loosening the bolts, remove mud and
foreign matter sticking around the head
cover by blowing air against them, while
holding the head cover.
3. Remove head cover (7).
a When removing the head cover, take care
<other than WA380Z-6, PC200-8M0, PC200LC-
not to hit it against a part around it.
8M0, PC220-8M0, PC220LC-8M0 and PC240LC-
8M0>
1. Remove cylinder head cover (1).
<The following photo shows 6D107E-1>
4. Loosen injector terminal nuts (8) to remove the

terminals (12 pieces) from the injectors.
<The following procedures are common to all the

machine models>
2. Remove plug (2) from the starting motor top
and install tool C1.
<The following photo shows PC200-8>
6 107E-1 Series
<The following photo shows WA380-6> <4D107E-1>
<6D107E-1>
3. Rotate the crankshaft forward with tool C1 and
set wide slit (b) on the disc having the revolu-
tion sensor slits at the rear of the crankshaft
pulley to projection top (a) of the front cover.
a Seeing from the air intake manifold side,
set projection top (a) into wide slit (b).
<The following photo shows 4D107E-1>
1) Insert clearance gauge C2 in the clear-

ance between rocker arm (3) and cross-
head (4).
2) Loosen locknut (5) and adjust the valve
clearance with adjustment screw (6).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
k
gauge lightly.
After this positioning, each cylinder is not
3) While fixing adjustment screw (6), tighten
set to the top dead center. Take care. locknut (5).
(Each cylinder is set 76 – 88° before the top 3 Locknut:
dead center.) 20 – 28 Nm {2.04 – 2.86 kgm}
q 4D107E-1: No. 1 cylinder or No. 4 cylinder a After tightening the locknut, check the
q 6D107E-1: No. 1 cylinder or No. 6 cylinder valve clearance again.
4. Adjust the valve clearance according to the fol-

lowing procedure.
a If you cannot move the rocker arms of the
exhaust valves (on the EX side) with the
hand, adjust the valves marked with Q in
the valve arrangement drawing.
a If you can move the rocker arms of the
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
107E-1 Series 7
5. Rotate the crankshaft forward by 1 turn with

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

step 4.
a If the valves marked with Q in the valve
arrangement drawing were adjusted in
step 4, adjust the valves marked with q.
7. After finishing adjustment, remove the adjust-

ing tools and return the removed parts.
k Remove tool C1 without fail.
3 Cylinder head cover mounting nut:
20 – 28 Nm {2.04 – 2.86 kgm}
3 Injector harness nut:
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
8 107E-1 Series
Testing compression pressure 1

a Testing tools for compression pressure 4. Loosen injector terminal nut (4) and remove
the terminal from the injector.
Symbol Part No. Part name
1 795-799-6700 Puller 5. Move the cylinder to be tested to the compres-
sion top dead center.
2 795-502-1590 Gauge assembly
D a See “Adjusting valve clearance”.
3 795-790-4410 Adapter
4 6754-11-3130 Gasket 6. Remove rocker arm assembly (5).
k When measuring the compression pres-

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

a On some machine models, the cylinder
head cover and rocker housing are inte-
grated.
7. Remove retainer (6) and disconnect fuel inlet
2. Disconnect injector harness connectors (2) (at connector (7).
6 places) and move the harnesses.
8. Remove holder (8).
9. Remove injector (9).

a Remove the injector using puller D1 and
the impact of slide hammer.
a Do not unclench the upper part of the
injector.
3. Disconnect fuel high-pressure tube (3).
107E-1 Series 9
15. Disconnect all the injector wiring harness con-

nectors.
k If the connectors are not disconnected,
the engine will start during measure-
ment and that is dangerous. Accord-
ingly, be sure to disconnect them.
k If the crankshaft is rotated without turn-
ing on the controller, the common rail
is damaged. Accordingly, be sure to
check that the controller is turned ON.
k Cover the disconnected connectors
with a vinyl sheet etc. to prevent elec-
tric leakage and grounding fault.
16. Rotate the engine with the starting motor and

10. Install gasket D4 to the tip of adapter D3 and
measure the compression pressure.
connect it to the injector mount.
a Read the pressure gauge pointer when it
is stabilized.
11. Fix adapter D3 with the injector holder.
a Tighten the holder mounting bolts alter-
17. After finishing testing, remove the testing tools
nately.
3 Holder mounting bolt:
and return the removed parts.
a Install the injector and fuel high-pressure
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
tube according to the following procedure.
1) Mate protrusion (a) of the injector with
12. Connect gauge assembly D2 to adaptor D3.
notch (b) of the holder, and set the injector
a Apply a little amount of engine oil to the
to the cylinder head.
connecting parts of the adapter and gauge
a Set the injector with the above mating
so that air will not leak easily.
position toward the fuel inlet connec-
tor insertion side.
13. Install rocker arm assembly (5).
3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
14. Adjust valve clearance.

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

3 to 4 threads.
3) Set fuel inlet connector (7).
a Press it in until you feel the O-ring
clicks in.
4) Install inlet connector (7) with retainer (6)
temporarily.
3 Retainer:
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
5) Alternately tighten injector holder mount-
ing bolt (10).
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
10 107E-1 Series
6) Tighten retainer (6) of the fuel inlet con-

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

pressure tube (3) in order of the head side
and common rail side.
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
18. After installing the rocker arm assembly, adjust

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

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

following torque.
3 Head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
107E-1 Series 11
Testing blowby pressure 1

a Testing tool for blowby pressure

1 799-201-1504 Blowby checker
E
2 795-790-3300 Blowby tool

a The photo below shows 6D107E-1 as an
example.
1. Install adaptor [1] of blowby checker E1 to the

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

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

blowby pressure.
machine.

12 107E-1 Series
Testing engine oil pressure 1

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

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

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

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

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

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

107E-1 Series 13
Handling fuel system parts Releasing remaining pressure in

1 fuel system 1
a Precautions for testing and maintaining fuel a Pressure is generated in the low-pressure cir-
system cuit and high-pressure circuit of the fuel sys-
The common rail fuel injection system (CRI) tem while the engine is running.
consists of more precise parts than the con- Low-pressure circuit:
ventional fuel injection pump and nozzle. If for- Feed pump – Fuel filter – Fuel supply
eign matter enters this system, it can cause a pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Fuel supply pump – Common rail –
take care more than before. If dust, etc. sticks Fuel injector
to any part, wash that part thoroughly with a The pressure in both low-pressure circuit and
clean fuel. high-pressure circuit lowers to a safety level
a Precautions for replacing fuel filter cartridge automatically 30 seconds after the engine is
Be sure to use the Komatsu genuine fuel filter stopped.
cartridge. a Before the fuel circuit is tested and its parts are
Since the common rail fuel injection system removed, the remaining pressure in the fuel
(CRI) consists of more precise parts than the circuit must be released completely. Accord-
conventional fuel injection pump and nozzle, it ingly, observe the following.
employs a high-efficiency special filter to pre- k Before testing the fuel system or removing
vent foreign matter from entering it. If a filter its parts, wait at least 30 seconds after stop-
other than the genuine one is used, the fuel ping the engine until the remaining pres-
system may have a trouble. Accordingly, never sure in the fuel circuit is released. (Do not
use such a filter. start the work just after stopping the engine
since there is remaining pressure.)
14 107E-1 Series
Testing fuel pressure 1

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

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
(10 × 1.0 mm o Rc1/8)
2 Adapter
G 795-790-4430
(10 × 1.0 mm o Rc1/8)
6215-81-9710 O-ring
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
2) Install adapter G2 and nipple [1] of
a See PAGE 18 for procedure of "Testing fuel hydraulic tester G1 and connect it to oil
pressure" of HB205-1M0 and HB215LC- pressure gauge [2].
1M0. a Use an oil pressure gauge of 2.5 MPa
a The test point is subject to machine models. {25 kg/cm2}.
a Test only the fuel pressure in the low-pressure <4D107E-1 (PC160LC-7) as an example>
circuit from the feed pump through the fuel
main filter to the supply pump and in the return
circuit from the supply pump through the com-
mon rail and the injector to the fuel tank.
k Since the pressure in the high-pressure cir-
cuit from the fuel supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Testing fuel low-pressure circuit pressure

1) Remove fuel pressure pickup plug (1)
from the fuel main filter fuel inlet.
<4D107E-1 (PC160-7) as an example>
<6D107E-1 (PC200-8) as an example>
107E-1 Series 15
3) Run the engine at low idle and test the fuel 2) Install adapter [4] of hydraulic tester G1
low-pressure circuit pressure. between return manifold (3) and quick
a If the fuel low-pressure circuit pres- coupler (4) and install hydraulic tester G1
sure is in the following range, it is nor- to the center with nipple [1].
mal. a Adapter [4]: 795-790-5200
0.5 – 1.3 MPa
At Low idle
{5.1 – 13.3 kg/cm2}
0.3 – 1.1 MPa
At cranking
{3.1 – 11.3 kg/cm2}
k When the engine cannot run, you

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

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

may measure while cranking the
engine with the starting motor. Do
4) After finishing testing, remove the testing not crank the engine for more than
tools and return the removed parts. continuous 20 seconds to protect
3 Fuel pressure pickup plug:
it, however.
10 ± 2 Nm {1 ± 0.2 kgm}
4) After finishing measurement, remove the
2. Checking fuel return circuit pressure measuring instruments and return the
(4D107E-1) removed parts.
1) Disconnect quick coupler (4) of the return
hose connected to the fuel filter of fuel
return manifold (3).
16 107E-1 Series
3. Check of fuel return circuit pressure 4. Measuring fuel negative-pressure circuit

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

tester G1 there and connect gauge G3.
a Nipple [3]: 790-301-1181, 07002-11223 2) Connect fuel hose (1) to supply pump (3)
by tool G4 instead of joint bolt (2).
a When installing tool G4, fit the gaskets to
both sides of the fuel hose joint.
3 Tool G4:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool G5 to tool G4.
3) Run the engine at low idle and test the fuel

return circuit pressure.
a If the fuel return circuit pressure is in
the following range, it is normal.
At Low idle Max. 0.02 MPa
4) Run the engine and measure the circuit
negative pressure at high idle.
k When the engine cannot run, you Circuit standard negative pressure:
may test it by cranking the engine Max. –50.7 kPa {–380 mmHg}
with the starting motor. To protect 5) If the negative pressure is higher than the
the starting motor, do not continu- standard pressure, the fuel prefilter may
ously crank the engine 20 seconds be clogged. In this case, replace the fuel
or more. prefilter and measure again.
4) After finishing testing, remove the testing measuring instruments and return the
tools and return the removed parts. removed parts.
3 Fuel pressure pickup plug: 3 Joint bolt (2):
24 ± 4 Nm {2.4 ± 0.4 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
107E-1 Series 17
a Procedure of "Testing fuel pressure" of a Use oil pressure gauge of 2.5 MPa
HB205-1M0 and HB215LC-1M0 is shown {25 kg/cm2}.
below.
a Testing tools for fuel pressure

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 × 1.0 mm o Rc1/8)
G
6215-81-9710 O-ring
5 799-201-2202 Boost gauge kit
6 795-790-5110 Screw
7 799-401-2320 Gauge
3) Start the engine and test the pressure in
the fuel low-pressure circuit with the auto-
k Place the machine on a level ground and deceleration OFF and the engine at low
lower the work equipment to the ground. idle.
a Test only the fuel pressure in the low-pressure a The pressure in the fuel low-pressure
circuit from the feed pump through the fuel circuit is normal when it is within the
main filter to the supply pump and the return following standard range.
circuit from the supply pump/common rail/
injector to fuel tank. At Low idle 0.5 to 1.3 MPa
k Testing of the high-pressure circuit con- (1,050 rpm) {5.1 to 13.3 kg/cm2}
necting the supply pump, the common rail 0.3 to 1.1 MPa
At cranking
and the injector can not be performed due {3.1 to 11.3 kg/cm2}
to the extremely high pressure generated
there. k If the engine cannot be started, you
may perform the measurement
1. Check of pressure in fuel low-pressure cir- while rotating the engine by the
cuit starting motor. However, do not
1) Open the side cover on the right side of crank the engine continuously for
the machine and remove fuel pressure more than 20 seconds for protec-
pickup plug (on the fuel inlet side) (1) from tion of the starting motor.
the fuel main filter head.
4) After finishing the test, remove the testing

2) Install adapter G2 and nipple [1] of tools and restore the machine.
hydraulic tester G1, and connect them to 3 Fuel pressure pickup plug:
oil pressure gauge [2]. 10 ± 2 Nm {1 ± 0.2 kgm}
18 107E-1 Series
2. Testing pressure in fuel return circuit 3) Start the engine and test the pressure in
1) Remove joint bolt (2) of the fuel return the fuel return circuit at low idle.
hose. a If the pressure in the fuel return circuit
is in the following range, it is normal.
At Low idle Max. 0.02 MPa
a If the engine cannot be started, you

may perform the measurement while
rotating the engine by the starting
motor. However, do not crank the
engine continuously for more than 20
seconds for protection of the starting
motor.
tools and restore the machine.
2) Install screw G6, and nipple [1] and hose 3 Joint bolt (2):
[2] of hydraulic tester G1 instead of joint 24 ± 4 Nm {2.45 ± 0.41 kgm}

bolt (2), and connect them to gauge G7.
a When installing screw G6, be sure to 3. Measuring fuel negative-pressure circuit
install the seal washer. pressure
3 Screw G6: 1) Open the engine hood and remove joint
24 ± 4 Nm {2.45 ± 0.41 kgm} bolt (2) of fuel hose (1) between the prefil-
a The nipple and hose of digital hydrau- ter and supply pump from supply pump
lic tester G1 can also be used. (3).
2) Using tool G6 instead of joint bolt (2), con-

nect fuel hose (1) to supply pump (3).
a When installing tool G6, place the
gaskets to both sides of eyejoint on
the fuel hose.
3 Tool G6:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
107E-1 Series 19
3) Connect tool G6 to tool G5.
4) Start the engine and test the circuit nega-

tive pressure at high idle.
Circuit standard negative pressure:
Min. -50.7 kPa {-380 mmHg}
5) If the negative pressure is higher than the
criteria, the fuel prefilter may be clogged.
In this case, replace the fuel prefilter and
measure the pressure again.
6) After finishing test, remove the testing
instruments and return the removed parts.
3 Joint bolt (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
20 107E-1 Series
Reduced cylinder mode operation No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced a Perform the no-injection cranking mode opera-
cylinder mode operation, if the engine speed tion with the engine mounted on the machine
and output do not change from the normal or connected to INSITE (troubleshooting kit).
operation (all-cylinder operation), that cylinder Before performing, see Testing method in the
has 1 or more defects. shop manual for the machine or INSITE (trou-
The possible defects are as follows. bleshooting kit).
q Leakage through cylinder head gasket
q Defective injection
q Defective piston or piston ring
q Defective valve mechanism
(Moving valve system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (trouble-
shooting kit).
Before performing, see Testing method in
the shop manual for the machine or
INSITE (troubleshooting kit).
107E-1 Series 21
Testing fuel delivery, return and leak amount 1

a Testing tools for fuel delivery, return and leak
amount.

1 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
H Commercially
5 Stopwatch
available
Commercially Hose
6
available (Inside diameter: 14 mm)
Commercially Hose
7 3) Crank the engine for 30 seconds and
available (Inside diameter: 8 mm)
measure the delivery with measuring cyl-
inder H4.
a See PAGE 29 for procedure of "Testing fuel a Adjust the route of the test hose so
discharge, return and leakage" of HB205- that it will not slacken and put its end
1M0 and HB215LC-1M0. in an oil container.
a Prepare a container of 20 l for fuel leakage a Do not crank the engine for more than
during testing. 30 seconds to protect the starting
motor in any case other than this
1. Measuring supply pump delivery measurement.
(4D107E-1) a If the supply pump delivery is in the
1) Loosen clamp (2) of discharge tube (1) of following standard range, it is normal.
the supply pump and disconnect tube (1).
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)
2) Install test hose H6 to the nipple on the

discharge side of the supply pump.
a Fix the hose with a wire etc.
a Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.
measuring instruments and return the
removed parts.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
24 ± 4 Nm {2.5 ± 0.4 kgm}
22 107E-1 Series
2. Measuring supply pump return rate

(4D107E-1)
hose of supply pump (1).

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

sure the returning fuel with measuring cyl-
inder H4 for 25 seconds.
a If the leakage from the supply pump
is in the following standard range, it is
normal.
At low idle
Max. 400 cc
(750 rpm)
107E-1 Series 23
2) Install connector H3 and cap nut [1] of tes- 4. Measuring injector return rate (4D107E-1)
ter kit H1 to the return hose to stop the fuel a The injector return rate must be measured
from flowing out. with the pressure limiter return hose con-
3) Connect test hose [2] of tester kit H1 to nected. Accordingly, check that no fuel
the common rail side. leaks from the pressure limiter in advance.
a Adjust the route of the test hose so 1) Referring to "Measuring supply pump
that it will not slacken and put its end return rate", set the supply pump under
in an oil container. the condition for measurement.
a While the injector return rate is mea-
sured, the fuel flows out of the supply
pump. Accordingly, put the test hose
end on the supply pump in an oil con-
tainer.
2) Disconnect return hose (6) from the mani-
fold.
a Fit the seal washer to the return hose.

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

removed parts.
24 107E-1 Series
5) Run the engine at low idle and measure 5. Measuring supply pump delivery
the return rate from the injector in 1 minute (6D107E-1)
with measuring cylinder H4. 1) Loosen clamp (2) of discharge tube (1) of
a If the return rate from the injector is in the supply pump and disconnect tube (1).
At Low idle Max. 120 cc
At cranking Max. 90 cc
a The fuel returning from the supply

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

measuring tools and return the removed
parts.
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Crank the engine for 30 seconds and
measure the delivery with measuring cyl-
inder H4.
a Do not crank the engine for more than
30 seconds to protect the starting
motor in any case other than this
measurement.
a If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)
107E-1 Series 25
2) Install connector H3 and cap nut [1] of tes-

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

removed parts.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
6. Testing supply pump return rate (6D107E-1) 4) Run the engine at low idle and measure
1) Disconnect return hose (1) of the supply the return rate from the supply pump with
pump. measuring cylinder H4 25 sec or more.
a If the return rate from the supply
pump is in the following range, it is
normal.
At Low idle 400 cc

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

26 107E-1 Series
7. Measuring leakage from pressure limiter

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

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

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

and connect test hose [2] of tester kit H1
and put its end in an oil container.
3) Install removed connector bolt (5) and cap
nut [1] of tester kit H1 to the return hose to
4) Run the engine at low idle and measure
prevent fuel leakage.
the leakage in 1 minute with measuring
4) Run the engine at low idle and test the
cylinder H4.
return rate from the injector with measur-
a If the leakage from the pressure lim-
ing cylinder H4 1 min or more.
iter is in the following range, it is nor-
a If the return rate from the injector is in
mal.
0 cc
At Low idle At Low idle Max. 180 cc/min.
(No leakage)
At cranking Max. 90 cc/min.
107E-1 Series 27

or more.

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
28 107E-1 Series
a Procedure of "Testing fuel discharge, 2) Remove clamp (2) and then disconnect
return and leakage" of HB205-1M0 and connector (3).
HB215LC-1M0 is shown below.
a Testing tools for fuel discharge, return and
leakage.

1 795-790-4700 Tester kit
6754-71-5340 Connector
2
6754-71-5350 Washer
3 6164-81-5790 Joint
4 6745-71-1130 Seal washer
H 5 07206-30812 Joint bolt
Commercially
6 Stopwatch 3) Remove fuel spray prevention caps (4) (2
available
places).
Commercially
7 Measuring cylinder 4) Remove clamps (5) (2 places), and
available
remove high-pressure pipe (6).
Commercially
8 Hose
available
a Since fuel flows out during the test, prepare a

container of approximately 20 l.
k Place the machine on a level ground and
lower the work equipment to the ground.
1. Testing supply pump discharge

1) Open the engine hood and remove cover
(1) on the top of the counterweight.
5) Install test hose H8 to the nipple on the

discharge side of the supply pump.
a Fix the hose using a band to prevent
the hose from coming off.
a Arrange the route of the test hose so
that it does not sag and put its end in
a container.
107E-1 Series 29
6) Crank the engine for 20 seconds and a Adjust the route of the test hose so
measure the delivery by using measuring that it does not slacken and put its
cylinder H7. end in an container.
a In order to protect the starter motor, it
is prohibited to continue cranking for
more than 20 seconds for any other
purpose than this measurement.
a If the supply pump delivery is in the
following standard range, it is proper.
(For 30 seconds conversion)
Engine speed Discharge [Q]
125 rpm Max. 75 cc
150 rpm Max. 90 cc
a Discharge [Q]:
Q = Engine speed × 0.6
4) Start the engine, measure the leak from
the pressure limiter by using the measur-
ing cylinder H7 for 1 minute while running
the engine at low idle.
a Leakage from the pressure limiter is
normal when it is within the following
standard value range.
At Low idle 0 cc (No leakage)

3 Tube sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
2. Testing leakage from pressure limiter

1) Disconnect quick coupler (7) of the pres-
sure limiter spill hose.

2) Install connector H3 and cap nut [1] of tes-

ter kit H1 to the spill hose side to stop the
fuel from flowing out.
3) Connect test hose [2] of tester kit H1 to
the common rail side.
30 107E-1 Series
3. Testing fuel return rate from injector k If the engine cannot be started, you
a The fuel return rate from the injector must may check the machine while rotat-
be measured with the pressure limiter spill ing the engine with the starting
hose connected. Accordingly, check that motor. Do not rotate for more than
no fuel leaks from the pressure limiter in tw enty seconds cont inuously,
advance. however, for protection of the start-
1) After removing clamp (1), remove joint bolt ing motor.
(check valve) (9) and disconnect spill hose
(10).

2) Install cap nut [1] of tester kit H1 to spill 3 Joint bolt (check valve) (9):
hose (10) to prevent outflow of fuel. 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
a When installing cap nut [1], be sure to
install seal washer H5.
3) Install joint H4 to the cylinder head side
with joint bolt H6.
a When installing joint H4, be sure to
3 Joint bolt H6:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install joint H4 to hose H9.
5) Start the engine and run it at low idle, and

measure the fuel return rate from the
injector for 1 minute by using measuring
cylinder H7.
a If the return rate from the injector is in
the following range, it is proper.
At low idle Max. 120 cc
At cranking Max. 90 cc
107E-1 Series 31
4. Testing supply pump return rate 5) Start the engine and run it at low idle, and
a Subtract the pressure limiter leakage and measure the return rate in 25 seconds by
injector return rate from overall return rate using measuring cylinder H7.
to measure the supply pump return rate. a Supply pump return rate = (Overall
Therefore, check that the leakage from the return rate) - (pressure limiter leak-
pressure limiter and return rate from the age) - (injector return rate)
injector are normal, and then perform the a When the return rate from the supply
measurement. pump is in the following range, it is
a Since fuel may flow back when discon- normal.
necting fuel return hose (12), drain the fuel
At low idle
from the fuel tank to the lower level than Max. 400 cc
(750 rpm)
the supply pump installation position.
1) Move rubber cover (11), and disconnect
fuel return hose (12).

2) Install cap nut [1] of tester kit H1 to fuel
return hose (12) side to prevent the fuel
from flowing out.
a When installing cap nut [1], be sure to
3) Install joint H3 to the supply pump side
with joint bolt H5.
a When installing joint H3 and joint bolt
H5, be sure to install seal washer H4.
3 Joint bolt H5:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4) Install joint H3 to hose H8.
32 107E-1 Series
Bleeding air from fuel circuit 1

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

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

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

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, air may not be
bled from the low-pressure circuit. In this
case, repeat the above work.
107E-1 Series 33
Testing fuel system for leakage 1

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

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

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

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

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

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

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
34 107E-1 Series
Handling controller high-voltage Replacing the fan belt 1

circuit 1 a The auto-tensioner is provided for the fan belt.
1. Disconnection or connection of the connector Thus, testing and adjustment of the belt is usu-
between the engine controller and engine must ally no necessary.
be done after turning off the starting switch. a Disconnect air conditioner compressor belt
before replacing the fan belt.
2. It is prohibited to start the engine when T-
adapter is inserted or connected, for trouble- 1. Insert a wrench (a) to the portion (A) (width
shooting purpose, to the connector between across flats T 12.7 mm) of the tensioner
the engine controller and engine. assembly (2), and rotate it to the opposite to
a You may turn the starting switch to the the winding-up direction to decrease the fan
OFF or ON position but must not turn it to belt (3) tension.
the START position. k Make sure that the wrench (a) is
secured at the portion (A) before rotat-
ing it. (The spring of the tensioner
assembly (2) is strong. If the wrench (a)
is loosely inserted, the wrench may
accidentally come off while being
rotated and it is extremely dangerous.)
k After removing the fan belt (3), return
the wrench (a) of the tensioner assem-
bly (2) slowly with care.
k Be careful not to get your fingers
caught between the pulley and fan belt
(3) during work.
2. Replace the fan belt (3).

q Check each pulley for breakage and crack.
107E-1 Series 35
SEN00250-09
© 2012 KOMATSU
All Rights Reserved
36
SEN00252-04
Engine 1SHOP MANUAL
107E-1 Series
40 Troubleshooting 1
General information on troubleshooting
Points on troubleshooting ............................................................................................................................... 2
Error and failure code table............................................................................................................................. 3
Troubleshooting method for open circuit in wiring harness of pressure sensor system.................................. 5
Information in troubleshooting table ................................................................................................................ 7
Connection table for connector pin numbers .................................................................................................. 9
T- branch box and T- branch adapter table ................................................................................................... 45
107E-1 Series 1
SEN00252-04 40 Troubleshooting
Points on troubleshooting 1
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. Do not rush at disassembling the machine even if a failure occurs.

Otherwise,
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose
the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is nec-
essary to carry out thorough prior investigation and to carry out troubleshooting in accordance with
the fixed procedure.
2. Questions to users and operators
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Inspections before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirmation of failure
Confirm the degree of failure on your own to verify if it is a real failure and the machine is handled or
operated improperly.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Pinpoint high possibility causes according to the results of examinations and inspections of items 2 to 4,
and find the failure location based on the troubleshooting table or troubleshooting flow (chart).
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Radical countermeasures against failure cause
Even if the immediate problem is removed, a similar failure will reoccur unless its root cause is removed.
To prevent reoccurence, examine the reason of the failure cause occurrence and remove the root
cause.
2 107E-1 Series
Error and failure code table 1

q Engine controller
Failure code of
Error code of Reference
applicable Trouble
INSITE document No.
machine
111 CA111 Abnormality in engine controller
115 CA115 Abnormality in engine NE and Bkup speed sensors
122 CA122 Charge pressure sensor high error
123 CA123 Charge pressure sensor low error
131 CA131 Throttle sensor power supply high error
132 CA132 Throttle sensor power supply low error
144 CA144 Coolant temperature sensor high error
145 CA145 Coolant temperature sensor low error
153 CA153 Charge temperature sensor high error
154 CA154 Charge temperature sensor low error
155 CA155 Derating of speed by charge temperature high error
187 CA187 Sensor power supply 2 low error
221 CA221 Atompspheric pressure sensor high error
222 CA222 Atompspheric pressure sensor low error
227 CA227 Sensor power supply 2 high error
234 CA234 Engine overspeed Troubleshooting of
electrical system
238 CA238 Abnormallity in Ne speed sensor power supply
(E-mode), Part 1
271 CA271 Short circuit in IMV/PCV1 SEN00254
272 CA272 Disconnection in IMV/PCV1
322 CA322 Disconnection, short circuit in injector No. 1
342 CA342 Calibration error in engine controller data
351 CA351 Abnormality in injector drive circuit
352 CA352 Sensor power supply 1 low error
386 CA386 Sensor power supply 1 high error
428 CA428 Water-in-fuel sensor high error
429 CA429 Water-in-fuel sensor low error
431 CA431 Abnormality in idle validation switch
432 CA432 Abnormality in idle validation processing
435 CA435 Abnormality in engine oil pressure switch
441 CA441 Abnormally low power supply voltage
442 CA442 Abnormally high power supply voltage
449 CA449 Common rail pressure high error 2 Troubleshooting of
electrical system
451 CA451 Common rail pressure sensor high error
(E-mode), Part 2
452 CA452 Common rail pressure sensor low error SEN00255
488 CA488 Derating of torque by charge temperature high error
553 CA553 Common rail pressure high error 1
559 CA559 No-pressure feed 1 by supply pump
107E-1 Series 3
Failure code of
Error code of Reference
applicable Trouble
INSITE document No.
machine
689 CA689 Abnormality in engine Ne speed sensor
731 CA731 Abnormality in engine Bkup speed sensor phase
757 CA757 Loss of all data in engine controller
778 CA778 Abnormality in engine Bkup speed sensor
1633 CA1633 Abnormality in KOMNET
2185 CA2185 Throttle sensor power supply high error
Troubleshooting of
2186 CA2186 Throttle sensor power supply low error electrical system
2249 CA2249 No-pressure feed 2 by supply pump (E-mode), Part 2
SEN00255
2311 CA2311 Abnormality in IMV solenoid
2555 CA2555 Disconnection in intake air heater relay
2556 CA2556 Short circuit in intake air heater relay
— B@BAZG Derating of speed by engine oil pressure reduction
— B@BAZK Engine oil level low
— B@BCNS Engine overheat
a Error code of INSITE:

3- or 4-digit error code displayed on INSITE when a failure occurrence condition is confirmed using
INSITE of Cummins. inc.
a Failure code of applicable machine:
5- or 6-digit failure code displayed on the machine monitor when a failure occurrence condition is con-
firmed using the machine monitor at the applicable machine side.
q Genrator controller only

Machine failure
Failure phenomenon Reference document No.
code
A8 Rated Speed Adjustment Volume (Isochronous) High Error
A9 Rated Speed Adjustment Volume (Isochronous) Low Error
AA Rated Speed Adjustment Volume (Droop) High Error
AB Rated Speed Adjustment Volume (Droop) Low Error
AF Abnormality in KOMNET (CR710 error recognition)
b6 Droop Rate Adjustment Volume High Error Troubleshooting of
b7 Droop Rate Adjustment Volume Low Error electrical system
(E-mode), Part 2
b8 Low Idle Speed Adjustment Volume High Error
SEN00255
b9 Low Idle Speed Adjustment Volume Low Error
bc Rated Speed Median Adjustment Volume High Error
bd Rated Speed Median Adjustment Volume Low Error
bE Ramp Time Adjustment Volume High Error
bF Ramp Time Adjustment Volume Low Error
4 107E-1 Series
Troubleshooting method for open circuit in wiring harness of pressure

sensor system 1
a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
107E-1 Series 5
List of pressure sensor measuring locations and reference values

Measuring location at sen-
Sensor Measured internal resis- Remarks
sor pin
tance of sensor (reference)
Charge pressure sen- R2: between (2) and (4) Approx. 100 z Sensor is common to engine models
sor R1: between (1) and (4) Approx. 200 z 107 and 114
Sensor is common to engine models
R2: Between (3) and (1) Approx. 23 kz
Common rail pressure 107 and 114
sensor R1: Between (1) (+) and If polarities are inverted, resistance is
Approx. 10 Mz
(2) (-) infinite
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)
6 107E-1 Series
Information in troubleshooting table 1

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

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

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

• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other
Possible abnormally.
causes and Possible causes of trouble
standard value (Given numbers are refer-
in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
3 bleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female“,
disconnect connector and insert T-adapters in both
male side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
107E-1 Series 7
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
8 107E-1 Series
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
107E-1 Series 9
10 107E-1 Series
107E-1 Series 11
12 107E-1 Series
107E-1 Series 13
14 107E-1 Series
107E-1 Series 15
16 107E-1 Series
107E-1 Series 17
18 107E-1 Series
107E-1 Series 19
20 107E-1 Series
107E-1 Series 21
22 107E-1 Series
107E-1 Series 23
24 107E-1 Series
107E-1 Series 25
26 107E-1 Series
107E-1 Series 27
28 107E-1 Series
107E-1 Series 29
30 107E-1 Series
107E-1 Series 31
32 107E-1 Series
107E-1 Series 33
34 107E-1 Series
107E-1 Series 35
36 107E-1 Series
107E-1 Series 37
38 107E-1 Series
107E-1 Series 39
40 107E-1 Series
107E-1 Series 41
42 107E-1 Series
107E-1 Series 43
44 107E-1 Series
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
107E-1 Series 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
46 107E-1 Series
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
107E-1 Series 47
© 2010KOMATSU
All Rights Reserved
48
SEN00254-04
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3
E-1 Code [111/CA111] Abnormality in engine controller....................................................................... 3
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor................................................ 3
E-3 Code [122/CA122] Charge pressure sensor high error ................................................................. 4
E-4 Code [123/CA123] Charge pressure sensor low error .................................................................. 6
E-5 Code [131/CA131] Throttle sensor power supply high error ......................................................... 8
E-6 Code [132/CA132] Throttle sensor power supply low error ......................................................... 10
E-7 Code [144/CA144] Coolant temperature sensor high error ......................................................... 12
E-8 Code [145/CA145] Coolant temperature sensor low error .......................................................... 14
E-9 Code [153/CA153] Charge temperature sensor high error.......................................................... 16
E-10 Code [154/CA154] Charge temperature sensor low error ......................................................... 18
E-11 Code [155/CA155] Derating of speed by charge temperature high error .................................. 20
E-12 Code [187/CA187] Sensor power supply 2 low error ................................................................ 22
E-13 Code [221/CA221] Atompspheric pressure sensor high error ................................................... 24
107E-1 Series 1
E-14 Code [222/CA222] Atompspheric pressure sensor low error .................................................... 26

E-15 Code [227/CA227] Sensor power supply 2 high error ............................................................... 28
E-16 Code [234/CA234] Engine overspeed ....................................................................................... 28
E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply .......................................... 29
E-18 Code [271/CA271] Short circuit in IMV/PCV1............................................................................ 30
E-19 Code [272/CA272] Disconnection in IMV/PCV1 ........................................................................ 32
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 ............................................... 34
E-26 Code [342/CA342] Calibration error in engine controller data ................................................... 46
E-27 Code [351/CA351] Abnormality in injector drive circuit.............................................................. 47
E-28 Code [352/CA352] Sensor power supply 1 low error................................................................. 48
E-29 Code [386/CA386] Sensor power supply 1 high error ............................................................... 50
E-30 Code [428/CA428] Water-in-fuel sensor high error.................................................................... 52
E-31 Code [429/CA429] Water-in-fuel sensor low error ..................................................................... 54
E-32 Code [431/CA431] Abnormality in idle validation switch............................................................ 56
E-33 Code [432/CA432] Abnormality in idle validation processing .................................................... 58
2 107E-1 Series
Troubleshooting of electrical system (E-mode), Part 1 1

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

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

causes and 1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
standard value
in normal state 2 Perform troubleshooting for failure code [CA441].
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor 1

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

Connectors of Ne speed sensor and Bkup speed sensor may be
Defective connection of sen-
1 connected defectively (or to wrong connection). Check them
sor connector
Possible directly.
causes and Defective Ne speed sensor Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure
2
standard value system code [CA689].
in normal state Defective Bkup speed sen-
3 Perform troubleshooting for failure code [CA778].
sor system
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is internal failure, troubleshooting cannot be performed.)
107E-1 Series 3
E-3 Code [122/CA122] Charge pressure sensor high error 1

Trouble Charge pressure sensor high error
122 CA122
Contents of
• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of
• Fixes charge pressure and continues operation.
controller
Problem that
appears • Engine output drops.
on machine
• Method of reproducing failure code: Starting switch ON.
Related
• If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in normal
information
condition.

Connecting parts among boost pressure sensor, temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
1
connector • Loose connector, broken lock, broken seal
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
Defective sensor power sup- If failure code [CA227] is indicated simultaneously, perform trouble-
2
ply 2 circuit shooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT.
3. Turn starting switch to ON position.
Defective boost pressure & If failure code changes from [CA122] to [CA123] ,boost pressure
3 sensor is defective.
Possible temperature sensor
a Failure code [CA153] for temperature sensor is displayed at the
causes and same time.
standard value Ignore this failure code since it appears because of disconnec-
in normal state tion of sensor.
2. Disconnect connectors ECM and BOOST PRESS & IMT, and
Short circuit in wiring har- connect T-adapter to female side of ECM.
4
ness
Resis- Min.
Between ECM (female) (37) and (44)
tance 100 kz
2. Disconnect connector BOOST PRESS & IMT, and connect T-
Hot short circuit in wiring adapter to connector ECM.
5 harness 3. Turn starting switch to ON position (with connector BOOST
(contact with 24 V circuit) PRESS & IMT disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
4 107E-1 Series
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
107E-1 Series 5
E-4 Code [123/CA123] Charge pressure sensor low error 1

Trouble Charge pressure sensor low error
123 CA123
Contents of
• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of
• Fixes charge pressure and continues operation.
controller
Problem that
on machine
• Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
Related
checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
information
adapter).
• If sensor connector is disconnected, this failure code is displayed.

Connecting parts among boost pressure sensor, temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
1
Defective sensor power If failure code [CA187] or [CA227] is indicated simultaneously, per-
2
supply 2 circuit form troubleshooting for it first.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS,
BOOST PRESS & IMT and ECM.
Short circuit in wiring har- 3. Connect T-adapter to female side of ECM.
3
ness Resis- Min.
tance 100 kz
Possible Resis- Min.
causes and Between ECM (female) (44) and (47)
tance 100 kz
standard value
in normal state 1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors ECM and BOOST PRESS & IMT, and
4 ness connect T-adapter to female side of ECM.
(contact with ground circuit) Resis- Min.
Between ECM (female) (44) and ground
tance 100 kz
Open circuit in wiring har- If no failure is found by above checks, there may be open circuit in
5
ness wiring harness. (*)
a If no failure is found by checks on 1 - 5 and check result of cause
6 is abnormal, sensor is defective.
Defective boost pressure & 1. Turn starting switch to OFF position.
temperature sensor 2. Insert T-adapter to connector ECM.
6
(improper input voltage to 3. Turn starting switch to ON position.
engine controller)
Sensor
Between ECM (44) and (47) Voltage 0.3 - 4.7 V
output
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related
information of troubleshooting".
6 107E-1 Series
107E-1 Series 7
E-5 Code [131/CA131] Throttle sensor power supply high error 1

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

Connecting parts among fuel control dial, engine unit wiring harness, and
engine controller are suspected. Inspect them directly.
Defective wiring har-
1 • Loose connector, broken lock, broken seal
ness connector
Defective throttle
If failure code [CA2185] is indicated simultaneously, perform troubleshoot-
2 sensor power supply
ing for it first.
system
2. Disconnect connector P20 and connect T-adapter to male side.
Defective fuel control Between P20 (male) (1) and (3) Resistance 4.0 - 6.0 kz
3
dial (throttle sensor)
Between P20 (male) (2) and (3) Resistance 0.25 - 5.0 kz
Between P20 (male) (1) and (2) Resistance 0.25 - 5.0 kz
Open or short circuit 2. Disconnect connector CE02, and connect T-adapter to female side.
4
in wiring harness Between CE02 (famale) (22) and (23) Resistance 4.0 - 6.0 kz
Possible
causes and Between CE02 (famale) (9) and (23) Resistance 0.25 - 5.0 kz
standard value a If no failure is found by checks on cause 4, this check is not required.
Short circuit in wiring 2. Disconnect connectors CE02 and P20, and connect T-adapter to female
5 side of either connector.
harness
Between CE02 (female) (9) and (22), or
Resistance Min. 1 Mz
between P20 (female) (1) and (2)
Hot short in wiring 2. Disconnect connector P20, and connect T-adapter to female side.
6 harness(contact with 3. Turn starting switch to ON position.
24 V circuit)
Between P20 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
• Reference
Defective engine con- 2. Insert T-adapter into connector CE02.
7
troller 3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply Voltage 4.75 – 5.25V
Between CE02 (9) and (23) Sensor output Voltage 0.5 – 4.5 V
* The terminal names and pin numbers are shown as examples of PC200-8.
8 107E-1 Series
Circuit diagram related to throttle sensor (PC200-8 as an example)
107E-1 Series 9
E-6 Code [132/CA132] Throttle sensor power supply low error 1

Trouble Throttle sensor power supply low error
132 CA132
Contents of
• Low voltage is detected in fuel control dial signal circuit.
trouble
Action of
• Depends on machine model.
controller
Problem that
appears • Depends on machine model.
on machine
Related
information
Connecting parts among fuel control dial, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
Defective wiring harness
connector
Defective throttle sensor If failure code [CA2186] is indicated simultaneously, perform trouble-
2
power supply system shooting for it first.
2. Disconnect connector P20 and connect T-adapter to male side.
Defective fuel control dial
3 Between P20 (male) (1) and (3) Resis- 4.0 - 6.0 kz
(throttle sensor)
Between P20 (male) (2) and (3) Resis- 0.25 - 5.0 kz
Between P20 (male) (1) and (2) Resis- 0.25 - 5.0 kz
Open or short circuit in 2. Disconnect connector CE02, and connect T-adapter to female side.
4
wiring harness Between CE02 (famale) (22) and (23) Resis- 4.0 - 6.0 kz
Possible Between CE02 (famale) (9) and (23) Resis- 0.25 - 5.0 kz
causes and a If no failure is found by checks on cause 4, this check is not required.
standard value 1. Turn starting switch to OFF position.
in normal state 2. Disconnect connectors CE02 and P20, and connect T-adapter to
Open circuit in wiring har- each female side.
ness Between CE02 (female) (22) and P20 Resis-
5 Max. 1 z
(wire breakage or defec- (female) (1) tance
tive contact of connector) Between CE02 (female) (9) and P20 Resis-
Max. 1 z
(female) (2) tance
Between CE02 (female) (23) and P20 Resis-
Max. 1 z
(female) (3) tance
a If no failure is found by checks on cause 4, this check is not required.
Short circuit in wiring har- 2. Disconnect connectors CE02 and P20, and connect T-adapter to
6 female side of either connector.
ness
Between CE02 (female) (9) and (23), or Resis-
Min. 1 Mz
between P20 (female) (2) and (3) tance
Ground fault of wiring 2. Disconnect connectors CE02 and P20, and connect T-adapter to
harness female side of either connector.
7
(contact with ground cir-
cuit) Between CE02 (female) (9) or P20 (female) Resis-
Min. 1 Mz
(2) and ground tance
10 107E-1 Series

• Reference
Possible 1. Turn starting switch to OFF position.
causes and 2. Insert T-adapter into connector CE02.
standard value 8 Defective engine control- 3. Turn starting switch to ON position.
in normal state ler 4. Operate fuel control dial and perform troubleshooting.
Power sup-
Between CE02 (22) and (23) Voltage 4.75 – 5.25V
ply
Sensor
Between CE02 (9) and (23) Voltage 0.5 – 4.5 V
output
Circuit diagram related to throttle sensor (PC200-8 as an example)
107E-1 Series 11
E-7 Code [144/CA144] Coolant temperature sensor high error 1

Trouble Coolant temperature sensor high error
144 CA144
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that
• Engine does not start easily at low temperature.
appears
• Overheat prevention function does not function.
on machine
• This failure code is displayed if temperature sensor connector is disconnected.
Related
• Since troubleshooting "socket" for this sensor features the female connector alone, it is not connect-
information
able to wiring harness side female connector and thus not usable for checking open circuit (not
designed as a T-adapter).

Connecting parts among coolant temperature, engine wiring harness,
connector
2. Disconnect connector COOLANT TEMP, and connect socket to
male side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with
coolant temperature above 0 °C, regard coolant temperature sen-
sor as normal.
Resis-
0 °C 30 - 37 kz
tance
Defective coolant tempera-
Possible 2 Between COOL- Resis-
ture sensor 25 °C 9.3 - 10.7 kz
causes and ANT TEMP (male) tance
standard value (A) and (B)
Resis-
in normal state a Coolant temper- 50 °C 3.2 - 3.8 kz
tance
ature- Resis-
tance Resis-
80 °C 1.0 - 1.3 kz
characteristics tance
Resis-
95 °C 700 – 800 z
tance
2. Disconnect connector ECM and connect T-adapter to female side.
Open or short circuit in wir- Between ECM (female) (15) and (38)
3 (Coolant temperature: Min. 0°C)
ing harness Resis-
a Use "Coolant temperature-Resis- 700 z – 37 kz
tance
tance characteristics" table shown
above as resistance criteria.
12 107E-1 Series
Circuit diagram related to coolant temperature sensor
107E-1 Series 13
E-8 Code [145/CA145] Coolant temperature sensor low error 1

Trouble Coolant temperature sensor low error
145 CA145
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that
• Engine does not start easily at low temperature.
appears
• Overheat prevention function does not function.
on machine
Related
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
information
[CA144] for "High Error" is displayed.

Connecting parts among coolant temperature, engine wiring harness, and
Defective wiring har-
ness connector
2. Disconnect connector COOLANT TEMP, and connect socket to male
side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with
coolant temperature above 0 °C, regard coolant temperature sensor as
normal.
Between COOLANT 0 °C Resistance 30 – 37 kz
Defective coolant TEMP (male) (A) and 25 °C Resistance 9.3 – 10.7 kz
2
temperature sensor (B)
50 °C Resistance 3.2 – 3.8 kz
a Coolant tempera-
ture- Resistance 80 °C Resistance 1.0 – 1.3 kz
Possible
causes and
characteristics 95 °C Resistance 700 – 800 z
standard value Whole
in normal state Between (B) and coolant
Resistance Min. 100 kz
ground tempera-
ture range
Short circuit in wiring Between ECM (female) (15) and (38) (Coolant
3 temperature: Min. 0 °C)
harness Resis-
a Use "Coolant temperature-Resistance 700 z – 37 kz
tance
characteristics" table shown above as re-
sistance criteria.
Ground fault in wiring 2. Disconnect connectors ECM and COOLANT TEMP, and connect T-
harness adapter to female side of ECM.
4
(contact with ground
circuit) Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
Defective engine con- If no failure is found by above checks, engine controller is defective.
5
troller (Since this is internal failure, troubleshooting cannot be performed.)
14 107E-1 Series
Circuit diagram related to coolant temperature sensor
107E-1 Series 15
E-9 Code [153/CA153] Charge temperature sensor high error 1

Trouble Charge temperature sensor high error
153 CA153
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature
trouble sensor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke is white since auto preheat does not operate at low temperature.
appears
• Boost temperature-based engine protection function does not function.
on machine
• Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable
Related
to wiring harness side female connector and thus not usable for checking open circuit (not designed
information
as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.

Connecting parts among boost pressure sensor, temperature sensor,
engine wiring harness, and engine controller are suspected. Inspect
Defective wiring harness them directly.
1
2. Disconnect connector BOOST PRESS & IMT, and connect socket
to male side.
-40 °C Resistance 41 – 48 kz
Between BOOST -20 °C Resistance 14 – 16 kz
Possible Defective boost tempera-
2 PRESS & IMT
causes and ture sensor 0 °C Resistance 5.4 – 6.1 kz
(male) (3) and (4)
standard value
a Boost tempera- 30 °C Resistance 1.6 – 1.8 kz
in normal state
ture -Resis- 60 °C Resistance 560 – 600 z
tance
chariacteristic 90 °C Resistance 230 – 250 z
130 °C Resistance 80 – 90 z
Open or short circuit in wir- Between ECM (female) (23) and (47)
3
ing harness a Use "boost temperature-Resistance Resis-
80 z – 48 kz
characteristics" table shown above as tance
resistance criteria.
16 107E-1 Series
107E-1 Series 17
E-10 Code [154/CA154] Charge temperature sensor low error 1

Trouble Charge temperature sensor low error
154 CA154
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke is white since auto preheat does not operate at low temperature.
appears
• Boost temperature-based engine protection function does not function.
on machine
Related
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
information
[CA153] for "High Error" is displayed.

Connecting parts among boost pressure sensor, temperature sensor,
engine wiring harness, and engine controller are suspected. Inspect
Defective wiring harness them directly.
1
2. Disconnect connector BOOST PRESS & IMT, and connect socket
to male side.
-40 °C Resistance 41 – 48 kz
Between BOOST -20 °C Resistance 14 – 16 kz
Defective boost tempera-
2 PRESS & IMT 0 °C Resistance 5.4 – 6.1 kz
ture sensor
(male) (3) and (4)
30 °C Resistance 1.6 – 1.8 kz
a Boost tempera-
ture -Resistance 60 °C Resistance 560 – 600 z
Possible
causes and chariacteristic 90 °C Resistance 230 – 250 z
standard value 130 °C Resistance 80 – 90 z
in normal state
2. Disconnect connector ECM and connect T-adapter to female
side.
Short circuit in wiring har-
3 Between ECM (female) (23) and (47)
ness
a Use "boost temperature-Resistance Resis-
80 z – 48 kz
characteristics" table shown above as tance
resistance criteria.
a If no failure is found by checks on cause 3, this check is not re-
quired.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
4 ness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and
(contact with ground circuit) connect T-adapter to female side of ECM.
Resis-
Between ECM (female) (23) and ground Min. 100 kz
tance
18 107E-1 Series
107E-1 Series 19
E-11 Code [155/CA155] Derating of speed by charge temperature high

error 1

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

Inspect following directly.
Drop in cooling performance • Loose, broken fan belt
1
Possible of aftercooler. • Lack of cooling air
causes and • Clogged aftercooler fin
standard value Abnormally high temperature
in normal state 2 Inspect related parts directly.
at turbocharger outlet
If no failure is found by above checks, boost temperature sensor
Defective boost temperature
3 system may be defective. Perform troubleshooting for failure codes
sensor
[CA153] and [CA154].
20 107E-1 Series
107E-1 Series 21
E-12 Code [187/CA187] Sensor power supply 2 low error 1

Trouble Sensor power supply 2 low error
187 CA187
Contents of
• Low voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge (boost) pressure and charge (boost) temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
• Engine output drops.
appears
• Engine starting performance becomes deteriorated.
on machine
Related
information

Connecting parts among each sensor, engine wiring harness, and
connector
2. Disconnect following connectors sequentially one by one and
turn starting switch to ON position each time.
3. After each troubleshooting, return to 1.
If this failure code is not displayed when a connector is discon-
nected, that sensor or engine wiring harness is defective.
Possible a Other failure codes are displayed, too. This is because of dis-
causes and connection of connector. Ignore failure codes other than
Defective sensor or wiring
standard value 2 [CA187].
harness
in normal state
Sensor or harness Connector
Boost pressure & tempera-
BOOST PRESS & IMT
ture sensor
Common rail pressure sensor FUEL RAIL PRESS
Bkup sensor CAM SENSOR
Engine wiring harness ECM
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM discon-
nected.
Between ECM (male) (37) and (47) Voltage 4.75 - 5.25 V
22 107E-1 Series
Circuit diagram related to sensor power supply 2
107E-1 Series 23
E-13 Code [221/CA221] Atompspheric pressure sensor high error 1

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

Connecting parts among atmospheric pressure sensor, engine wir-
ing harness, and engine controller are suspected. Inspect them
Defective wiring harness directly.
1
Defective sensor power sup- If failure code [CA352] or [CA386] is displayed simultaneously, per-
2
ply 1 system form troubleshooting for it first.
2. Disconnect connector AMB. AIR PRESSURE.
Defective ambient pressure 3. Turn starting switch to ON position.
3
sensor
If failure code changes from [CA221] to [CA222], sensor is defec-
Possible tive.
causes and 1. Turn starting switch to OFF position.
standard value 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and
in normal state Short circuit in wiring har- connect T-adapter to female side of either one.
4
ness Between ECM (female) (33) and (3), or
Resis- Min.
between AMB. AIR PRESSURE (female) (1)
tance 100 kz
and (3)
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR
Hot short circuit in wiring PRESSURE or insert T-adapter in connector ECM.
5 harness 4. Turn starting switch to ON position (with connector AMB. AIR
(contact with 24 V circuit) PRESSURE disconnected).
Between ECM (3) and (38), or between
Voltage Max. 1 V
AMB. AIR PRESSURE (female) (3) and (2)
24 107E-1 Series
Circuit diagram related to atmospheric pressure sensor
107E-1 Series 25
E-14 Code [222/CA222] Atompspheric pressure sensor low error 1

Trouble Atmospheric pressure sensor low error
222 CA222
Contents of
• Low voltage is detected in atmospheric pressure sensor
trouble
Action of
controller
Problem that
appears
on machine
Related • Method of reproducing failure code: Starting switch ON.
information • If sensor connector is disconnected, this failure code is displayed.

Connecting parts among atmospheric pressure sensor, engine
wiring harness, and engine controller are suspected. Inspect them
Defective wiring harness con- directly.
1
nector • Loose connector, broken lock, broken seal
If failure code [CA352] or [CA386] is also displayed, perform trou-
bleshooting for it first.
Defective power supply line of 2. Disconnect connector AMB. AIR PRESSURE and connect T-
2
ambient pressure sensor adapter to female side.
Between AMB. AIR PRES- Power
Voltage 4.75 –5.25 V
SURE (female) (1) and (2) input
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and
Possible
connect T-adapter to each female side.
causes and
standard value a If power supply input in checks on
in normal state cause 2 is normal, this check is not
required. Resistance Max. 10 z
Between ECM (female) (33) and
Short circuit in wiring harness AMB. AIR PRESSURE (female) (1)
3 (wire breakage or defective
contact of connector) a If power supply input in checks on
cause 2 is normal, this check is not
required. Resistance Max. 10 z
Between ECM (female) (38) and
AMB. AIR PRESSURE (female) (2)
Between ECM (female) (3) and AMB.
AIR PRESSURE (female) (3) (sensor Resistance Max. 10 z
output)
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and
Ground fault in wiring harness connect T-adapter to female side of either one.
4
(contact with ground circuit) Between ECM (female) (3) and
ground, or between AMB. AIR PRES- Resistance Min. 100 kz
SURE (female) (3) and ground
26 107E-1 Series

2. Disconnect connectors ECM and AMB. AIR PRESSURE, and
connect T-adapter to female side of either one.
5 Short circuit in wiring harness
Between ECM (female) (3) and (38), or
between AMB. AIR PRESSURE Resistance Min. 100 kz
(female) (2) and (3)
Possible
causes and a If no failure is found by checks on causes 1 to 5 and check re-
standard value sult for cause 6 is abnormal, sensor is defective.
in normal state Defective ambient pressure 1. Turn starting switch to OFF position.
6 sensor (improper input volt- 2. Insert T-adapter to connector ECM.
age to engine controller) 3. Turn starting switch to ON position.
Sensor
Between ECM (3) and (38) Voltage 0.5 – 4.5 V
output
If no failure is found by above checks, engine controller is defec-
7 Defective engine controller tive. (Since this is internal failure, troubleshooting cannot be per-
formed.)
Circuit diagram related to atmospheric pressure sensor
107E-1 Series 27
E-15 Code [227/CA227] Sensor power supply 2 high error 1

Trouble Sensor power supply 2 high error
227 CA227
Contents of
• High voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge (boost) pressure and charge (boost) temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
appears
• Engine starting performance becomes deteriorated.
on machine
Related
information

causes and
standard value Perform troubleshooting for failure code [CA187].
in normal state
E-16 Code [234/CA234] Engine overspeed 1

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

1 Use of improper fuel Check fuel used directly (for high viscosity).
Possible
causes and Machine may be used improperly. Instruct operator on proper way
2 Improper way of use
standard value to use.
in normal state If no failure is found by checks on causes 1 and 2, engine controller
3 Defective engine controller may be defective. (Since this is internal failure, troubleshooting
cannot be performed.)
28 107E-1 Series
E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply 1

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

Connecting parts among each sensor, engine wiring harness, and
connector
2. Disconnect following connectors one by one and turn starting
switch to ON position each time.
3. After each troubleshooting, return to step 1.
Possible If this failure code is not displayed when sensor is disconnected,
causes and sensor or engine wiring harness is defective.
Defective sensor or wiring
standard value 2
harness a Other failure codes are displayed, too. This is because of dis-
in normal state connection of connector. Ignore failure codes other than
[CA238].
Ne speed sensor CRANK SENSOR
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM discon-
nected.
Between ECM (male) (16) and (48) Voltage 4.75 – 5.25 V
Circuit diagram related to engine Ne speed sensor
107E-1 Series 29
E-18 Code [271/CA271] Short circuit in IMV/PCV1 1

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

Connecting parts among supply pump actuator, engine wiring har-
ness, and engine controller are suspected. Inspect them directly.
connector
2. Disconnect connector CP3 PUMP REGULATOR.
Defective supply pump actu- 3. Turn starting switch to ON position.
2
ator
If failure code changes from [CA271] to [CA272] , supply pump
actuator is defective.
side.
Short circuit or ground fault
3 Resis-
in wiring harness Between ECM (female) (2) and (32) 1–5z
Possible tance
causes and Resis- Min.
standard value Between ECM (female) (2) and ground
tance 100 kz
in normal state
quired.
Short circuit in wiring har- 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and
4
ness connect T-adapter to female side of ECM.
Resis- Min.
tance 100 kz
quired.
5 ness 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and
(contact with ground circuit) connect T-adapter to female side of ECM.
Resis- Min.
tance 100 kz
30 107E-1 Series
Circuit diagram related to supply pump actuator (metering unit)
107E-1 Series 31
E-19 Code [272/CA272] Disconnection in IMV/PCV1 1

Trouble Disconnection in IMV/PCV1
272 CA272
Contents of
• There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that
• Engine speed runs, but in unstable condition.
appears
• Common rail fuel pressure is above command value.
on machine
Related • Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable
information to harness side female connector and thus not usable for checking open circuit (not designed as a
T-adapter).

Connecting parts among supply pump actuator, engine wiring har-
connector
Defective supply pump actu- 2. Disconnect connector CP3 PUMP REGULATOR.
2
ator Between CP3 PUMP REGULATOR (male) Resis-
Max. 5 z
(1) and (2) tance
Possible
causes and Open or short circuit in wir-
3 side.
standard value ing harness
in normal state Resis-
Between ECM (female) (2) and (32) Max. 5 z
tance
1.Turn starting switch to OFF position.
2.Disconnect connector CP3 PUMP REGULATOR.
3.Insert T-adapter to connector ECM.
Hot short circuit in wiring 4.Turn starting switch to ON position and perform troubleshooting
4 harness after one minute or longer (with connector CP3 PUMP REGU-
(contact with 24 V circuit) LATOR disconnected).
a Average voltage is displayed because of PWM.
Between ECM (2) and (32) Voltage Max. 3 V
32 107E-1 Series
Circuit diagram related to supply pump actuator (metering unit)
107E-1 Series 33
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 1

Trouble Disconnection, short circuit in injector No. 1
322 CA322
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that
• There is irregular combustion or hunting.
appears
• Output drops.
on machine
Related
• While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
information
cannot be measured by using multimeter because it cannot measure pulse voltages.

Connecting parts among injector No. 1, engine wiring harness, and
connector
2. Disconnect connector INJECTOR CYL 1&2 and connect T-
adapter to male side.
2 Defective No. 1 injector Between INJECTOR CYL 1&2 (male) (3) Resis-
Max. 2 z
and (4) tance
Between INJECTOR CYL 1&2 (male) (3) Resis- Min.
and ground tance 100 kz
side.
Open circuit or ground fault
Possible 3 Resis-
in wiring harness Between ECM (female) (45) and (53) Max. 2 z
causes and tance
standard value Resis- Min.
in normal state Between ECM (female) (45) and ground
tance 100 kz
quired.
Open circuit in wiring har- 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and
ness connect T-adapter to each female side.
4
(wire breakage or defective
Between ECM (female) (45) and INJECTOR Resis-
contact of connector) Max. 2 z
CYL 1&2 (female) (3) tance
Max. 2 z
quired.
5 ness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and
(contact with ground circuit) connect T-adapter to female side of either one.
Between ECM (female) (45) or INJECTOR Resis- Min.
CYL 1&2 (female) (3) and ground tance 100 kz
34 107E-1 Series

2. Disconnect connectors ECM and INJECTOR CYL 1&2 and
connect T-adapter to female side of ECM.
Short circuit in wiring har- a Check by using multimeter in continuity mode.
6
Possible ness Between ECM (female) (45) and each pin No continuity (no
causes and other than (45) sound is heard.)
standard value Between ECM (female) (53) and each pin No continuity (no
in normal state other than (53) sound is heard.)
Defective other cylinder If failure codes for other injectors are displayed, perform trouble-
7
injectors or wiring harness shooting for them, too.
If no failure is found by checks on causes 1 to 7, engine controller is
8 Defective engine controller defective. (Since this is internal failure, troubleshooting cannot be
performed.)
Circuit diagram related to injector No. 1
107E-1 Series 35

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

connector
Max. 2 z
and (4) tance
side.
Possible 3 Resis-
causes and tance
tance 100 kz
quired.
4
Max. 2 z
quired.
36 107E-1 Series

Possible 6
ness Between ECM (female) (46) and each pin No continuity (no
standard value
in normal state Between ECM (female) (60) and each pin No continuity (no
other than (60) sound is heard.)
7
* This code is not applicable to 4D107E-1.
107E-1 Series 37

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

connector
Max. 2 z
and (4) tance
side.
Possible 3 Resis-
causes and tance
tance 100 kz
quired.
4
Max. 2 z
quired.
38 107E-1 Series

Possible 6
standard value
7
107E-1 Series 39

325 CA325
Contents of
trouble
Action of
controller
Problem that
appears • There is irregular combustion or hunting.
on machine
Related
• While engine is running normally, pulse voltage of apporx. 65 V is applied to injector (+) side but
information

connector
2 Defective injector No. 6 Between INJECTOR CYL 5&6 (male) (1) Resis-
Max. 2 z
and (2) tance
side.
Possible 3 Resis-
causes and tance
tance 100 kz
quired.
Open circuit in wiring har- 2. Disconnect connectors ECM and INJECTOR CYL 5&6,
ness and connect T-adapters to each female side.
4
Max. 2 z
quired.
40 107E-1 Series

Possible 6
standard value
7
* This code is not applicable to 4D107E-1.
107E-1 Series 41

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

connector
Max. 2 z
and (2) tance
side.
Possible 3 Resis-
causes and tance
tance 100 kz
quired.
4
Max. 2 z
quired.
42 107E-1 Series

Possible 6
standard value
7
107E-1 Series 43

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

connector
Max. 2 z
and (2) tance
side.
Possible 3 Resis-
causes and tance
tance 100 kz
quired.
4
Max. 2 z
quired.
44 107E-1 Series

Possible 6
standard value
7
107E-1 Series 45
E-26 Code [342/CA342] Calibration error in engine controller data 1

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

causes and 1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
standard value Defective power supply volt-
age system
46 107E-1 Series
E-27 Code [351/CA351] Abnormality in injector drive circuit 1

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

causes and 1 Defective related system If another failure code is indicated, perform troubleshooting for it.
standard value Defective power supply volt-
age system
107E-1 Series 47
E-28 Code [352/CA352] Sensor power supply 1 low error 1

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

Connecting parts among atmospheric pressure sensor, engine wir-
1
2. Disconnect following connectors one by one and turn starting
switch to ON position each time.
3. After each troubleshooting, return to step 1.
Possible
causes and If this failure code is not displayed when sensor is disconnected,
Defective sensor or wiring sensor or engine wiring harness is defective.
standard value 2
in normal state
harness a Other failure codes are displayed as well. This is because con-
nector is unplugged. Ignore all failure codes other than [CA352].
Ambient pressure sensor AMB. AIR PRESSURE
3. Turn starting switch to ON position with connector ECM discon-
3 Defective engine controller nected.
4.75 -
Between ECM (male) (33) and (38) Voltage
5.25V
48 107E-1 Series
Circuit diagram related to sensor power supply 1
107E-1 Series 49
E-29 Code [386/CA386] Sensor power supply 1 high error 1

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

causes and
standard value Perform troubleshooting for failure code [CA352]
in normal state
50 107E-1 Series
107E-1 Series 51
E-30 Code [428/CA428] Water-in-fuel sensor high error 1

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

Connecting parts among fuel water sensor, engine wiring harness,
connector
2. Disconnect connector P47, and connect T-adapter to female
Defective water-in-fuel sen- side.
2
sor installed to fuel pre-filter a If water is in water separator, drain it.
Resis- Min.
Between P47 (female) (1) and (2)
tance 100 kz
Open or short circuit in wir- side.
3
ing harness
Possible Between ECM (female) (14) and (47) Resis- Min.
causes and (Resistance of water-in-fuel sensor) tance 100 kz
standard value a If no failure is found by checks on cause 3, this check is not re-
in normal state quired.
Open circuit in wiring har- 2. Disconnect connectors ECM and P47, and connect T-adapter to
ness each female side.
4
Between ECM (female) (14) and P47 Resis-
(female) (1) tance
Between ECM (female) (47) and P47 Resis-
Max. 10 z
(female) (2) tance
2. Disconnect connectors ECM and P47, and connect T-adapters
Short circuit in wiring har- to female side of ECM.
5 a Check by using multimeter in continuity mode.
ness
Between ECM (female) (14) and each pin No continuity (no
52 107E-1 Series
Circuit diagram related to water-in-fuel sensor
a The terminal names and pin numbers are shown as examples of PC200-8 .
107E-1 Series 53
E-31 Code [429/CA429] Water-in-fuel sensor low error 1

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

Connecting parts among fuel water sensor, engine wiring harness,
connector
2. Disconnect connector P47, and connect T-adapter to female
side.
Defective water-in-fuel sen- a If water is in water separator, drain it.
2
sor installed to fuel pre-filter Resis- Min.
Between P47 (female) (1) and (2)
tance 100 kz
Resis- Min.
Between P47 (female) (1) and ground
tance 100 kz
Possible side.
Short circuit or ground fault
causes and 3 Between ECM (female) (14) and (47) Resis- Min.
in wiring harness
standard value (Resistance of water-in-fuel sensor) tance 100 kz
in normal state Resis- Min.
tance 100 kz
2. Disconnect connectors ECM and P47, and connect T-adapters
Short circuit in wiring har- to female side of ECM.
ness
Between ECM (female) (14) and each pin No continuity (no
quired.
5 ness 2. Disconnect connectors ECM and P47, and connect T-adapter to
(contact with ground circuit) female side of either one.
Between ECM (female) (14) and ground or Resis- Min.
between P47 (female) (1) and ground tance 100 kz
54 107E-1 Series
Circuit diagram related to water-in-fuel sensor
a The terminal names and pin numbers are shown as examples of PC200-8.
107E-1 Series 55
E-32 Code [431/CA431] Abnormality in idle validation switch 1

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

Connecting parts among accelerator pedal, engine unit wiring har-
connector
a Prepare with starting switch OFF, then perform troubleshooting
without turning starting switch ON.
WAS1 (Male) Accelerator pedal Resistance
2 Defective accelerator pedal Release Max. 1 z
Between (5) – (4)
Press Min. 1 Mz
Release Min. 1 Mz
Between (6) – (4)
Press Max. 1 z
Disconnection in wiring har-
Between J2 (female) (11) – WAS1 (female) Resis- Max.
ness
(5) tance 10 z
3 (Disconnection in wiring or
Possible defective contact in connec- Between J2 (female) (1) – WAS1 (female) Resis- Max.
causes and tor) (6) tance 10 z
standard value Between J2 (female) (32) – WAS1 (female) Resis- Max.
in normal state (4) tance 10 z
Between J2 (female) (11) – J2 (female) Resis- Min.
(each pin) (With also WAS1 disconnected) tance 100 kz
Short circuit in wiring harness Between J2 (female) (1) – J2 (female) Resis- Min.
4
(With another wiring harness) (each pin) (With also WAS1 disconnected) tance 100 kz
Between J2 (female) (11) – J3 (female) (3) Resis- Min.
(With also WAS1 disconnected) tance 100 kz
Between J2 (female) (1) – J3 (female) (3) Resis- Min.
(With also WAS1 disconnected) tance 100 kz
J2 (Female) Accelerator pedal Resistance
5 Defective engine controller Release Max. 1 z
Between (11) – (32)
Press Min. 1 Mz
Release Min. 1 Mz
Between (1) – (32)
Press Max. 1 z
* The terminal names and pin numbers are shown as an example.
56 107E-1 Series
Circuit diagram related to accelerator pedal (as an example)
107E-1 Series 57
E-33 Code [432/CA432] Abnormality in idle validation processing 1

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

Connecting parts among accelerator pedal, engine unit wiring har-
connector
2 Defective accelerator pedal WAS1 (Male) Accelerator pedal Resistance
Release 1.5 – 3.0 kz
Between (2) – (1)
Press 0.25 – 1.5 kz
Disconnection in wiring har- without turning starting switch ON.
Possible ness
causes and Between J2 (female) (22) – WAS1 (female) Resis- Max.
3 (Disconnection in wiring or
standard value (1) tance 10 z
defective contact in connec-
in normal state tor) Between J2 (female) (9) – WAS1 (female) Resis- Max.
(2) tance 10 z
Short circuit in wiring harness Between J2 (female) (22) – J2 (female) Resis- Min.
4
(With another wiring harness) (each pin) (With also WAS1 disconnected) tance 100 kz
Between J2 (female) (9) – J2 (female) Resis- Min.
(each pin) (With also WAS1 disconnected) tance 100 kz
5 Defective engine controller J2 (Female) Accelerator pedal Resistance
Release 1.5 – 3.0 kz
Between (22) – (9)
Press 0.25 – 1.5 kz
* The terminal names and pin numbers are shown as an example.
58 107E-1 Series
Circuit diagram related to accelerator pedal (as an example)
107E-1 Series 59
© 2010 KOMATSU
All Rights Reserved
60
SEN00255-04
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of electrical system
(E-mode), Part 2
E-34 Code [435/CA435] Abnormality in engine oil pressure switch................................................................ 3
E-35 Code [441/CA441] Abnormally low power supply voltage...................................................................... 4
E-36 Code [442/CA442] Abnormally high power supply voltage .................................................................... 6
E-37 Code [449/CA449] Common rail pressure high error 2 .......................................................................... 7
E-38 Code [451/CA451] Common rail pressure sensor high error ................................................................. 8
E-39 Code [452/CA452] Common rail pressure sensor low error................................................................. 10
E-40 Code [488/CA488] Derating of torque by charge temperature high error ............................................ 12
E-41 Code [553/CA553] Common rail pressure high error 1 ........................................................................ 12
E-42 Code [559/CA559] No-pressure feed 1 by supply pump...................................................................... 13
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor ................................................................ 15
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase.................................................. 17
E-45 Code [757/CA757] Loss of all data in engine controller ....................................................................... 18
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor ............................................................ 19
E-47 Code [1633/CA1633] Abnormality in KOMNET.................................................................................... 22
107E-1 Series 1
E-48 Code [2185/CA2185] Throttle sensor power supply high error ............................................................ 23
E-49 Code [2186/CA2186] Throttle sensor power supply low error.............................................................. 24
E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump .................................................................. 25
E-51 Code [2311/CA2311] Abnormality in IMV solenoid ............................................................................... 25
E-52 Code [2555/CA2555] Disconnection in intake air heater relay ............................................................. 26
E-53 Code [2556/CA2556] Short circuit in intake air heater relay................................................................. 28
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction ............................................ 30
E-55 Code [---/B@BAZK] Engine oil level low .............................................................................................. 30
E-56 Code [---/B@BCNS] Engine overheat .................................................................................................. 31
E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error ............................................... 32
E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error ................................................ 34
E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error......................................................... 36
E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error.......................................................... 38
E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) ........................................................... 40
E-62 Code [b6] Droop Rate Adjustment Volume High Error ........................................................................ 44
E-63 Code [b7] Droop Rate Adjustment Volume Low Error .......................................................................... 46
E-64 Code [b8] Low Idle Speed Adjustment Volume High Error ................................................................... 48
E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error.................................................................... 50
E-66 Code [bc] Rated Speed Median Adjustment Volume High Error .......................................................... 52
E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error........................................................... 54
E-68 Code [bE] Ramp Time Adjustment Volume High Error......................................................................... 56
E-69 Code [bF] Ramp Time Adjustment Volume Low Error.......................................................................... 58
2 107E-1 Series
E-34 Code [435/CA435] Abnormality in engine oil pressure switch 1

Trouble Abnormality in engine oil pressure switch
435 CA435
Contents of
• Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
controller
Problem that
appears • Engine oil pressure switch-based engine protection function does not function.
on machine
• Method of reproducing failure code: Starting switch ON or start engine
• Engine oil pressure switch is closed (ON) when oil pressure is low (when engine is stopped), but is
Related open (OFF) when high (when engine is running).
information • To generate this failure code, engine controller checks if engine oil pressure switch is closed (ON),
that is, if signal voltage is at GND level or not only while engine is stopped.
• When engine is running, engine oil pressure switch error is shown by failure code [B@BAZG].

Connecting parts among engine oil pressure switch, engine wiring
harness, and engine controller are suspected. Inspect them
1
Possible 2. Disconnect connector OIL PRESSURE SWITCH and connect T-
causes and Defective engine oil pres- adapter to male side.
2
standard value sure switch
Between OIL PRESSURE SWITCH (male) Resis-
in normal state Max. 10 z
(1) and ground tance
Open or short circuit in wir- side.
3
ing harness
Resis-
Between ECM (female) (17) and ground Max. 10 z
tance
Circuit diagram related to engine oil pressure switch
107E-1 Series 3
E-35 Code [441/CA441] Abnormally low power supply voltage 1

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

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
Loose terminal or partial
2 Check terminals of alternator, battery relay, ground terminal (T12),
open circuit at terminal
etc.
Connecting parts among fuse No. 19, engine unit wiring harness,
connector
2. Perform troubleshooting with starting switch at OFF position and
4 Improper battery voltage at engine cranking.
Possible Between battery terminals (+) and (-). Voltage 20 – 30 V
causes and
standard value
2. Insert T-adapter into connector E12.
in normal state 5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between E12 (1) and ground Voltage 27.5 – 29.5 V
tive.
• Reference
1. Turn starting switch to OFF position and disconnect ground
cable.
2. Insert T-adapter in connector CE03.
6 Defective engine controller 3. Connect ground cable.
4. Measure voltage with starting switch at ON position and when
starting engine.
Between CE03 (3)
Starting switch: ON Voltage 20 – 30 V
and (1)
Between CE03 (3) Starting switch:
Voltage Min. 12 V
and (1) START
4 107E-1 Series
Circuit diagram related to engine controller power supply (PC200-8, as an example)
107E-1 Series 5
E-36 Code [442/CA442] Abnormally high power supply voltage 1

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

causes and
standard value Perform troubleshooting for failure code [CA441].
in normal state
6 107E-1 Series
E-37 Code [449/CA449] Common rail pressure high error 2 1

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

1 Defective related system If another failure code is indicated, perform troubleshooting for it.
Inspect it for air entry directly according to the following procedure.
1) Remove pressure pickup plug (outlet side) from fuel main filter.
2 Air in low-pressure circuit
2) Operate feed pump of fuel pre-fuel filter.
3) Inspect fuel and air from pressure pickup plug for leakage level.
a For check of pressure in fuel return circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Possible Defective fuel return circuit
3 At low idle
causes and device Fuel return circuit Max. 0.02 MPa
or
standard value pressure {Max. 0.19 kg/cm2}
cranking
in normal state
Defective common rail
4 Perform troubleshooting for failure codes [CA451] and [CA452]
pressure sensor
a For testing of leakage from pressure limiter, see TESTING AND
ADJUSTING, Testing leakage from pressure limiter and return
5 Defective pressure limiter rate from injector.
Leakage
At low idle 0 cc (No leakage)
from pressure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
107E-1 Series 7
E-38 Code [451/CA451] Common rail pressure sensor high error 1

Trouble Common rail pressure sensor high error
451 CA451
Contents of
• High voltage occurred in common rail pressure sensor.
trouble
Action of
controller
Problem that
• Engine speed or output drops.
appears
• Engine does not start.
on machine
• This failure code is displayed if common rail pressure sensor connector is disconnected.
Related
• Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
information
checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).

Connecting parts among common rail pressure sensor, engine wir-
1
Defective common rail pres-
If failure code [CA227] or [CA187] is also displayed, perform trou-
2 sure sensor power supply
bleshooting for it first.
line
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS,
Short circuit in wiring har- BOOST PRESS & IMT and ECM.
3 3. Connect T-adapter to female side of ECM.
ness
Resis- Min.
tance 100 kz
Possible
causes and
2. Disconnect connector FUEL RAIL PRESS, and connect T-
standard value
adapter to connector ECM.
in normal state Hot short circuit in wiring 3. Turn starting switch to ON position (with connector FUEL RAIL
4 harness PRESS disconnected).
(contact with 24 V circuit) a Pin (25) of ECM is connected to 5V line via resistor inside engine
controller.
Between ECM (25) and (47) Voltage Approx. 5 V
Open circuit in wiring har- If no failure is found by above checks, there may be open circuit in
5
ness wiring harness. (*)
a If no failure is found by checks on causes 1 to 5 and check result
for cause 6 is abnormal, sensor is defective.
Defective common rail pres- 1. Turn starting switch to OFF position.
sure sensor 2. Insert T-adapter to connector ECM.
6
(improper input voltage to 3. Turn starting switch to ON position.
engine controller)
Sensor
Between ECM (25) and (47) Voltage 0.2 – 4.6 V
output
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related
information of troubleshooting".
8 107E-1 Series
Circuit diagram related to common rail pressure sensor
107E-1 Series 9
E-39 Code [452/CA452] Common rail pressure sensor low error 1

Trouble Common rail pressure sensor low error
452 CA452
Contents of
• Low voltage occurred in common rail pressure sensor.
trouble
Action of
controller
Problem that
• Engine speed or output drops.
appears
on machine
Related
• If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
information
is displayed.

Connecting parts among common rail pressure sensor, engine wir-
1
If failure code [CA187] (ground fault in sensor power supply line) or
2 sure sensor power supply
[CA227] is indicated, perform troubleshooting for it first.
line
a Check that failure code [CA187] (Ground fault in sensor power
supply line) is not displayed.
Possible Defective common rail pres- 1. Turn starting switch to OFF position.
3 2. Disconnect connector FUEL RAIL PRESS.
causes and sure sensor
standard value
in normal state If failure code [CA452] changes to [CA451] , sensor is defective.
Ground fault in wiring har- 2. Disconnect connectors ECM and FUEL RAIL PRESS, and
4 ness connect T-adapter to female side of ECM.
(contact with ground circuit) Resis- Min.
tance 100 kz
2. Disconnect connectors ECM and FUEL RAIL PRESS, and
Short circuit in wiring har- connect T-adapter to female side of ECM.
5
ness
Resis- Min.
tance 100 kz
10 107E-1 Series
Circuit diagram related to common rail pressure sensor
107E-1 Series 11
E-40 Code [488/CA488] Derating of torque by charge temperature high

error 1

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

Inspect following directly.
Drop in cooling performance • Loose, broken fan belt
Possible 1
of aftercooler. • Lack of cooling air
causes and • Clogged aftercooler fin
standard value
in normal state Abnormally high temperature Outlet temperature of turbocharger may be abnormally high. Check
2
at turbocharger outlet related parts directly.
Defective charge (boost)
3 Perform troubleshooting for failure codes [CA153] and [CA154].
temperature sensor
E-41 Code [553/CA553] Common rail pressure high error 1 1

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

1 Defective related system If another failure code is indicated, perform troubleshooting for it.
Inspect following directly for connection of ground terminal.
• Ground terminal (battery (–)) of machine main unit.
Possible Defective connection of
2 • Ground terminal of engine
causes and ground terminal
• Ground terminal of engine controller
standard value
• Ground terminal of starting motor
in normal state
Defective O-ring of supply
3 O-ring of supply pump actuator may be damaged. Check it directly.
pump actuator
sure sensor system
12 107E-1 Series
E-42 Code [559/CA559] No-pressure feed 1 by supply pump 1

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

1 Use of improper fuel Fuel used may be improper. Check it directly (for high viscosity).
Fuel may leak to outside. Check it directly (Check visually while
2 Fuel leakage to outside
running engine at low idle).
a For contents of troubleshooting, see “Note 1”.
a For measurement of pressure in fuel low-pressure circuit, see
TESTING AND ADJUSTING, “Measurement of fuel pressure”.
Fuel supply pump
At high idle
inlet negative pres- Max. –50.7 kPa
(When engine can be
sure (Fuel prefilter {Max. –380 mmHg}
Defective fuel low-pressure started)
3 outlet side)
circuit parts
During cranking
0.3 – 1.1 MPa
(When engine can-
{3.1 – 11.3 kg/cm2}
Fuel main filter inlet not be started)
pressure At low idle
0.5 – 1.3 MPa
(When engine can be
{5.1 – 13.3 kg/cm2}
started)
a For testing of leakage from pressure limiter, see Testing and
Possible adjusting, “Testing fuel delivery, return and leak amount”.
causes and 4 Defective pressure limiter
standard value Leakage
At low idle 0 cc (No leakage)
in normal state from pressure limiter
a For testing of return rate from injector, see Testing and adjusting,
“Testing fuel delivery, return and leak amount”.
At cranking
Defective injector
(When engine Max. 90 cc/min.
5 (High-pressure piping in
Return rate from cannot be started)
head included)
injector At low idle
can be started)
a For testing of return rate from supply pump, see Testing and
adjusting, “Testing fuel delivery, return and leak amount”.
At cranking
6 Defective supply pump
Return rate from cannot be started)
supply pump At low idle
(When engine Max. 1,000 cc/min.
can be started)
sure sensor system
107E-1 Series 13
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Leaking or clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace the fuel filters when trouble does not cancel it even if clogging is checked.
14 107E-1 Series
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor 1

Trouble Abnormality in engine Ne speed sensor
689 CA689
Contents of
• Abnormality occurred in signals from engine Ne speed sensor.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that • There is hunting from engine.
appears • Starting performance is poor.
on machine • Engine output drops.
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related
• Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured
information
with multimeter.
• Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of
crankshaft vibration damper and rotated by crankshaft.

Connecting parts among engine Ne speed sensor, engine wiring
1
Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting
2
power supply line for it first.
Breakage or improper instal-
Engine Ne speed sensor may be broken or may have improper
3 lation (looseness) of engine
installation (looseness). Check it directly.
Ne speed sensor
2. Disconnect connector CRANK SENSOR and connect T-adapter
Defective Ne speed sensor to female side.
4 3. Turn starting switch to ON position.
power supply input
Possible Between CRANK SENSOR Power
Voltage 4.75 - 5.25V
causes and (female) (1) and (2) input
standard value 1. Turn starting switch to OFF position.
in normal state 2. Disconnect connectors ECM and CRANK SENSOR.
a If no failure is found by checks on
cause 4, this check is not required. Resis-
Max. 10 z
Open circuit in wiring har- Between ECM (female) (16) and tance
ness CRANK SENSOR (female) (1)
5
(wire breakage or defective a If no failure is found by checks on
contact of connector) cause 4, this check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and tance
CRANK SENSOR (female) (2)
Between ECM (female) (27) and CRANK Resis-
Max. 10 z
SENSOR (female) (3) tance
2. Disconnect connectors ECM and CRANK SENSOR.
Short circuit in wiring har- Between ECM (female) (16) and (27) or Resis-
6 Min. 100 kz
ness CRANK SENSOR (female) (1) and (3) tance
Between ECM (female) (27) and (48) or Resis-
Min. 100 kz
CRANK SENSOR (female) (2) and (3) tance
107E-1 Series 15

Ground fault in wiring har- 2. Disconnect connectors ECM and CRANK SENSOR.
7 ness
(contact with ground circuit) Between ECM (female) (27) or CRANK Resis-
Min. 100 kz
SENSOR (female) (3) and ground tance
Hot short circuit in wiring 2. Disconnect connector CRANK SENSOR.
Possible 8 harness 3. Turn starting switch to ON position.
causes and (contact with 24 V circuit) Between CRANK SENSOR (female) (3)
standard value Voltage Max. 1 V
and ground
in normal state
Damage or loose mounting
9 Check speed sensing wheel directly.
of wheel for speed sensing
If no failure is found by above checks, Ne speed sensor is defec-
10 Defective Ne speed sensor tive. (Since this is internal failure, troubleshooting cannot be per-
formed.)
formed.)
Circuit diagram related to engine Ne speed sensor
16 107E-1 Series
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase 1

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

Broken engine Ne speed
1 Inspect engine Ne speed sensor for breakage directly.
sensor
Broken engine Bkup speed
2 Inspect engine Bkup speed sensor for breakage directly.
sensor
Speed sensing wheel on crankshaft side may be installed defec-
tively or broken. Check it according to following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
Defective or broken mount of
a Do not align with mark of No. 1 cylinder compression top
3 rotation sensing wheel on
dead center. (Approx. 80 ° before compression top dead
crankshaft side
center)
2. If center of oblong hole (WS) of speed sensing wheel aligns with
Ne speed sensor top (M2), installation is correct.
Possible Speed sensing ring on camshaft side may be installed defectively
causes and or broken. Check it according to the following procedure.
standard value 1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
in normal state a Do not align with mark of No. 1 cylinder compression top
Defective or broken mount of
dead center. (Approx. 80 ° before compression top dead
4 rotation sensing ring on cam-
center)
shaft side
2. Remove Bkup speed sensor.
3. If you can see double-slot part (with one crest) (B) on speed
sensing ring through sensor mounting hole (H), speed sensing
ring is installed correctly.
Defective timing between
5 Inspect crankshaft and camshaft for timing directly.
crankshaft and camshaft
Inspect following directly for connection of ground terminal.
• Ground terminal (battery (–)) of machine main unit.
Defective connection of
6 • Ground terminal of engine
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
107E-1 Series 17
E-45 Code [757/CA757] Loss of all data in engine controller 1

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

causes and 1 Defective related system If another failure code is indicated, perform troubleshooting for it.
standard value
18 107E-1 Series
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor 1

Trouble Abnormality in engine Bkup speed sensor
778 CA778
Contents of
• Abnormality is detected in signals of engine Bkup speed sensor.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Problem that
appears
• Output drops.
on machine
• Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related be determined to be normal by measuring its resistance with multimeter.
information • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
• Speed sensor scans rotating slot of speed sensing ring mounted on the camshaft.

Connecting parts among engine Bkup speed sensor, engine wiring
1
Defective sensor power sup- If failure code [CA187] or [CA227] is also displayed, troubleshoot it
2
ply 2 line first.
Damage or incorrect (loose)
Engine Bkup speed (cam) sensor directly as it may be damaged or
3 installation of engine Bkup
incorrectly (loosely) installed. Check it directly.
speed (cam) sensor
2. Disconnect connector CAM SENSOR , and connect T-adapter
Defective power supply input to female side.
4 to engine Bkup speed sen- 3. Turn starting switch to ON position.
Possible sor
causes and Between CAM SENSOR Power 4.75 -
Voltage
standard value (female) (1) and (2) supply 5.25V
2. Disconnect connectors ECM and CAM SENSOR, and connect
T-adapter to each female side.
Open circuit in wiring har- Between ECM (female) (37) and CAM SEN- Resis-
ness Max. 10 z
5 SOR (female) (1) tance
Between ECM (female) (47) and CAM SEN- Resis-
SOR (female) (2) tance
Between ECM (female) (26) and CAM SEN- Resis-
Max. 10 z
SOR (female) (3) tance
2. Disconnect connectors ECM and CAM SENSOR, and connect
T-adapter to female side of either connector.
Short circuit in wiring har-
6 Between ECM (female) (26) and (37) or Resis- Min.
ness
CAM SENSOR (female) (1) and (3) tance 100 kz
Between ECM (female) (26) and (47) or Resis- Min.
CAM SENSOR (female) (2) and (3) tance 100 kz
107E-1 Series 19

Ground fault in wiring har- 2. Disconnect connectors ECM and CAM SENSOR, and connect
7 ness T-adapter to female side of either connector.
(contact with ground circuit) Between ECM (female) (26) or CAM SEN- Resis- Min.
SOR (female) (3) and ground tance 100 kz
2. Disconnect connector CAM SENSOR, and connect T-adapter to
Hot short circuit in wiring female side.
Possible 8 harness 3. Turn starting switch to ON position.
causes and (contact with 24 V circuit)
standard value Between CAM SENSOR (female) (3) and
Voltage Max. 1 V
in normal state ground
Remove engine Bkup speed (cam) sensor, and check ring directly
through hole (H).
9 Loose speed sensing ring
a If speed sensing ring (B) is loosely installed, follow instructions
given in the "Reference" column.
If no failure is found by above checks, engine Bkup speed (cam)
Defective engine Bkup
10 sensor is defective. (Since this is internal failure, troubleshooting
speed (cam) sensor
cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
20 107E-1 Series
Reference for troubleshooting for CA778 (107 5. Check mounting bolt (4) of camshaft ring (5) for
series engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4):
Remove the front cover and check the camshaft ring 10 ± 2 Nm
for looseness. (DP): Dowel pin
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-190
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
(DP): Dowel pin
Connection 40-190
a See the figures in "Removal" for installation.
1. Install front cover (2).
3 Front cover:
Liquid gasket (LG-7)
2. Install the front seal according to the following
procedure. For details, see "Removal and instal-
lation of front seal" in Disassembly and
assembly.
1) Install front seal (3).
3. Remove front cover (2). 2) Install the damper with the dowel pin (DP)
4. Remove front seal (3). assembly.
(RING): Ring 3) Install fan belt, and install the fan.
4) Install the cooling system assembly.
107E-1 Series 21
E-47 Code [1633/CA1633] Abnormality in KOMNET 1

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

causes and Perform troubleshooting for CAN communication of machine side.
standard value • PC series : failure code [DA2RMC]
in normal state • WA, bulldozer and dump truck series : [DB2RKR]
Circuit diagram related to KOMNET communication (PC200-8, as an example)
22 107E-1 Series
E-48 Code [2185/CA2185] Throttle sensor power supply high error 1

Trouble Throttle sensor power supply high error
2185 CA2185
Contents of • High voltage (min. 5.25 V) occurred in throttle sensor power supply circuit.
trouble
controller
Problem that • Depends on machine model.
appears
information

Connecting parts among fuel control dial, engine unit wiring harness,
connector
2. Disconnect connector P20, and turn starting switch to ON posi-
Defective throttle sensor tion.
2
(fuel control dial) If this failure code is not displayed, throttle sensor is defective.
a Other failure codes are displayed, too. This is because of discon-
nection of connector. Ignore failure codes other than [CA2185].
Possible
causes and
2. Disconnect connectors CE02, CE03 and P20, and connect T-
standard value
adapters to each female side of connectors CE02 and CE03.
in normal state Short circuit in wiring har-
3 Between CE02 (female) (22) and each
ness Resistance Min. 1 Mz
pin other than (22)
Between CE02 (female) (22) and CE03 Resistance Min. 1 Mz
(female) (3)
Hot short circuit in wiring 2. Disconnect connector P20, and connect T-adapter to female side.
4 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between P20 (female) (1) and ground Voltage 4.75 - 5.25V
2. Disconnect connector CE02, and connect T-adapter to male side.
3. Turn starting switch to ON position with wiring harness discon-
nected.
Circuit diagram related throttle sensor (PC200-8, as an example)
107E-1 Series 23
E-49 Code [2186/CA2186] Throttle sensor power supply low error 1

Trouble Throttle sensor power supply low error
2186 CA2186
Contents of • Low voltage occurred in throttle sensor power supply circuit.
trouble
controller
Problem that • Depends on machine model.
appears
information

Connecting parts among fuel control dial, engine unit wiring har-
connector
2. Disconnect connector P20, and turn starting switch to ON posi-
Defective throttle sensor tion.
2
(fuel control dial) If this failure code is not displayed, throttle sensor is defective.
a Other failure code is displayed too. This is because of discon-
nection of connector. Ignore failure codes other than [CA2186].
Possible
Ground fault of wiring har- 2. Disconnect connectors CE02 and P20, and connect T-adapter
causes and
3 ness to female side of either connector.
standard value
in normal state (contact with ground circuit) Between CE02 (female) (22) or P20 Resis- Min. 1 Mz
(female) (1) and ground tance
2. Disconnect connectors CE02 and P20, and connect T-adapter
Short circuit in wiring har- to female side of connector CE02.
4
ness 3. Turn starting switch to ON position.
Between CE02 (female) (22) and each Resis-
Min. 1 Mz
pin other than (22) tance
2. Disconnect connector CE02, and connect T-adapter to male
side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness discon-
nected.
Between CE02 (male) (22) and (23) Voltage 4.75 - 5.25V
Circuit diagram related to throttle sensor (PC200-8, as an example)
24 107E-1 Series
E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump 1

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

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

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

causes and
standard value Perform troubleshooting for failure codes [CA271] and [CA272].
in normal state
107E-1 Series 25
E-52 Code [2555/CA2555] Disconnection in intake air heater relay 1

Trouble Disconnection in intake air heater relay
2555 CA2555
Contents of • Open circuit is detected in drive circuit (primary circuit) of preheater relay.
trouble
Action of • None in particular.
controller
Problem that
• Intake air heater does not work in auto preheating (degraded starting performance at low tempera-
appears
ture and emission of white smokes)
on machine
• Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is
below -4 °C)
Related • Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit
information (coil) of preheater relay R18.
• For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see [E-
mode] in Troubleshooting of each machine shop.

Connecting parts among auto preheat relay, engine unit wiring har-
connector
2. Disconnect relay R18, and connect T-adapter to male side.
Between R18 (male) (1) and (2) Resis- 200 – 400 z
tance
Defective preheater relay
2 1. Turn starting switch to OFF position.
R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defec-
tive.
2. Disconnect connector CE02, and connect T-adapter to female side.
Possible Open or short circuit in wir-
causes and 3 Between CE02 (female) (40) and (42)
ing harness Resis-
standard value a Resistance of preheater relay R18 coil 200 – 400 z
tance
in normal state resistance
quired.
2. Disconnect connector CE02 and relay R18, and connect T-adapter
Open circuit in wiring har- to each female side.
4
ness
Between CE02 (female) (40) and R18 Resis- Max. 1 z
(female) (1) tance
Resis-
Between R18 (female) (2) and CE02 (42) Max. 1 z
tance
2. Disconnect connector CE02 and relay R18, and connect T-adapter
Short circuit in wiring har- to female side of CE02.
ness
Between CE02 (female) (40) and each pin No continuity
other than (40) (No sound is heard)
6 Defective engine controller If no failure is found by above checks, engine controller is defective.
* The terminal names and pin nambers are shown as examples of PC200-8.
26 107E-1 Series
Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)
107E-1 Series 27
E-53 Code [2556/CA2556] Short circuit in intake air heater relay 1

Trouble Short circuit in intake air heater relay
2556 CA2556
Contents of
• Short circuit is detected in drive circuit (primary circuit) of preheater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not work in auto preheating (degraded starting performance at low tempera-
appears
ture and emission of white smokes)
on machine
• Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is
below -4 °C)
Related • Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit
information (coil) of preheater relay R18.
• For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see [E-
mode] in Troubleshooting of each machine shop.

Connecting parts among auto preheat relay, engine unit wiring har-
connector
2. Disconnect relay R18, and connect T-adapter to male side.
Resis-
Between R18 (male) (1) and (2) 200 – 400 z
tance
Defective preheater relay
2 1. Turn starting switch to OFF position.
R18
2. Replace relay R18 with another one.
Possible
If this failure code disappears, original preheater relay R18 is
causes and
defective.
standard value
2. Disconnect connector CE02 and relay R18, and connect T-
Ground fault in wiring har- adapter to female side of either connector.
3
ness
Between CE02 (female) (40) or R18 Resis-
Min. 1 Mz
(female) (1) and ground tance
2. Disconnect connector CE02 and relay R18, and connect T-
Short circuit in wiring har- adapter to female side of CE02.
ness
Between CE02 (female) (40) and each pin No continuity
other than (40) (No sound is heard)
formed.)
28 107E-1 Series
Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)
107E-1 Series 29
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure

reduction 1

Trouble Derating of speed by engine oil pressure reduction
--- B@BAZG
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits engine output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
• Output of engine drops.
appears
• If machine is operated as it is, engine may be damaged.
on machine
Related
information

causes and This fault is indicated on only machine side when detected.
standard value perform troubleshooting on
1 Accordingly, contents of troubleshooting depend on machine
in normal state machine side
model. See Shop manual for machine.
E-55 Code [---/B@BAZK] Engine oil level low 1

Trouble Engine oil level low
--- B@BAZK
Contents of
• Engine oil level is below operating range.
trouble
Action of
• Limits engine output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
• Outpu of engine drops.
appears
• If machine is operated as it is, engine may seize up.
on machine
Related
information

1 Accordingly, contents of troubleshooting depend on machine
model. See Shop manual for machine.
30 107E-1 Series
E-56 Code [---/B@BCNS] Engine overheat 1

Trouble Engine overheat
--- B@BCNS
Contents of
• Engine coolant temperature is above operating range.
trouble
Action of
• Limits engine output and continues operation.
controller
Problem that
• Output of engine drops.
appears
• If machine is operated as it is, engine may seize up.
on machine
Related
information

1 Accordingly, contents of troubleshooting depend on machine model.
See Shop manual for machine.
107E-1 Series 31
E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High

Error 1

Failure rank Failure code Rated Speed Adjustment Volume (Isochronous) High Error
Trouble
Mild A8 (Generator controller system)
Contents of
• Voltage from the rated speed adjustment volume is kept above 4.7 V for 1 second.
trouble
Action of con-
• Fixes the median of adjustable range.
troller
Problem on
• The rated speed changes .
machine
Related infor- • Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume
mation is 0.5 - 4.5 V if system is normal.

2. Disconnect connector CN1 and connect T-adapter to male
Defective 5 V power supply side.
1 for adjustment volume (gen- 3. Turn starting switch to ON position.
erator controller)
Approx.
Between CN1 (male) (22) and (21) Voltage
5V
2. Disconnect connector CN1 and connect T-adapter to female
side.
Defective rated speed 3. Turn the rated speed adjustment (Isochronous) volume
Possible
adjustment (Isochronous) between Min. and Max.
causes and 2
volume or open circuit or
standard value Resis-
short circuit in wiring harness Between CN1 (female) (7) and (21) Min. 450 z
in normal state tance
Resis-
Between CN1 (female) (7) and (22) Min. 450 z
tance
2. Insert T-adapter into connector CN1.
Hot short circuit in wiring har- 3. Turn starting switch to ON position.
3 4. Turn the rated speed adjustment (Isochronous) volume
ness
between Min. and Max.
Between CN1 (7) and (21) Voltage 0.5 - 4.5 V
If cause is not found by above checks, generator controller is
4 Defective generator controller
defective.
32 107E-1 Series
Circuit diagram related to rated speed adjustment (Isochronous) volume
107E-1 Series 33
E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low

Error 1

Failure rank Failure code Rated Speed Adjustment Volume (Isochronous) Low Error
Trouble
Mild A9 (Generator controller system)
Contents of
• Voltage from the rated speed adjustment (Isochronous) volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
• The rated speed changes.
machine
Related infor- • Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment vol-
mation ume is 0.5 - 4.5 V if system is normal.

erator controller)
Approx.
5V
Defective rated speed side.
adjustment (Isochronous) 3. Turn the rated speed adjustment (Isochronous) volume
2 volume or open circuit or between Min. and Max.
short circuit in wiring har- Resis- Min.
Between CN1 (female) (7) and (21)
Possible ness tance 450 z
standard value tance 450 z
in normal state
Ground fault in wiring har- 2. Disconnect connector CN1 and connect T-adapter to female
3 ness side.
(Contact with ground circuit) Resis- Min.
Between CN1 (female) (7) and ground
tance 1 Mz
defective.
- Reference
Defective generator control- 2. Insert T-adapter into connector CN1.
4
ler 3. Turn starting switch to ON position.
4. Turn the rated speed adjustment (Isochronous) volume
between Min. and Max.
34 107E-1 Series
Circuit diagram related to rated speed adjustment (Isochronous) volume
107E-1 Series 35
E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error 1

Failure rank Failure code Rated Speed Adjustment Volume (Droop) High Error
Trouble
Mild AA (Generator controller system)
Contents of
• Voltage from the rated speed adjustment (Droop) volume is kept below 4.7 V for 1 second.
trouble
Action of con-
troller
Problem on
machine

erator controller)
Approx.
5V
side.
Defective rated speed 3. Turn the rated speed adjustment (Droop) volume between
Possible
adjustment (Droop) volume Min. and Max.
causes and 2
or open circuit or short cir-
cuit in wiring harness Between CN1 (female) (13) and (21)
in normal state tance 450 z
Resis- Min.
tance 450 z
Hot short circuit in wiring 3. Turn starting switch to ON position.
3 harness 4. Turn the rated speed adjustment (Droop) volume between
Min. and Max.
Defective generator control- If cause is not found by above checks, generator controller is
4
ler defective.
36 107E-1 Series
Circuit diagram related to rated speed adjustment (Droop) volume
107E-1 Series 37
E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error 1

Failure rank Failure code Rated Speed Adjustment Volume (Droop) Low Error
Trouble
Mild AB (Generator controller system)
Contents of
• Voltage from the rated speed adjustment (Droop) volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
machine

erator controller)
Approx.
5V
side.
Defective rated speed 3. Turn the rated speed adjustment (Droop) volume between
adjustment (Droop) volume Min. and Max.
2
or open circuit or short circuit
Resis- Min.
in wiring harness Between CN1 (female) (13) and (21)
Possible tance 450 z
standard value tance 450 z
in normal state
3 ness side.
(Contact with ground circuit) Resis-
Between CN1 (female) (13) and ground Min. 1 z
tance
defective.
- Reference
4
4. Turn the rated speed adjustment (Droop) volume between
Min. and Max.
38 107E-1 Series
Circuit diagram related to rated speed adjustment (Droop) volume
107E-1 Series 39
E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) 1
Failure rank Failure code Abnormality in KOMNET (CR710 error recognition)

Trouble
(Generator controller system)
Serious AF
Contents of • No data has been received through KOMNET (CAN) communicat for 3 seconds. (Generator con-
trouble troller can not communicate with engine controller.)
Action of con-
troller
Problem on
• Engine stops or does not start.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• Since each controller is connected to battery directly, power is supplied even while starting switch
is at OFF position.
Related infor- • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
mation multimeter.
• Since failure code is displayed, power is supplied to generator controller, thus 5A and 30 A fuse is
not broken.
• There are 2 CAN terminal resistors; One on engine side and the other on controller side. Although
these do not have respective connector labels, they will be called CAN1 and CAN2 in troubleshoot-
ing.
Cause Standard value in normal state/Remarks on troubleshooting

a Check ground terminal T12 for looseness and rust.
Improper power supply to 2. Disconnect connector J3, and connect T-adapter to female side.
1
engine controller 3. Turn starting switch to ON position.
Between J3 (female) (3) and (1) Voltage 20 – 30 V
Between J3 (female) (4) and (2) Voltage 20 – 30 V
Possible 1. Turn starting switch to OFF position.
causes and 2. Replace relay RyA.
standard value 2 Defective relay RyA 3. Turn starting switch to ON position.
in normal state a If this failure code is not displayed, original relay RyA is defec-
tive.
Defective CAN terminating 2. Disconnect connectors CAN1 and CAN2, and connect T-
resistor adapter to each male side.
3
(open or short circuit in inter- Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
nal wiring)
Between CAN2 (male) (A) and (B) Resistance 120 ± 12 z
40 107E-1 Series

q CAN communication line
a CAN terminating resistor of 120 z is also installed inside ma-
chine monitor. Since 120 z resistors are connected in parallel, if
combined resistance measured at connector of controller is
60 z, CAN communication line has no open circuit.
1. Turn starting switch to OFF position and disconnect battery
ground cable.
2. Disconnect connectors J2 or CN2 one by one, and connect T-
adapter to female side of connector disconnected.
Open or short circuit in wiring a If short circuit occurs (if resistance between terminals is 1 z or
4 less), disconnect all of connectors J2 and CN2. Then, check
harness
whether failure is short circuit between wiring harnesses or with-
in controller.
Approx.
Between J2 (female) (46) and (47) Resistance
60 z
Approx.
Between CN2 (female) (32) and (22) Resistance
60 z
Approx.
Between CAN1 (female) (A) and (B) Resistance
120 z
Approx.
Between CAN2 (female) (A) and (B) Resistance
120 z
a If no failure is found by checks on cause 4 , this check is not re-
quired.
ground cable.
Possible 2. Disconnect connectors CN2, J2, CAN1 and CAN2 one by one,
causes and and connect T-adapter to each female side.
standard value Between CN2 (female)( 32) and J2
in normal state Resistance Max. 1 z
(female) (46)
Between CN2 (female) (22) and J2
Resistance Max. 1 z
(female) (47)
Between CN2 (female) (32) and CAN2
Resistance Max. 1 z
(female) (A)
Between CN2 (female) (22) and CAN2
Resistance Max. 1 z
(female) (B)
Between J2 (female) (46) and CAN1
Resistance Max. 1 z
Open circuit in wiring harness (female) (A)
5 (wire breakage or defective Between J2 (female) (47) and CAN1 Resistance Max. 1 z
contact of connector) (female) (B)
q ACC signal from starting switch
ground cable.
2. Insert T-adapters into connector J2.
3. Connect battery ground cable and turn starting switch to ON
position.
Between J2 (39) and ground Voltage 20 – 30 V
a If no failure is found by above checks, this check is not required.
ground cable.
2. Disconnect connector J2 and connect T-adapter to female side.
Between starting switch (ACC) and
Resistance Max. 1 z
relay RyA input
Between relay RyA output and J2
Resistance Max. 1 z
(female) (39)
107E-1 Series 41

a If no failure is found by checks on cause 4 (no open circuit),
measure resistance at one connector.
ground cable.
Ground fault in wiring har- 2. Disconnect connectors CN2 and J2 and connect T-adapter to
6 ness female side of connector disconnected.
(contact with ground circuit) Between CN2 (female) (32) or J2
(female) (46) and ground
Between CN2 (22) or J2 (47) and
ground
a If no failure is found by checks on cause 4 (no open circuit),
measure voltage at one connnector.
ground cable.
Possible 2. Insert T-adapter into connector J2 or CN2.
causes and 3. Connect battery ground cable.
standard value Short circuit or hot short cir- 4. Turn starting switch to ON position.
in normal state 7 cuit in wiring harness (con- a CAN_H and CAN_L lines are considered to be normal if their
tact with 24 V circuit) voltage are between 1 to 4 V. Since their normal voltage is 2.5
± 1 V.
Voltage 1–4V
ground
Voltage 1–4V
ground
If no failure is found by above checks , engine controller is defec-

tive. (Since this is internal failure, troubleshooting cannot be per-
formed.)
If no failure is found by above checks, generator controller
Defective generator control- is defective.
9
ler (Since this is an internal failure, troubleshooting cannot be per-
formed.)
42 107E-1 Series
Circuit diagram related to CAN communication line
107E-1 Series 43
E-62 Code [b6] Droop Rate Adjustment Volume High Error 1

Failure rank Failure code Droop Rate Adjustment Volume High Error
Trouble
Mild b6 (Generator controller system)
Contents of
• Voltage from the droop rate adjustment volume is kept above 4.7 V for 1 second.
trouble
Action of con-
troller
Problem on
• The droop rate changes.
machine
Related infor- • Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume
mation is 0.5 - 4.5 V if system is normal.

erator controller)
Approx.
5V
side.
Defective droop rate adjust- 3. Turn the droop rate adjustment volume between Min. and
Possible
ment volume or open circuit Max.
causes and 2
or short circuit in wiring har-
ness Between CN1 (female) (8) and (21)
Resis- Min.
tance 450 z
Hot short circuit in wiring har- 3. Turn starting switch to ON position.
3 4. Turn the droop rate adjustment volume between Min. and
ness
Max.
4
ler defective.
44 107E-1 Series
Circuit diagram related to droop rate adjustment volume
107E-1 Series 45
E-63 Code [b7] Droop Rate Adjustment Volume Low Error 1

Failure rank Failure code Droop Rate Adjustment Volume Low Error
Trouble
Contents of
• Voltage from the droop rate adjustment volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
• The droop rate changes.
machine

erator controller)
Approx.
5V
side.
Defective droop rate adjust- 3. Turn the droop rate adjustment volume between Min. and
2
Resis- Min.
Possible ness Between CN1 (female) (8) and (21)
tance 450 z
causes and
3 ness side.
(Contact with ground circuit)
Between CN1 (female) (8) and ground Voltage 0.5 - 4.5 V
defective.
- Reference
4
4. Turn the droop rate adjustment volume between Min. and
Max.
46 107E-1 Series
Circuit diagram related to droop rate adjustment volume
107E-1 Series 47
E-64 Code [b8] Low Idle Speed Adjustment Volume High Error 1
1
Failure rank Failure code Low Idle Speed Adjustment Volume high Error
Trouble
Contents of
• Voltage from the low idle speed adjustment volume is kept below 4.7 V for 1 second.
trouble
Action of con-
troller
Problem on
• The low idle speed changes.
machine

erator controller)
Approx.
5V
side.
Defective low idle speed 3. Turn the low idle speed adjustment volume between Min. and
Possible
adjustment volume or open Max.
causes and 2
circuit or short circuit in wir-
ing harness Between CN1 (female) (19) and (21)
Resis- Min.
tance 450 z
3 harness 4. Turn the low idle speed adjustment volume between Min.
and Max.
4
ler defective.
48 107E-1 Series
Circuit diagram related to low idle speed adjustment volume
107E-1 Series 49
E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error 1

Failure rank Failure code Low Idle Speed Adjustment Volume Low Error
Trouble
Contents of
• Voltage from the low idle speed adjustment volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
• The low idle speed changes.
machine

erator controller)
Approx.
5V
side.
Defective low idle speed 3. Turn the low idle speed adjustment volume between Min.
adjustment volume or open and Max.
2
circuit or short circuit in wir-
Resis- Min.
Possible ing harness Between CN1 (female) (19) and (21)
tance 450 z
causes and
3 ness side.
defective.
- Reference
4
4. Turn the low idle speed adjustment volume between Min. and
Max.
50 107E-1 Series
Circuit diagram related to low idle speed adjustment volume
107E-1 Series 51
E-66 Code [bc] Rated Speed Median Adjustment Volume High Error 1

Failure rank Failure code Rated Speed Median Adjustment Volume High Error
Trouble
Mild bc (Generator controller system)
Contents of
• Voltage from the rated speed median adjustment volume is kept above 4.7 V for 1 second.
trouble
Action of con-
troller
Problem on
• The target rated speed changes after the engine is started.
machine

erator controller)
Approx.
5V
side.
Defective rated speed 3. Turn the rated speed median adjustment volume between
Possible
median adjustment volume Min. and Max.
causes and 2
or open circuit or short cir-
cuit in wiring harness Between CN1 (female) (1) and (21)
Resis- Min.
tance 450 z
3 harness 4. Turn the rated speed median adjustment volume between
Min. and Max.
4
ler defective.
52 107E-1 Series
Circuit diagram related to rate speed median adjustment volume
107E-1 Series 53
E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error 1

Failure rank Failure code Rated Speed Median Adjustment Volume Low Error
Trouble
Mild bd (Generator controller system)
Contents of
• Voltage from the rated speed median adjustment volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
• The target rated speed changes after the engine is started.
machine

erator controller)
Approx.
5V
side.
Defective rated speed 3. Turn the rated speed median adjustment volume between
median adjustment volume Min. and Max.
2
or open circuit or short circuit
Resis- Min.
Possible in wiring harness Between CN1 (female) (1) and (21)
tance 450 z
causes and
3 ness side.
defective.
- Reference
4
4. Turn the rated speed median adjustment volume between
Min. and Max.
54 107E-1 Series
Circuit diagram related to rated speed median adjustment volume
107E-1 Series 55
E-68 Code [bE] Ramp Time Adjustment Volume High Error 1

Failure rank Failure code Ramp Time Adjustment Volume High Error
Trouble
Mild bE (Generator controller system)
Contents of
• Voltage from the ramp time adjustment volume is kept above 4.7 V for 1 second.
trouble
Action of con-
troller
Problem on
• The ramp time changes.
machine

erator controller)
Approx.
5V
side.
Defective ramp time adjust- 3. Turn the ramp time adjustment volume between Min. and
Possible
causes and 2
ness Between CN1 (female) (2) and (21)
Resis- Min.
tance 450 z
3 harness 4. Turn the ramp time adjustment volume between Min. and
Max.
4
ler defective.
56 107E-1 Series
Circuit diagram related to ramp time adjustment volume
107E-1 Series 57
E-69 Code [bF] Ramp Time Adjustment Volume Low Error 1

Failure rank Failure code Ramp Time Adjustment Volume Low Error
Trouble
Mild bF (Generator controller system)
Contents of
• Voltage from the ramp time adjustment volume is kept below 0.3 V for 1 second.
trouble
Action of con-
troller
Problem on
• The ramp time changes.
machine

erator controller)
Approx.
5V
side.
Defective ramp time adjust- 3. Turn the ramp time adjustment volume between Min. and
2
Resis- Min.
Possible ness Between CN1 (female) (2) and (21)
tance 450 z
causes and
3 ness side.
defective.
- Reference
4
4. Turn the ramp time adjustment volume between Min. and
Max.
58 107E-1 Series
Circuit diagram related to ramp time adjustment volume
107E-1 Series 59
© 2010 KOMATSU
All Rights Reserved
60
SEN00253-02
Engine 1SHOP MANUAL
107E-1 Series
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start..................................................................................................................... 9
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 17
S-9 Oil becomes contaminated quickly .............................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 20
S-12 Oil pressure drops ..................................................................................................................... 21
107E-1 Series 1
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 22

S-14 Coolant temperature becomes too high (overheating) .............................................................. 23
S-15 Abnormal noise is made ............................................................................................................ 24
S-16 Vibration is excessive ................................................................................................................ 25
2 107E-1 Series
107E-1 Series 3
Troubleshooting of mechanical system (S-mode) 1

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

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

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

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

q Insufficient supply of fuel
Defective alternator (regulator section)

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

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

Worn piston ring, cylinder
fuel injection timing electrically. Accordingly, even if the
starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

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

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

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

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

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

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

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

General causes why engine does not turn
q Seized parts inside engine
o See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

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

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

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

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

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

Carry out troubleshooting

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

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

q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
107E-1 Series 9
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes
out
q Fuel is not being supplied
q Supply of fuel is extremely small

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

Seized, abnormally worn feed pump

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

Insufficient fuel in tank
Defective fuel injector

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

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

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

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E- q q
mode
Carry out troubleshooting according to “Abnormality in supply pump PCV (*2)” in E-
mode q
Inspect pressure relief valve directly q

Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
*1: Code [559/CA559] and code [2249/CA2249] in E mode

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

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

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

q Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery

Clogging of fuel filter

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

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

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

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

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

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

q Defective condition of fuel injection

q Controller is controlling in derate mode

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


Improper valve clearance

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

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

Troubleshooting
Inspect valve clearance directly q

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

General causes why engine stops during opera- Causes
tions
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

q Internal parts of engine seized
Defective engine controller power supply wiring

q There is overheating

q Problem in drive devices on applicable
Broken, seized piston, connecting rod

machine side

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

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

Broken supply pump shaft
Defective hydraulic pump

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

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

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

Inspect piston, connecting rod directly q
Carry out troubleshooting on
Inspect crankshaft bearing directly q

Inspect gear train directly q
applicable machine
Troubleshooting

Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply
pump (*1)” in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor,
q
etc.) is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
107E-1 Series 13
S-5 Engine does not rotate smoothly 1

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

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

Defective G speed sensor, wiring harness


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

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


Troubleshooting

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

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

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

Defective installation of boost pressure sensor
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

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

high (Overheating)“

Clogged fuel spill piping


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

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

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

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

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

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

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



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

Improper fuel injection pressure

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

Crushed, clogged muffler
Abnormally worn injector

Improper injection timing
electrical system)
Clogged, seized injector

Suddenly became black w w Q Q Q
w Q Q
Questions
Color of exhaust gas is Gradually became black

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

Check items

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

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

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

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

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

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

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

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

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

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

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

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

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

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

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

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

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

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

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

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

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

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

Defective fuel supply pump oil seal
Defective common rail pressure

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

Defective spray by injector
Improper injection timing

E E E
Questions

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

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

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

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

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

Cracks inside cylinder block
Holes caused by pitting
machine side
E E
Questions

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

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

shooting
Trouble-
Inspect cylinder block directly q q troubleshooting

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

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

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation
and Maintenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

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

Coolant, fuel in oil
Clogged oil filter

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

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

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

Troubleshooting
Inspect oil pan strainer, pipe directly q q

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

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

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

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

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

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

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

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

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

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

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

q Drop in heat dissipation efficiency
Clogged, crushed radiator fins

q Problem in coolant circulation system
Clogged, broken oil cooler
Broken fan pulley bearing

q Rise in oil temperature in power train
applicable machine side

o Carry out troubleshooting on applicable machine
Clogged radiator core

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

(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed)
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged w w

with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)

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

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

When operation of thermostat is carried out, it does not open at cracking
temperature q
Temperature difference between upper and lower tanks of radiator is slight q

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

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

Defective inside of muffler (dividing board out of position)
q Abnormal combustion
Leakage of air between turbocharger and cylinder head

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

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

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

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

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

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

Clogged, seized injector

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

mality, however.

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

some cylinders is low w Q

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

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

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

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

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature
Broken output shaft, parts in damper on applicable machine side

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

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

Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

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

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

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
107E-1 Series 25
26
SEN00257-06
Engine 1SHOP MANUAL
107E-1 Series

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
107E-1 Series 1
SEN00257-06 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.1)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 107E-1 Series
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they are not available
5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
107E-1 Series 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 107E-1 Series
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
107E-1 Series 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 107E-1 Series
Special tools list 1
a Tools with part number 79 T-

tools to be made locally).
* *** ****
- means that they are not available from Komatsu Ltd. (i.e.
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
a Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are
CUMMINS part Nos.
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
790-501-2001
A Repair stand t 1
795-799-1150
Disassembly and assembly Specialized for Komatsu
of engine assembly — N
repair stand
B Adapter t 1
Specialized for CUMMINS
795-799-7210 N
repair stand
Removal and installation of 795-102-2103
C Spring pusher q 1
air intake and exhaust valves 795-799-8800 N
Removal and installation of
D 795-100-2800 Piston ring tool t 1
piston ring
Installation of piston E 795-921-1100 Piston holder t 1 φ75 – 175 mm
Removal of injector F 795-799-6700 Puller t 1 N
G 795-799-6500 Seal driver q 1 N
rear seal
H 795-799-6400 Seal driver q 1 N
front seal
790-331-1120 Wrench (angle)
Angle tightening of bolt J q 1
795-799-2240 Angle gauge
Commercially
Adjusting valve clearance K Clearance gauge q 1
available
Adjusting gear backlash and Commercially
L Dial gauge and stand q 1
end play available
Removal of fuel inlet
M 795-799-8150 Remover q 1 N
connector
U 795-799-2270 Remover and installer q 1
main bearing
Rotation of crankshaft V 795-799-1131 Gear q 1
Tightening of injector har-
W 795-799-7110 Torque wrench q 1 N
ness nut
Measurement of cylinder
X 795-790-4510 Gauge q 1 N
head bolt length
Y 795-799-6130 Support t 1
fuel supply pump gear
107E-1 Series 7
SEN00257-06
© 2012 KOMATSU
All Rights Reserved
8
SEN00258-07
Engine 1SHOP MANUAL
107E-1 Series

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

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

Remove mounting bolt (1) and then remove Remove rear engine sling bracket (1) from the
starting motor assembly (2). flywheel housing (FWH).
<4D107E-1>
5. Fan pulley
<6D107E-1> 1) Remove fan belt (1).
q Insert a wrench to the portion (A)
(width across flats T 12.7 mm) of the
tensioner assembly (2), and rotate it
to the opposite to the winding-up
direction to decrease the fan belt (1)
tension, then remove.
k Make sure that the wrench is
secured at the portion (A) before
rotating it. (The spring of the ten-
sioner assembly (2) is strong. If the
wrench is loosely inserted, the
wrench may accidentally come off
w h i l e b e i n g r o ta t e d a n d i t i s
extremely dangerous.)
k After removing the fan belt (1),
4. Engine sling bracket on rear side return the tensioner assembly (2)
<All engine except for generator> slowly with care.
Remove rear engine sling bracket (1) from the k Be careful not to get your fingers
cylinder head. caught between the pulley and fan
belt (1) during work.
2) Remove bolt (3) and then remove fan pul-
ley (4).
107E-1 Series 3
6. Vibration damper and crankshaft pulley 8. Fan hub

q 4D107E-1 (Without damper) Remove 4 bolts (1) and then remove fan hub
Remove bolts (1) and crankshaft pulley (2).
(2).
<4D107E-1>
9. Alternator
q 6D107E-1 (With damper) 1) Remove plate (1).
Remove bolts (1) and vibration damper 2) Remove bolt (2) and then remove alterna-
(2). tor (3).
<6D107E-1>
3) Remove alternator bracket (4) and front

7. Belt tensioner side sling bracket (5).
Remove bolt (1) and then remove belt ten-
sioner (2).
4 107E-1 Series
10. Thermostat 11. Water pump

1) Remove coolant outlet connector (1). 1) Remove coolant inlet connector (1).
<4D107E-1> 2) Remove water pump (2).
<6D107E-1>
12. Turbocharger and exhaust manifold
<4D107E-1>
1) Remove turbocharger heat insulation
cover (1) and lubricating oil inlet tube (2).
a When loosening the flange nut of tube (2),
fix the connectors on the turbocharger or
oil cooler side with a spanner to prevent
them from being dragged.
<4D107E-1>
2) Remove thermostat (2).
107E-1 Series 5
a In the case of water-cooled turbocharger, 5) Remove exhaust manifold (10).

remove water-cooled inlet tube (11), outlet <4D107E-1>
tube (12) and (13).
(6D107E-1)
2) Remove head cover (5) and oil return tube 1) Remove turbocharger lubricating oil inlet
flange bolt (on the head cover side). tube (1) and drain tube (2).
3) Remove turbocharger assembly mount- <6D107E-1>
ing nuts (3) and place turbocharger
assembly (4) on the stud bolts.
<4D107E-1>
2) Remove turbocharger assembly (3) and

exhaust manifold (4).
<6D107E-1>
4) Since there is not sufficient clearance on
the exhaust manifold side, move turbo-
charger assembly (4) to the right and
remove the flange bolts (6) of drain tube
(7) with hexagonal wrench [1].
<4D107E-1>
6 107E-1 Series
13. Fuel filter assembly 14. Harness assembly

<4D107E-1> < O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 ,
Since the fuel prefilter and main filter are PC200LC-8M0, PC220-8M0, PC220LC-8M0
installed to the chassis, they do not need to be and PC240LC-8M0>
removed for general disassembly of the Disconnect the harness from the sensor and
engine. controller, and then remove the clamp to
<6D107E-1> remove harness assembly (1).
1) Disconnect hoses (1) and (2) from the fil-
ter.
2) Disconnect drain hose (3) from filter
bracket (4).
3) Remove fuel filter assembly (5).
q Removal of hose
While pressing the adapter (by the
right and left sides) at the hose end,
pry off the hose end face with a
screwdriver.
k The internal parts of the adapter
may be damaged when the hose is
removed. Accordingly, do not
reuse the adapter but always use
new one when installing the hose <WA380Z-6, PC200-8M0, PC200LC-8M0,
again. PC220-8M0, PC220LC-8M0 and PC240LC-
<6D107E-1> 8M0 only>
Disconnect three connectors (2) of the injector
harness.
a To disconnect connector (2), pull it out in
the direction of the arrow while pressing
claw lock (a).
<6D107E-1>
107E-1 Series 7
15. Fuel high-pressure piping and common rail 16. Air intake manifold cover
<4D107E-1> 1) Remove tube (1) and electrical intake air
1) Remove boots (8) of high-pressure pip- heater (2).
ings (1) to (5) and then remove the high- 2) Remove manifold covers (3) and (4).
pressure pipings. <4D107E-1>
2) Remove fuel drain hose (9).
3) Remove common rail (7).
<6D107E-1>
1) Remove boots (9) of high-pressure pip-
ings (1) to (7) and then remove the high-
pressure pipings.
2) Remove fuel drain hose (8).
3) Remove common rail (10).
q Removal of hose
Remove the hose by prying the hose
end face with screwdriver while push-
ing the mouthpiece (on both sides) of
the hose termination.
k Do not use the hose again,
because inside of the mouthpiece <6D107E-1>
removed. Always use a new hose
when assembling.
<4D107E-1>
17. Head cover and rocker housing

< O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 ,
PC200LC-8M0, PC220-8M0, PC220LC-8M0
and PC240LC-8M0>
1) Remove nuts (2) and then remove head
<6D107E-1>
cover (3) together with duct (1) and gasket
(3a).
2) Remove duct (1) from head cover (3).
8 107E-1 Series
<WA380Z-6, PC200-8M0, PC200LC-8M0,

PC220-8M0, PC220LC-8M0 and PC240LC-
8M0 only>
1) Remove bolts (2) and then remove head
cover (3) together with duct (1).
2) Remove duct (1) from head cover (3).
3) Remove nuts (4) of the harness from

injector.
a Harness installation position

Color of cable Cylinder No.
White 1, 3, 5
Black 2, 4, 6
Note: No.5 and 6 cylinders are equipped

with 6D107E-1 only.
4) Remove bolt (5) and then remove rocker

housing assembly (6).
a Do not remove the injector harness
connector (7) from rocker housing
unless it is required.
3) Remove nuts (4) of the harness from

injector.
a The injector harness and nut have no
positional distinction. (Their right and
left sides may be reversed)
4) Remove gasket assembly (4a).
107E-1 Series 9
19. Push rod

Remove push rods (1).
18. Rocker arm assembly and crosshead

1) Remove bolts (1) and rocker arm assem-
bly (2).
a Loosen the locknut and then loosen 20. Fuel injector assembly
the adjustment screw fully so that the 1) Remove retainer (5) and then remove 6
tension of the valve spring will not be inlet connectors (1).
applied to the rocker arm assembly q Use tool M when removing the inlet
mounting bolts. connector.
2) Remove crosshead (3). 2) Remove mounting bolts (3) of injector (2)
and then remove holder (4).
3) Remove injector (2).
a Record the position of the crosshead

and the shapes of holes "a" and "b"
(to install the crosshead in the same
a Lift and remove the injector using tool
direction again).
F. (Don't try to pry the top of the injec-
tor.)
10 107E-1 Series
21. Cylinder head assembly 3) Raise the cylinder head assembly, pull
Remove bolts (1) and cylinder head assembly and remove valve (6) and then remove
(2). valve seal (7).
a Apply a marking to valve (6) to make
4 Cylinder head assembly:
it identifiable to which cylinder head it
50 kg (4D107E-1)
should be combined.
4 Cylinder head assembly:
70 kg (6D107E-1)
22. Oil cooler

1) Remove oil filter (1). (When filter is
q Disassemble the cylinder head assembly installed to engine)
according to the following procedure. a The oil filter of 4D107E-1 is installed
1) Using tool C, compress valve spring (3) to to the chassis.
remove valve cotter (4).
2) Remove mounting bolts (6), cover (2) and

cover gasket (3).
2) Remove upper seat (5) and valve spring 3) Remove oil cooler (4) and cooler gasket
(3). (5).
107E-1 Series 11
23. Engine controller 24. Fuel supply pump

1) Remove engine controller (1). 1) Remove 3 hoses (1).
2) Disconnect ground cable (2). 2) Remove 3 nuts (2) and then remove sup-
ply pump (3).
<4D107E-1>
3) Remove cooling plate (3).
<6D107E-1>
3) When disassembling the fuel pump drive

gear from the fuel supply pump, follow the
procedure described below.
1] Use a support Y and a 1/2 inch
breaker bar (10) to retain the gear,
then loosen the nut (11).
a Do not remove the nut (11) from
the shaft.
12 107E-1 Series
2] Install a puller [1] between the flange 25. Flywheel

and gear (12). <Generator>
1) Remove lock nut (1).
2) Remove speed sensor (2).
3) Remove boss (3).
3] Install a puller [2] onto the puller [1]

and the shaft.
4] Rotate the center bolt (13) until the
gear is separated from the shaft.
5] Remove the pullers [1], [2]. Install guide bolt [1] and then remove flywheel
(1).
4 Flywheel:
35 kg <6D107E-1>
15 kg <4D107E-1>
110 kg <Generator>
k Be careful not to injure your finger with
the flywheel that can fall off from the
shallow spigot joint.
6] Remove the nut (11), lock washer

(15), and gear (16) from the shaft (14).
107E-1 Series 13
26. Rear oil seal 28. Oil pan

1) Install tool G to the crankshaft. 1) Remove bolts (1) and then remove oil pan
2) Screw in tapping screw [1] of tool G to the (2).
seal carrier section of rear oil seal (1).
3) Turn the handle counterclockwise to
remove rear oil seal (1).
2) Remove suction tube (3).

3) Remove plate (4) and 3 plates (5).
a Plates (5) are not installed in 4D107E-1.
27. Flywheel housing

Remove bolts (1) and then remove flywheel 29. Front cover
housing (2). 1) Remove engine Bkup speed sensor (1).
2) Remove bolts (2) and then remove front
cover (3).
3) Remove front seal (4).
14 107E-1 Series
30. Oil pump assembly 2) Remove thrust plate (2).

Remove bolts (1) and then remove oil pump
assembly (2).
3) Rotate camshaft (3) when removing the

plate.
31. Camshaft
a Rotate the crankshaft to align punch mark
A on camshaft gear (1) to the chamfered
tooth of crankshaft gear (4) (preventing of
interference with the connecting rod when
removing the camshaft).
32. Gear housing

Remove bolts (1) and then remove gear hous-
ing (2).
1) Remove gear (1).
107E-1 Series 15
33. Piston and connecting rod assembly 6) Push in and remove the piston and con-
1) Rotate the crankshaft and bring the piston necting rod assembly with a wood bar, etc.
to be removed to the bottom dead center. from the oil pan side, while supporting pis-
2) Scrub the carbon off the top wall of the cyl- ton (6) on the cylinder head side.
inder liner with fine sandpaper. a Take care in the removal so that inner
3) Apply a marking to each of connecting rod surface of the cylinder liner may not
cap (1) assembly position on respective be damaged by corners of the con-
cylinders. necting rod.
a Before removing the piston and con- a Make a cylinder No. mark on the pis-
necting rod assembly, measure the ton.
side clearance between the connect-
ing rod and crankshaft using tool K.
7) Remove the other piston and connecting

rod assemblies according to the above
4) Remove bolt (2). procedure.
5) Hit connecting rod cap (1) with a plastic a Take care not to damage the sliding
hammer lightly, and remove connecting portions of the pistons and bearings.
rod cap (1) and connecting rod bearing as
a unit. q Disassemble the piston and connecting
a Keep the connecting rod and connecting rod assembly according to the following
rod cap so that their mating faces will not procedure.
be damaged. 1] Remove snap ring (3).
If their mating faces are damaged, replace 2] Separate piston (6) from connecting
them. rod by pulling out piston pin (5) while
supporting connecting rod (4) with
hand.
3] Remove the snap ring on the oppo-
site side.
16 107E-1 Series
4] Using tool D, remove piston ring (7). 1) Remove mounting bolts (2) of main cap
a Keep the piston, connecting rod, (1).
connecting rod bearing, piston 2) Insert the bolts in the bolt holes of main
rings, and piston pin by cylinder. cap (1) and remove the cap, while shaking
it.
a Installation position numbers are
marked on the main cap. No. 1 starts
from the front side of the cylinder
block.
<4D107E-1>
34. Crankshaft
a Before removing the crankshaft, measure
its end play X with dial gauge.
<6D107E-1>
a Check that the position No. of the

main cap (stamped at part A) is
directed toward the oil cooler.
107E-1 Series 17
3) Remove bottom lower bearing (3) from 5) Remove upper thrust bearing (5) and
main cap (1). upper bearings (6).
a Mark the installation position number
on claw (A) of the removed bearing.
(Don't apply the number on the sliding
surface of the bearing.)
Mark the assembly position on the main

cap, upper bearing and upper thrust bear-
ing (in the claw of the bearing). It is
advised to maintain the bearings of a main
4) Lift off crankshaft (4) using the nylon sling. cap separately from that for another main
a When lifting and removing the crank- cap. And take care not to damage these
shaft, take care not to damage it by parts.
bumping against the cylinder block.
a Keep the crankshaft in a safe place 35. Piston cooling nozzle
so that its sliding portions will not be Remove bolt (1) and then remove piston cool-
damaged. ing nozzles (2).
4 Crankshaft: 45 kg (4D107E-1)
18 107E-1 Series
36. Tappet
Remove tappets (1) and then mark the installa-
tion position on them.
a When reusing the camshafts and tappets,
be sure to install them in the original posi-
tion.
37. Cylinder block

Remove cylinder block (1) from tool A.
4 Cylinder block: 100 kg (4D107E-1)
107E-1 Series 19
SEN00258-07
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 06-12 (01)
20
SEN00259-10
Engine 1SHOP MANUAL
107E-1 Series

Disassembly and assembly, Part 2
General assembly of engine ........................................................................................................................... 2
107E-1 Series 1
General assembly of engine 1 a Don't invert the cylinder block by 90°

or more. Otherwise, the tappet may
a This document describes the general assem- fall off from the mounting hole during
bly procedure of SAA4D107E-1 and assembly.
SAA6D107E-1. The shapes, quantity, loca-
tions, etc. of the parts depend on each applica-
ble machine.
a When reusing a part, be sure to install it to its
original position.
a Unspecified photos and drawings show those
of 6D107E-1.
1. Preparation work
1) Install tool B.
2) Install cylinder block (1) to tool A.
3 Mounting bolt:
77 ± 12 Nm {7.9 ± 1.2 kgm}
3. Piston cooling nozzle

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

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

crankshaft (4).
a When installing, take care not to dam-
age the upper thrust bearing.
<6D107E-1>
3) Fit lower bearing (3) to the main cap,

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

camshaft with a dial gauge.
a End play: 0.10 – 0.36 mm
q The end play is determined by thick-
ness of the thrust plate and groove of
the camshaft.
a Backlash: 0.076 – 0.280 mm
107E-1 Series 9
<Generator> a Make sure after rotating the

a 2 types of bolts are used. Make sure crankshaft by a turn that the
when tightening that the specified gauge pointer is returned to the
torque is used. position where it had situated
3] M12: when the crankshaft was started
85 ± 10 Nm {8.7 ± 1.0 kgm} to turn.
(E mark)
4] M10:
49 ± 5 Nm {5.0 ± 0.5 kgm}
(T mark)
q Measurement of facial runout

1] Like in measurement of the radial
runout, contact the probe of the dial
gauge at right angle against the end
face of the flywheel housing.
a Before conducting the measure-
ment, move the crankshaft either
in the front or rear side in order to
prevent errors due to the end
play.
2] Set graduations of the dial gauge to
"0" and then rotate the crankshaft by
a turn to measure the difference in the
maximum deflections of the gauge
pointer.
3) After installing the flywheel housing, mea-

sure the radial runout and facial runout
with tool L.
a Radial runout:
Max. 0.20 mm <All engine except for
generator>
Max. 0.5 mm <Generator>
a Facial runout:
Max. 0.20 mm <All engine except for
generator>
Max. 0.28 mm <Generator>
q Measurement of radial runout
1] Install tool L to the crankshaft end
face.
2] Contact the probe of the dial gauge at
right angle against part of the spigot
joint of the flywheel housing.
3] Set graduations of the dial gauge to
"0" and then rotate the crankshaft by
a turn to measure differences in the
maximum deflections of the gauge
pointer.
10 107E-1 Series
9. Rear oil seal 4) Using tool G, insert the oil seal until it is
1) Insert pilot [2] to rear oil seal (4). flush with the flywheel housing end face.
a Before inserting the pilot, clean,
degrease and dry the oil seal lip sur-
face.
a When pushing in the oil seal, make

sure that the seal carrier is free from
bending.
2) Insert oil seal (4), together with pilot [2], to a Installed dimension
the crankshaft and then push in the seal X = Max. 0.38 mm
carrier of oil seal (4) to the flywheel hous-
ing (1).
a Before inserting the oil seal, clean,
degrease and dry the surface where
the seal is contacted against the
crankshaft.
3) Pull out pilot [2] and then further push in
oil seal (4).
10. Flywheel
1) Install guide bolt [1] and flywheel (1).
2 Flywheel mounting bolt:
Engine oil (EO30)
4 Flywheel assembly:
35 kg <6D107E-1>
15 kg <4D107E-1>
110 kg <Generator>
107E-1 Series 11
2) Tighten the mounting bolts in the order

indicated in the figure.
3 Mounting bolt:
137 ± 7 Nm {14.0 ± 0.7 kgm}
<Generator>
a Installation procedure for speed sensor
2 Threads of sensor: Adhesive (LT-2)
1) Install boss (3) on the flywheel housing
2) Screw the sensor (2) into the flywheel
3) After installing the flywheel, measure the
housing to touch it to the ring gear.
radial runout and facial runout with tool L.
3) Return the sensor by 1/2-2/3 turns. (Clear-
a Radial runout: Max. 0.13 mm
ance between the sensor and ring gear:
a Facial runout: Max. 0.20 mm
0.75-1 mm)
q Measurement of radial runout
4) Tighten Sensor locknut (1)
3 Sensor locknut (1):
1] Install tool L to the flywheel housing.
2] Contact the probe of the dial gauge at 39.2 - 44.1 Nm {4 - 4.5 kgm}
right angle against section (a) of the
spigot joint or periphery of the fly-
wheel housing.
3] Rotate the flywheel by a turn to mea-
sure the differences in the maximum
deflections of the dial gauge pointer.
a Make sure after rotating the fly-
wheel by a turn that the dial
gauge pointer is returned to the
position where it had situated
when the flywheel was started to
turn.
q Measurement of facial runout
1] Like in measurement of the radial
runout, contact the probe of the dial
gauge at right angle against end face
(b) situated near the periphery of the
flywheel housing.
a Before conducting the measure-
ment, move the crankshaft either
in the front or rear side in order to
prevent errors due to the end
play.
2] Rotate the flywheel by a turn to mea-
sure the differences in the maximum
deflections of the dial gauge pointer.
12 107E-1 Series
11. Oil pump assembly

a Fill up the oil pump rotor space and the
idler shaft bore with engine oil (EO15W-
40) and then rotate the rotor by two turns.
12. Front cover

1) Apply gasket sealant to installation sur-
face (A) of cover (2).
2 Front cover: Gasket sealant (LG-7)
1) Install oil pump assembly (2) with bolts (1). q Diameter of gasket sealant line shall
be 1 – 2 mm.
2) Tighten the mounting bolts in the order

indicated in the figure.
3 Mounting bolt:
1st time:
8 ± 1 Nm {0.8 ± 0.1 kgm} (Fig.a)
2nd time:
24 ± 4 Nm {2.4 ± 0.4 kgm} (Fig.b)
3) Measurement of backlash
Stop move of a gear of either side and
then measure backlash (C) of the pump
and idler gear.
a Total amount of backlash (C):
0.2 ± 0.05 mm
107E-1 Series 13
2) Tighten the mounting bolts according to 4)Install engine Bkup speed sensor (1).
the numbers [1] o [13] shown in the figure. a Adjustment of installing position of the
3 Mounting bolt: sensor is unnecessary.
24 ± 4 Nm {2.4 ± 0.4 kgm} 3 Mounting bolt:
8 ± 2 Nm {0.82 ± 0.20 kgm}
3) Using tool H, install front seal (3).

a Before installing the seal, check that 13. Oil pan
the end corners and lip sliding sur- 1) Install plate (4) and 3 plates (5).
faces of the crankshaft are free from 3 Mounting bolt:
flaw, burr, and rust of the housing. 43 ± 5 Nm {4.4 ± 0.5 kgm}

a When installing the seal, do not apply q Plate (5) is not installed to 4D107E-1.
oil or grease to the shaft and seal lip. 2) Install suction tube (3).
Wipe off the oil from the shaft. 3 Flange mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a The deviation of seal (3) from cover

(2) must be as follows:
q Extrusion (x): Max. 0.38 mm 3) Remove the gasket sealant projected from
q Facial runout (TIR) (y): Max. 0.25 mm between the cylinder block and front cover
and between the cylinder block and gear
housing (4 places marked with A) with a
scraper.
a When removing only the oil pan,
remove the used gasket sealant filled
in the borders (4 places marked with
A) with a scraper, too.
4) Apply gasket sealant between the cylinder
block and front cover and between the cyl-
inder block and gear housing (4 places
marked with A).
2 Oil pan part A:
Gasket sealant (LG-7)
q Diameter of gasket sealant line: 3 mm
14 107E-1 Series
<The figure shows 4D107E-1 as an example> <4D107E-1>
<6D107E-1>
5) Apply gasket sealant to installation sur-
face (A).
2 Oil pan: Gasket sealant (LG-7)
q Diameter of gasket sealant line:
Straight line: 3 mm, curved line: 1 mm
14. Crankshaft pulley and vibration damper

1) Install crankshaft pulley (4D107E-1) and
vibration damper (6D107E-1) by fitting in
their knock holes to dowel pin (a) of the
crankshaft.
6) Install oil pan (2) with bolts (1). 2) Bolt (1) tightening procedure
1] Tighten the bolt's opposing corner
sequentially with 55 ± 5 Nm {5.6 ±
0.5 kgm}.
2] Loosen the bolt by 180°.
3] Tighten the bolt's opposing corner
sequentially with 55 ± 5 Nm {5.6 ±
0.5 kgm}.
4] 90° ± 5° (When angle tightening
tool J is used)
7) Tighten the mounting bolts according to

the numbers shown in the figure.
3 Mounting bolt:
28 ± 2 Nm {2.9 ± 0.2 kgm}
107E-1 Series 15
q When not using angle tightening tool: 3] Use the support Y and 1/2 inch
Make marks on the crankshaft pulley breaker bar (10) to hold the gear in
or vibration damper and each bolt place while tightening the nut (11).
with paint and then tighten the bolt by 3 Mounting nut of fuel supply
90° ± 5°. pump gear:
105 ± 5 Nm {10.7 ± 0.51 kgm}
15. Fuel supply pump

2) Install supply pump (3) with 3 nuts (2).
k If grease is applied too much to the
1) How to install the gear (16)
a The shaft (14) and gear (16) mating face
must be clean (without dirt or foreign O-ring when the supply pump is
material) and dry prior to assembly. installed, it will ooze out during
1] Install the gear (16) onto the shaft operation. Accordingly, do not
(14). apply grease too much. (Apply
grease to O-ring groove area A.)
k When removing and installing the
2] Install the lock washer (15) and nut
(11) and finger tighten.
supply pump mounting stud bolts
of the gear housing, apply LOC-
TITE to the root side.
3 Mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Install new 3 hoses (1).
k The internal parts of the adapter
removed. Accordingly, do not
reuse the adapter but always use
new one when installing the hose
again, as a rule.
16 107E-1 Series
<4D107E-1> 2) Install engine controller (1) and tighten

mounting bolts (5).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Install ground wire (3).
<6D107E-1>
17. Oil cooler

1) Install gaskets (5) and (3), oil cooler (4)
and cover (2) with bolts (6).
16. Engine controller

1) Install cooling plate assembly (2) and
tighten mounting bolts (4).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Tighten the bolts in the numeric order

3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 17
2)For a model such as WA380-6 which has 3] Raise the cylinder head and install
the oil filter on its engine, select oil filter valve spring (3) and upper seat (5).
(1).
a Apply engine oil to the seal.
2 Oil filter seal:
3 Filter: 13 ± 2 Nm {1.3 ± 0.2 kgm}
Or tighten 3/4 turns after contacting
mating part.
<6D107E-1>
4] Using tool C, compress valve spring

(3) to install valve cotter (4).
18. Cylinder head assembly

1) Assemble the cylinder head assembly
according to the following procedure.
1] Install valve seal (7).
2] Apply engine oil to the valve stem and
inside of valve guide and install valve
(6).
2 Valve stem and valve guide: a Hit the valve stem lightly with a plastic
Engine oil (EO15W-40) hammer to make sure that the valve
collet is positively fitted to the groove
of the valve stem.
2) Before tightening the cylinder head
mounting bolt, check the following.
1] Measure stem length (a) of every bolt
to make sure that they are less than
the using limit.
q Using limit length of bolt stem (a):
Max. 132.1 mm
a If a bolt is longer than the using
limit, do not reuse it but replace
it.
18 107E-1 Series
3) Check that the cylinder head mounting <4D107E-1>

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

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

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

– 3 turns or more by hand, and then
tighten them according to the follow-
ing procedure.
2 Apply engine oil (EO15W-40) to the
threaded portion and head seat of
each bolt.
3 Mounting bolt:
a Tighten the bolts 3 times in the order
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] 90 ± 3 Nm {9.2 ± 0.3 kgm}
3] 90° ± 5° (When tightened with
angle tightening tool J)
107E-1 Series 19
19. Fuel injector assembly 4] Where there is a worn part or an

a When replacing the injector, replace the uneven contact part on seat surface
inlet connector, too. (e) of the inlet connector.
a Make sure that the injector sleeve is free a If high-pressure fuel leaks
from damages or dirt. through the inlet connector, seat
1) Attach the gasket (6) and O-ring (7) to surface is eroded and fine
injector (2). streaks or flaws are made on it.
2) Apply engine oil (EO15W-40) to the O-ring
(7) of injector (2) as well as the head side.
3) Insert injector (2) to the cylinder head
while directing its fuel inlet hole to the
manifold.
4) Install holder (4) and then tighten bolt (3) 3
to 4 threads.
6) Apply engine oil (EO15W-40) to the O-ring

of inlet connector (1) as well as the head
side.
7) Insert inlet connector (1) in the mounting
hole of injector (2) and tighten retainer (5)
temporarily.
3 Retainer:
5) Check the inlet connector for the following 15 ± 5 Nm {1.5 ± 0.5 kgm}
items. If it is defective, replace it. a The above is temporary tightening
1] When there is a burr or a worn part at torque. Tighten permanently in step
front end (a) or rear end (b) of the 9).
inlet connector. 8) Tighten bolts (3) alternately.
2] When there is foreign matter in the 3 Bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
edge filter at rear end (c) of the inlet 9) Tighten retainer (5).
connector. 3 Retainer:
3] When there is a crack or a deterio- 50 ± 5 Nm {5.1 ± 0.5 kgm}
rated part on the O-ring at top (d) of
the inlet connector.
20 107E-1 Series
a Apply liquid gasket (LG-7) onto O-ring (8)

of injector harness connector (6) and
flange surface (9) prior to installation.
Apply liquid gasket (LG-7) (with 3 mm
width) until the groove for O-ring is fully
filled.
If O-ring is damaged, replace the harness
as an assembly.
3 Mounting bolt of injector harness
connector (7):
10 ± 2 Nm {1.0 ± 0.2 kgm}
<Other than WA380Z-6, PC200-8M0, PC200LC-
8M0> 21. Rocker arm assembly
1) Install crosshead (3).
2) Install rocker arm assembly (2) and
tighten bolts (1).
a Before tightening the mounting bolts,
check that the ball of the adjustment
screw is fitted to the socket of the
push rod.
3 Bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm}

8M0>
a Shape of the holes (a) and (b) on the

crosshead is not identical. Thus when
using this part again, the same air
intake and exhaust valves must be
assembled in the same direction.
20. Push rod

1) Install push rod (1).
a Check that the push rod is fitted in the
tappet.
a Refill the push rod socket with engine
oil (EO15W-40).
107E-1 Series 21
22. Adjusting valve clearance 2) Rotating tool V, rotate the crankshaft for-
Adjust the valve clearance according to the fol- ward and set wide slit (b) on the disc hav-
lowing procedure. ing the revolution sensor slits at the rear of
a As the valve clearance, adjust the clear- the crankshaft pulley to projection top (a)
ance between the crosshead and rocker of the front cover.
arm to the following value. a Seeing from the air intake manifold
a Valve clearance (when cold) side, set projection top (a) into wide
Unit: mm slit (b).
k Be aware that each cylinder is not
Air intake valve Exhaust valve
set to the top dead center after this
0.25 ± 0.05 0.51 ± 0.05
positioning. (Each cylinder is set
76 – 88° before the top dead cen-
1)Remove plug (1) on the top of the starting ter.)
motor and install tool V. q 4D107E-1: No. 1 cylinder or No. 4 cylinder
a The position of plug (1) is subject to q 6D107E-1: No. 1 cylinder or No. 6 cylinder
the applicable machine. Reference: The position for wide slit (b) on
<PC160-7, PC200-8 as examples> the damper of 6D107E-1 is
painted white.
<4D107E-1>
<The photo shows WA380-6 as an example>
<6D107E-1>
22 107E-1 Series
3) Adjust the valve clearance according to 4) Insert clearance gauge K in the clearance
the following procedure. between rocker arm (2) and crosshead
a If you cannot move the rocker arms of (3).
the exhaust valves (on the EX side) 5) Loosen locknut (4) and adjust the valve
with the hand, adjust the valves clearance with adjustment screw (5).
marked with Q in the valve arrange- a With the clearance gauge inserted,
ment drawing. turn the adjustment screw to a degree
a If you can move the rocker arms of that you can move the clearance
the exhaust valves (EX) with the hand gauge lightly.
by the valve clearance, adjust the 6) While fixing adjustment screw (5), tighten
valves marked with q in the valve locknut (4).
arrangement drawing. 3 Locknut:
<4D107E-1> 20 – 28 Nm {2.04 – 2.86 kgm}
a After tightening the locknut, check the
valve clearance again.
<6D107E-1>
7) Rotate the crankshaft forward by 1 turn

with tool V and set wide slit (b) to projec-
tion top (a) according to step 2).
8) Adjust the other valve clearances accord-
ing to steps 3) – 5).
a If the valves marked with Q in the
valve arrangement drawing were
adjusted in steps (4) and (5), adjust
the valves marked with q.
23. Rocker housing and head cover

< O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 ,
PC200LC-8M0, PC220-8M0, PC220LC-8M0
and PC240LC-8M0>
1) Install rocker housing assembly (6) with
bolt (5).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install nuts (4) of the harness.
a Harness installation position
Color of cable Cylinder No.
White 1, 3, 5
Black 2, 4, 6
Cylinders No. 5 and No. 6 are applied for
6D107E-1 only.
107E-1 Series 23
a Check that the injector harness does <WA380Z-6, PC200-8M0, PC200LC-8M0,

not interfere with the rocker arm. PC220-8M0, PC220LC-8M0 and PC240LC-
3 Mounting nut: 8M0 only>
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} 1) Install gasket assembly (4a).
2) Install nuts (4) of the harness.
a The injector harness and nut have no
positional distinction. (Their right and
left sides may be reversed)
a Check that the injector harness does
not interfere with the rocker arm.
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
3) Install duct (1) to head cover (3).

3 Duct (1) mounting bolt:
7 ± 2 Nm {0.71 ± 0.20 kgm}
4) Fit the gasket (3a) and then install head
cover (3) together with duct (1) using nuts
(2).
3 Mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Head cover (3) of 4D107E-1 will be
i n s tal l ed aft er th e t ur b oc h ar g er
assembly is installed. Accordingly,
install the head cover temporarily at
this time.
3) Install duct (1) to head cover (3).

3 Duct (1) mounting bolt:
7 ± 2 Nm {0.71 ± 0.20 kgm}
4) Install head cover (3) together wit ducts
(1) using bolts (2).
3 Mounting bolt:
24 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Head cover (3) of 4D107E-1 will be
i ns tal l ed a ft er th e tu r b oc h ar g er
assembly is installed. Accordingly,
install the head cover temporarily at
this time.
24 107E-1 Series
24. Air intake manifold cover

1) Fit the gasket and then install manifold
covers (3) and (4).
2) Fit the gasket and then install tube (1) and
electrical intake air heater (2).
3 Tube mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
<4D107E-1>
<6D107E-1>
<PC200-8M0, PC200LC-8M0, PC220-8M0,

PC220LC-8M0 and PC240LC-8M0 only>
a If oil filler tube (7) is removed, install oil
filler tube according to the following pro-
cedure.
1] Install O-ring (8) to oil filler tube (7).
2] Apply liquid adhesive (LOCTITE 263)
(a) to contact surface of oil filler tube
(7) and head cover (3).
3] Install oil filler tube (7).
3 Oil filler tube:
15 ± 3 Nm {1.53 ± 0.31 kgm}
107E-1 Series 25
25. Fuel pressure sensor and relief valve 5] Install the relief valve.
1) Replace fuel pressure sensor (2), if neces- 2 Threaded part of relief valve:
sary, according to the following procedure. Gear oil (#90)
a Do not remove fuel pressure sensor 3 Relief valve:
(2) from common rail (1) for a pur- 100 ± 4 Nm {10.2 ± 0.4 kgm}
pose other than replacement. Excessive tightening can cause
a Once the fuel pressure sensor is leakage. Take care not to tighten
removed from the common rail, be too strongly.
sure to replace it. 6] Start the engine and check that fuel
1] Before removing the fuel pressure does not leak.
sensor, remove mud etc. from around For the testing procedure, see Testing
it thoroughly and clean it. and adjusting, "Testing fuel system for
2] Remove the fuel pressure sensor. leakage".
3] Check the fuel pressure sensor con-
nector for crack, breakage, damage
of the seal, foreign matter on the pin
and corrosion, bend and breakage of
the pin.
4] Install a new fuel pressure sensor.
2 Threaded part of fuel pressure
sensor: Gear oil (#90)
3 Fuel pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5] Connect the engine wiring harness.
At this time, take care not to connect
the wiring harness in reverse.
6] Start the engine and check that fuel
does not leak.
26. Common rail and fuel high-pressure piping
For the testing procedure, see Testing
(4D107E-1)
k It is prohibited to bend high-pressure
and adjusting, "Testing fuel system for
leakage".
pipings used.
k The clamps used for fixing high-pres-
<Fuel pressure sensor of 4D107E-1 is shown
below>
sure pipings must be the genuine part.
And the specified tightening torque
must be strictly observed.
k A clearance of 10 mm minimum must
be provided between the installed high-
pressure piping and harness.
a Fuel leakage can occur on a high-pressure
piping that has visible lengthwise slits (b)
or dents such as patchy damages (c) on its
taper seal of the piping connection (part
(a): 2 mm space from the tip). The same
holds true for a high-pressure piping that
catches claw because of fatigued steps in
part (d) (end of the taper seal: a 2 mm
2) Replace relief valve (3), if necessary, space from the tip). Such high-pressure
according to the following procedure. piping must be replaced.
1] Before removing the relief valve,
remove mud etc. from around it thor-
oughly and clean it.
2] Remove the relief valve.
3] If the leakage from the relief valve
exceeds the specified value, do not
reuse it.
4] Check that high-pressure seal sur-
faces (A) of the relief valve and rail
are free from damage.
26 107E-1 Series
<4D107E-1>
1) Temporarily install common rail (8) and

high-pressure pipings (1) to (5). <4D107E-1>
3 Sleeve nut and mounting bolt
(Temporary tighten):
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten high-pressure pipings (1) to (5)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
1] Head side of high-pressure pipings
(1) and (4)
2] Rail side of high-pressure pipings (1)
and (4)
(2) o (3)
o (3)
5] Pump side of high-pressure piping (5) 27. Common rail and fuel high-pressure piping
and then its rail side (6D107E-1)
3) Tighten clamp mounting bolts (11) of k It is prohibited to bend high-pressure
high-pressure pipe (5). pipings used.
3 Mounting bolt (11): k The clamps used for fixing high-pres-
24 ± 4 Nm {2.4 ± 0.4 kgm} sure pipings must be the genuine part.
4) Tighten common rail (7) with 4 bolts. And the specified tightening torque
a Apply sealant (LG-7) to the threaded must be strictly observed.
part of 2 bolts inside the engine. k A clearance of 10 mm minimum must
3 Mounting bolt: be provided between the installed high-
24 ± 4 Nm {2.4 ± 0.4 kgm} pressure piping and harness.
5) Install boots (8). a Fuel leakage can occur on a high-pressure
k Set the slits of each boots out and piping that has visible lengthwise slits (b)
down. or dents such as patchy damages (c) on its
a The boots are installed so that fuel taper seal of the piping connection (part
will not spout over the hot parts of the (a): 2 mm space from the tip). The same
engine and catch fire when it leaks for holds true for a high-pressure piping that
some reason. catches claw because of fatigued steps in
6) Install fuel return hose (9). part (d) (end of the taper seal: a 2 mm
3 Joint bolt: space from the tip). Such high-pressure
24 ± 4 Nm {2.4 ± 0.4 kgm} piping must be replaced.
107E-1 Series 27
a The boots are installed so that fuel

will not spout over the hot parts of the
engine and catch fire when it leaks for
some reason.
6) Install fuel return hose (8).
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
<6D107E-1>
1) Temporarily install common rail (10) and

high-pressure pipings (1) to (7).
3 Sleeve nut and mounting bolt
(Temporary tighten):
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten high-pressure pipings (1) to (7)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm} <WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-
1] Head side of high-pressure pipings 8M0, PC220LC-8M0 and PC240LC-8M0 only>
(6) and (1)
and (1)
(2) o (3) o (4) o (5)
o (3) o (4) o (5)
5] Pump side of high-pressure piping (7)
and then its rail side
3) Tighten clamp mounting bolts (12), (13)
and (14) of high-pressure pipe (7).
<WA380Z-6, PC200-8M0, PC200LC-8M0,
PC220-8M0, PC220LC-8M0 and
PC240LC-8M0 only>
3 Mounting bolt (12):
24 ± 4 Nm [24 ± 0.4 kgm] 8M0, PC220-8M0, PC220LC-8M0 and PC240LC-
<Other than WA380Z-6, PC200-8M0, 8M0>
PC200LC-8M0, PC220-8M0, PC220LC-
8M0 and PC240LC-8M0>
24 ± 4 Nm {2.4 ± 0.4 kgm}
10 ± 2 Nm {1.0 ± 0.2 kgm}
4) Tighten common rail (10) with 4 bolts.
a Apply sealant (LG-7) to the threaded
part of 2 bolts inside the engine.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Install boots (9).
a Set the slits of each boots out and
down.
28 107E-1 Series
28. Harness assembly 29. Fuel filter assembly

< O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 , 1) Install filter bracket assembly (4).
PC200LC-8M0, PC220-8M0, PC220LC-8M0 2) Install drain hose (3) to the filter bracket.
and PC240LC-8M0> 3) Install filter inlet hose (1) and outlet hose
Connect harness assembly (1) to the controller (2).
and sensor and then fix it to the engine. 4) Install fuel filter (5).
k Before connecting the harness connec- a As the gasket touched the filter head,
tor, clean sands, dusts or water in the tighten the fuel filter 1/2 turn to install
controller side connector. it.
<WA380Z-6, PC200-8M0, PC200LC-8M0, 30. Exhaust manifold

PC220-8M0, PC220LC-8M0 and PC240LC- 1) Fit a new gasket and then install exhaust
8M0 only> manifold (4) to the cylinder head. Tighten
Connect three connectors (2) of the injector the mounting bolts according to the num-
bers shown in the figure.
3 Mounting bolts tightening proce-
harness.
a Push in connector (2) in the direction of
the arrow until it clicks. dure:
1] Tighten every bolt with 24 ± 4
Nm {2.4 ± 0.4 kgm}.
2] Tighten every bolt with 53 ± 6
Nm {5.4 ± 0.6 kgm}.
3] Tighten [1] to [4] bolts alone in
the figure in this order with 53
± 6 Nm {5.4 ± 0.6 kgm}.
<4D107E-1>
107E-1 Series 29
<6D107E-1>
5) Install oil feed tube (2) to the turbocharger

assembly and then install heat insulation
31. Turbocharger assembly (4D107E-1) cover (1).
1) Remove the head cover installed in the 3 Mounting nut on oil cooler side:
previous step. 24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Fit gasket (9) and place turbocharger 3 Mounting nut on turbocharger side:
assembly (4) temporarily on the exhaust 36 ± 5 Nm {3.6 ± 0.5 kgm}
manifold stud bolts. Then, fit gasket (8) to 3 Heat insulation cover mounting
the turbocharger and install oil return tube bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
(7).
a Tighten oil return tube mounting bolt
(6) with hexagonal wrench [1] under
the condition shown in the figure.
3 Oil return tube mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
32. Turbocharger assembly (6D107E-1)

1) Fit the gasket and install turbocharger
assembly (3) to exhaust manifold (4).
3 Mounting nut:
43 ± 6 Nm {4.4 ± 0.6 kgm}
3) Install turbocharger assembly (4) to the a Tighten the mounting nuts in the diag-
exhaust manifold with mounting nuts (3). onal order.
4) Check that the oil return tube (7) does not
interfere with the exhaust manifold and
install head cover (5).
3 Turbocharger mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Tighten the mounting nuts in the diag-
onal order.
3 Head cover mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
30 107E-1 Series
2) Install the turbocharger assembly oil feed 34. Thermostat

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

1) Attach the seal ring and then install water
pump (2).
2) Attach the seal ring and then install cool-
ant inlet connector (1).
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
35. Alternator
1) Install front side sling bracket (5) and
alternator bracket (4).
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series 31
2) Install alternator (3) temporarily using 38. Fan pulley

mounting bolt (2). 1) Install fan pulley (4) with mounting bolt (3).
3) Install plate (1). 3 Mounting bolt:
4) Tightening alternator mounting bolt (2). 43 ± 6 Nm {4.4 ± 0.6 kgm}
2) Install fan belt (1).
q Insert a wrench to the portion (A)
(width across flats T 12.7 mm) of the
tensioner assembly (2), and rotate it
to the opposite to the winding-up
direction to decrease the fan belt (1)
tension, then install.
k Make sure that the wrench is
secured at the portion (A) before
rotating it. (The spring of the ten-
sioner assembly (2) is strong. If the
wrench is loosely inserted, the
wrench may accidentally come off
w h i l e b e i n g r o ta t e d a n d i t i s
extremely dangerous.)
36. Fan hub k After removing the fan belt (1),
Install fan hub (2) with mounting bolt (1). return the tensioner assembly (2)
3 Mounting bolt: slowly with care.
32 ± 5 Nm {3.3 ± 0.5 kgm} k Be careful not to get your fingers
caught between the pulley and fan
belt (1) during work.
37. Belt tensioner

Install tensioner (2) with mounting bolt (1).
3 Mounting bolt: 39. Engine sling bracket on rear side
43 ± 6 Nm {4.4 ± 0.6 kgm} <All engine except for generator>
a Check visually or using a ruler, that the Install engine sling bracket (1) to the cylinder
belt mounts of the tensioner pulley and bracket.
alternator pulley are parallel.
32 107E-1 Series
<Generator> 41. Removal from engine repair stand

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

Fit the gasket and then install starting motor
assembly (2) with bolt (1).
2 Apply 1 mm wide gasket sealant (LG-
7) to the entire circumference of the
front and back sides of the gasket.
<4D107E-1>
<6D107E-1> 3) Set engine assembly (1) on stable engine

stand [1] provided on both sides.
4) Install oil gauge assembly (2).
<4D107E-1>
107E-1 Series 33
<6D107E-1>
42. Refilling with oil

1) Check that the engine oil drain plug is
tightened.
2) Add oil through the oil filler to the specified
level.
5 Engine oil pan:
Approx. 16 l (4D107E-1)
5 Engine oil pan:
Approx. 23 l (6D107E-1)
34 107E-1 Series
107E-1 Series 35
SEN00259-10
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 06-12 (01)
36
SEN05211-00
107-1 Series
SEN05211-00
Engine
Shop Manual
107E-1 Series
Machine model Serial number

107E-1 SERIES........................
90 Repair and Replacement of

parts
Infomation related repair and replacement
Special tool table......................................................................................................................................... 2
107E-1 Series 1
SEN05211-00 90 Repair and Replacement of parts
Special tool table
Sym-
Repair/ Replacement item Part No. Part name Q'ty Remarks
bol
A 795-799-4500 Grooving kit 1
B 795-799-4700 Slide hammer 1 Intake and exhaust
C 795-799-6140 Remover (Collet) 1 Intake
Replacement of valve seat D 795-799-6800 Valve seat cutter 1
insert E 795-799-6910 Guide (Arbor) 1
1 795-799-6920 Seat cutter 1 0.010 mm
F
2 795-799-6930 Seat cutter 1 0.020 mm (Oversize)
G 795-799-6150 Valve seat installer 1
Grinding of valve H 795-790-2100 Spring tester 1
Camshaft bushing replacement
Repair of cylinder block J 795-799-1360 1
kit
K 795-799-1500 Push tool kit 1
1 795-799-1530 Mandrel 1
2 795-799-1510 Anvil 1
3 795-799-1540 Ring 1 For locking bushing
Replacement of connect- For removing/installing
ing rod bushing 4 795-799-1550 Ring 1
K bushing
5 795-799-1520 Cap 1
6 - Cotter pin 1
Operation and Maintenance
7 795-799-1560 1
Manual
2 107E-1 Series
90 Repair and Replacement of parts SEN05211-00
107E-1 Series 3
©2009 KOMATSU
All Rights Reserved
4
SEN05212-00
107-1 Series
SEN05212-00
Engine
Shop Manual
107E-1 Series

107E-1 SERIES........................

parts
Parts related to cylinder head
Repair of cylinder head ............................................................................................................................... 2

Check of valve guide................................................................................................................................... 3
Replacement of valve seat insert................................................................................................................ 4
Vacuum test of valve seat insert ................................................................................................................. 6
Grinding of valve ......................................................................................................................................... 7
107E-1 Series 1
Repair of cylinder head
Check q If the sinking quantity of the valve and

projection of the injector can be changed
1. Check the cylinder head mounting face for into the allowable range, the cylinder
breakage and erosion. head can be repaired by grinding.
a Cylinder head height (Reference):
2. Peel off the remaining gasket and clean the 105 ± 0.25 mm
cylinder head mounting face. a If the sinking quantity of the valve and
projection of the injector are out of the al-
lowable range, replace the cylinder head.
3. Using a precision ruler and a feeler gauge,

measure the flatness of the cylinder head
mounting face.
a Flatness of mounting face
q End-to-End: Max. 0.305 mm
q Side-to-Side: Max. 0.076 mm
a If the flatness is out of the specified range, re-

pair the cylinder head by grinding or replace
it according to the following criteria.
1) Measure the sinking quantity of the valves.
a Valve sinking quantity
q Intake side: 0.584 – 1.092 mm
q Exhaust side: 0.965 – 1.473 mm
2) Measure the projection of injector nozzle.
a Projection of injector nozzle:
2.45 – 3.15 mm
2 107E-1 Series
Check of valve guide
1. Check the valve guide for scuffing and seizure.
2. Measure the valve guide bore.

a Valve guide bore: 7.027 – 7.077 mm
a If the valve guide bore is larger than the spec-
ified value or the inside wall of the valve
guide is damaged, replace the cylinder head.
107E-1 Series 3
Replacement of valve seat insert
a Valve seat insert replacement tools 7. Tighten the T-handle firmly to bend tool C to
under the valve seat insert or into the groove.
A 795-799-4500 Grooving kit 8. Hit the top nut of tool B until the valve seat insert
B 795-799-4700 Slide hammer comes off.
C 795-799-6140 Remover (Collet)
D 795-799-6800 Valve seat cutter 9. Rotate the T-handle counterclockwise to remove
the valve seat insert from tool C.
a Judge if the valve seat insert needs to be re-

placed by the condition and sinking quantity of
the valve and the contact condition of the valve
seat insert.
Removal
1. Check the contact faces of the valve seat insert

and cylinder head and confirm that there is a
sufficient groove on the valve seat.
2. If there is a sufficient groove on the valve seat

insert, go to step 5.
Testing
3. If there is not a sufficient groove on the valve
seat insert, make a sufficient groove with tool A. Measure the valve seat insert bore of the cylinder
head.
a Valve seat insert bore:
34.847 – 34.863 mm
4. Using tools B and C, remove the valve seat

insert.
a When installing, be sure to set tool C perpen-
dicular to the cylinder head.
5. Insert the tool C in valve seat insert and rotate

the T-handle clockwise until tool C is meshed
with the valve seat insert lightly.
6. Set tool C to the groove of the valve seat insert.
4 107E-1 Series
Installation 3. If a new valve seat insert is installed or the leak

through the valve is out of the allowable range,
a When installing the valve seat inserts, note that polish the valve seat and valve.
the ones for the exhaust valves are different from a Before installing the valve, apply engine oil
those for the intake valves. (EO15W-40) to its stem.
a Valve seat angle (Intake side): 30 degrees
(Exhaust side): 45 degrees 1) Apply fine lapping compound to the valve
a Direct the chamfered periphery end (1) of the thinly and evenly.
valve seat insert toward the bottom of the coun- 2) Press an electric or hand polishing tool
terbore. against the center of the valve and rotate the
valve clockwise and counterclockwise alter-
1. Using tool D, drive the intake and exhaust valve nately.
seat inserts into the counterbores. 3) Continue to polish until the valve seat insert
and valve are fitted to each other without
clearance between them, judging from the
sticking condition of the compound.
2. After installing the new valve seat insert,

measure valve sinking quantity (A) and check for
leak through the valve.
a The lapping compound is abrasive.
If all the dirt is not removed from the
cylinder head, valve and valve seat, it
affects the engine badly.
4) Wipe off the lapping compound from each
part.
107E-1 Series 5
Vacuum test of valve seat insert
q If the valve seems to be leaking, test the sealing

performance between the valve and valve seat
insert with the valve vacuum tester (Part No.
3824277) and cup (Part No. ST-1257-6).
a The vacuum must not reduce more than 25.4
mmHg in 5 seconds.
a Vacuum between valve and valve seat insert
q Used parts: 51 kPa
q New parts: 69 kPa
a If the valve vacuum tester is not available, test

the valve seat contact surface by the following
method.
q Make marks on the valve seal face with a pencil
as shown in the figure.
q Install the valve in the valve guide.
q While keeping the valve in contact with the valve
seat insert, rotate it clockwise and counterclock-
wise 3 – 4 turns.
q If the valve is in contact with the valve seat insert
normally, the pencil marks all around the valve
seal are erased evenly.
a If the vacuum between the valve and valve seat

insert or the valve seat contact face is out of the
allowable range, disassemble the cylinder head
and check the valve and valve seat insert for
damage. Repair according to the following pro-
cedure, as necessary.
1. Clean the valve and valve seat insert, and then

polish the valve again.
2. Replace any damaged valves and valve seat

inserts. (If there are replacement parts)
3. Replace the cylinder head.
6 107E-1 Series
Grinding of valve
a Valve measuring tool Reuse of valve

When reusing a valve, check the following.
H 795-790-2100 Spring tester q The valve head and valve stem are not worn ex-
cessively.
k
q The valve stem end is not worn excessively.
When polishing the valve with an electric q The valve is not bent or distorted.
brush, put on safety glasses to avoid injury.
k When using cleaning liquid containing sol-
vent or acid or alkaline substance, observe
the items recommended by the manufactur-
er. Be sure to put on safety glasses and pro-
tective clothes to avoid injury.
1. Clean the valve head with a soft rotary wire

brush.
a Keep each valve on a labeled rack etc. be-
fore measurement to avoid a mistake.
q Check the valve for damage and check the collet

groove for wear.
q Measure the outside diameter of the valve stem.
a Measure the outside diameter of each valve
stem at 3 places of 40 mm, 90 mm and 140
mm from the end.
a Outside diameter of valve stem: 6.96 – 7.01
mm
a If the valve is damaged or the outside diame-
ter of its stem is out of the specified range, re-
place it with new one.
2. Polish the valve stem with Scotch-Brite 7448
(Part No. 3823258) and solvent.
107E-1 Series 7
q Measure the rim thickness and polish the valve Reuse of valve spring
only when the rim thickness can be secured suf-
ficiently after polishing. q When reusing a valve spring, check the follow-
a Allowable valve rim thickness: Min. 0.79 mm ing.
a If the valve rim thickness is out of the allow-
able value, replace the valve with new one. 1. Measure the free length of valve spring.
a Free length of valve spring: Approximately
47.75 mm
2. Place a square by the valve spring and measure

the inclination of the valve spring with a feeler
gauge.
a Inclination (max.) of valve spring: 1.5 mm
3. Using tool H, measure the tension of the valve

spring.
q If the load to compress the valve spring to a
height of 35.33 mm is 320.8 – 358.8 N (32.7
– 36.6 kg), the valve spring is in the allowable
range.
a If the valve spring is out of the allowable
range, replace it with new one.
8 107E-1 Series
107E-1 Series 9
©2009 KOMATSU
All Rights Reserved
10
SEN05213-00
107-1 Series
SEN05213-00
Engine
Shop Manual
107E-1 Series

107E-1 SERIES........................

parts
Parts related to cylinder block
Repair of cylinder block............................................................................................................................... 2

Repair of crankshaft.................................................................................................................................... 12
Replacement of connecting rod bushing..................................................................................................... 15
107E-1 Series 1
Repair of cylinder block
Initial testing a A thicker head gasket to compensate for the

ground part of the cylinder block mounting
a Before removing the piston and connecting rod face is not prepared. If the projection of the
assembly, measure the projection of the piston. piston is not to be within the specified value
The projection of the piston measured before after the grinding work, replace the cylinder
disassembly will be used for reference to judge if block.
the cylinder block can be repaired by grinding. a Cylinder block height (New):
322.978 ± 0.08 mm
Check a: Height
b: Cylinder block top
1. Measure the flatness of the cylinder block c: Crankshaft hole center
mounting face.
a Flatness of mounting face
q End-to-End: Max. 0.076 mm
q Side-to-Side: Max. 0.051 mm
2. Check for a local dent and unevenness.

a If there is any local dent or unevenness, grind
the cylinder block mounting face.
a The cylinder block mounting face can be
ground only when the projection of the piston
is to be within the specified value after the
grinding work.
a Projection of piston: 0.3180 ± 0.167 mm
2 107E-1 Series
Check of bore Removal of camshaft bushing
a If the cylinder block is placed on the engine a Camshaft bushing replacement tools
stand or the main bearing metal cap is not in-
stalled, measurement cannot be performed ac-
curately because of distortion. Perform all Camshaft bushing replace-
J 795-799-1360
measurement of the cylinder block after install- ment kit
ing the main bearing metal cap and placing the
cylinder block on a flat surface. (Cylinder bore,
a The camshaft bushings are press fitted to the fol-
main bearing bore, camshaft bore, etc.)
lowing journals.
q 4D107E-1: No. 1, No. 5 (No bushings are
press fitted to Nos. 2 – 4)
q 6D107E-1: No. 1, No. 7 (No bushings are
press fitted to Nos. 2 – 6)
1. Using tool J, remove the camshaft bushing. The

following kit can be used to remove and install
the camshaft bushing.
q Camshaft bushing kit (Part No. 3165045)
2. Slide the drive bar from the centering guide.

Insert the drive bar into the camshaft bore from
the rear of the cylinder block.
3. Insert the camshaft bushing remover to push out

the front and rear camshaft bushings from the
cylinder block.
107E-1 Series 3
Measurement of camshaft bore
a Measure the camshaft bore with the camshaft

bushing removed.
a Camshaft bore
q Portion where camshaft bushing has been fit-
ted:
Max. f 59.248 mm
q Portion where camshaft bushing has not
been fitted:
Max. f 54.164 mm
a If the bore at the portion where the camshaft
bushing has been fitted is out of the specified
value, replace the cylinder block.
a If the bore at the portion where the camshaft
bushing has not been fitted is out of the specified
value, the camshaft bushing can be press fitted
after the bore is so worked that the camshaft
bushing of the standard size can be press fitted.
q Bore to which camshaft bushing of standard
size can be press fitted: f 59.235 ± 0.013
mm
q Bore after camshaft bushing is press fitted:
f 54.083 – 54.147 mm
a After the camshaft bushing is press fitted, if the
bore is out of the specified value, remove the
camshaft bushing and check the camshaft bore
of the cylinder block.
4 107E-1 Series
Installation of camshaft bushing a Be sure to match the larger oil hole of the
camshaft bushing to the larger oil hole on the
1. Make match marks (1) at the larger oil hole of the lower side of the camshaft bore.
camshaft bushing and the oil hole of the cylinder a The oil hole must be of a size through which
block with a marker. a rod 3.2 mm in diameter will go.
Use the match marks to align the bushing and
bore when installing.
a Use the match marks to align the bushing
and bore when installing.
2. Slide and install the camshaft bushing to the

camshaft bushing remover.
3. Align match marks (1) of the camshaft bushing

and cylinder block and drive the front camshaft
bushing to the correct installed depth.
a At the correct installed depth of the front cam-
shaft bushing, its end is 1.5 mm lower than
the machined face of the cylinder block and
its oil hole is matched to the oil hole of the cyl-
inder block.
107E-1 Series 5
Measurement of cylinder bore Repair
a Do not measure the cylinder bore in the area of a When repairing, take care that foreign matter will
50 mm from the cylinder block mounting face not enter the engine lubrication passage since it
since it cannot be measured accurately in that can damage the engine.
area. a When repairing the cylinder bore, cover the lubri-
a When measuring, polishing or boring the cylin- cating oil holes and tappet holes on the cylinder
der block, check that all the main bearing metal block mounting face with water-resistant tapes.
caps are positioned normally and tightened to
proper torque.
(See "Structure, function and maintenance stan-
dard")
q Check the cylinder bore for a damage and ex-

cessive wear.
q Using a dial bore gauge, measure the cylinder
bore at 4 peripheral points equally spaced (90
degrees) at the top and bottom of the piston slid-
ing surface of the cylinder.
a Cylinder bore (New cylinder block):
106.990 – 107.010 mm
a Cylinder bore (Used cylinder block):
106.990 – 107.030 mm
a Roundness: Max. 0.038 mm
a Taper: Max. 0.076 mm
a The cylinder can be bored only once only when
the piston and piston ring of the oversize (0.5
mm) are used.
The repair sleeve cannot be installed.
For the procedure, see "Overbore".
6 107E-1 Series
Honing work
q The cylinder bore surface can be finished by

honing work to accuracy required for installation
of the piston rings. Honing can be performed
only when the cylinder bore is within the speci-
fied value.
a Do not use new piston rings for the cylinder bore
after it is worn to mirror surface.
a Using ball-type grinding stones, hone the cylin-

der at a rotation speed of 300 – 400 rpm and at
a pitch of 1 vertical moving cycle per second.
a Be sure to use mixture of 50% high-quality hon-
ing oil or engine oil (EO30W) and 50% diesel fuel
as lubricating oil for honing.
a Move the grinding stones vertically, smoothly
and continuously along the cylinder bore length.
q After honing 10 cycles, check the cylinder bore.

a The cross hatch angle is decided by the rotation
speed and the vertical moving speed of the
grinding stones. A proper cross hatch angle
cannot be obtained if the speed is too high or too
low.
a If the cylinder is honed correctly, cross hatch
lines appear at angles of 25 – 30 degrees to the
cylinder block mounting face.
107E-1 Series 7
Overbore
q If the cylinder bore is out of the specified value or

cylinder surface is damaged, the cylinder can be
bored to the piston and piston rings of the over-
size.
q The boring work shall be performed with a prop-
er boring machine by a skilled worker.
a The cylinder must be perpendicular to the com-
bustion chamber face of the cylinder block and
the taper and roundness of the cylinder bore
must be within the standard values.
q After boring the cylinder to the oversize, finish it

by honing in 2 steps.
a Use a honing machine for engine cylinder.
a Use ball-type grinding stones only when the cyl-
inder does not need to be bored again.
a The boring dimensions shown below are not the

finished dimensions of the cylinder bore. The fin-
ished dimensions of the cylinder bore are ob-
tained by the final honing work.
a Boring dimensions: 107.45 mm
a The cutting depth of each pass must not exceed
0.228 mm.
a The cylinder can be bored only once. If the cylin-
der has been bored or a flaw on its surface can-
not be removed, replace the cylinder block.
q After boring, cut the inside edge at an angle of 15

degrees to about 1.25 mm with honing stones.
8 107E-1 Series
a Hone the cylinder at a rotation speed of 300 –

400 rpm and at a pitch of 1 vertical moving cycle
per second.
a Be sure to use mixture of 50% high-quality hon-
ing oil or engine oil (EO30W) and 50% diesel fuel
as lubricating oil for honing.
q For the 1st honing pass or rough honing, use soft

(high-speed cutting) silicone carbide grinding
stones of 80 grits. Finish the cylinder to the final
dimension by the honing work in this step.
a Dimension after honing work: 107.490 – 107.510
mm
q For the 2nd honing pass or finish honing, use

medium-hard silicone carbide grinding stones of
285 grits.
a Move the grinding stones at a pitch of 15 – 20
strokes to obtain proper cross hatch.
a If the cylinder is honed accurately, cross hatch
lines appear at angles of 25 – 30 degrees to the
cylinder block top.
a : Cylinder block top

b : Cross hatch angle
107E-1 Series 9
Cleaning 3. Check the cleanliness of the cylinder bore with a

white lint-free cloth impregnated with oil lightly.
q After the polishing or finish-honing work, clean If any grits are left, repeat the cleaning work until
the cylinder bore with high-concentration deter- they are removed.
gent solution and warm water. q If any dust is left, repeat the cleaning work
until it is removed.
1) Clean the cylinder bore with solvent.
2) Dry the cylinder bore with compressed air.
k When using compressed air, put on proper

personal protective item to protect your eyes
and face from chips and dirt that will be
blown off.
k When using cleaning liquid containing sol-
4. If the cylinder block is not used right away, apply
rust preventive to all the machined surfaces.
vent or acid or alkaline substance, observe
Cover the cylinder block to protect its inside and
the items recommended by the manufactur-
outside from dust and chips.
er. Be sure to put on safety glasses and pro-
tective clothes to avoid injury.
a Clean the cylinder bore immediately after the
polishing and finish-honing work since chips and
dirt can damage the engine.
a After finishing the cleaning work, be sure to re-
move the tapes which are covering the tappet
holes since they can damage the engine.
1. Rinse the cylinder bore until all the detergent is

washed away.
2. Dry the cylinder bore with compressed air.
a Before using a new cylinder block or a cylin-

der block which has been kept, be sure to re-
move oil and rust preventive from its cylinder
bore, gasket seal and main bearing bore.
10 107E-1 Series
107E-1 Series 11
Repair of crankshaft
Regrinding of crankpin journal fillet radius Regrinding of main journal fillet radius
Recommended procedure Recommended procedure - Journal
q Smoothly connect the radius of 4.00 ± 0.20 mm q Smoothly connect the radius of 4.2 ± 0.2 mm to
to the reground diameter and side. the reground diameter.
Finishing of surface Finishing of surface
(A): The fillet connected to the journal surface must (A): The fillet connected to the journal surface must
be 0.8 Ra or less in the range of at least 45 degrees. be 0.8 Ra or less in the range of at least 45 degrees.
(B): The other parts of the fillet must be 1.6 Ra or (B): The other parts of the fillet must be 1.6 Ra or
less. less.
(C): Max. 0.3 Ra (Journal surface) (C): Max. 0.3 Ra (Journal surface)
(D): New undercut dimension (D): Original dimension
(E): Original dimension (E): New undercut dimension
a Perform grinding in the opposite direction to the a Perform grinding in the opposite direction to the
engine rotation and perform polishing in the engine rotation and perform polishing in the
same direction as the engine rotation. same direction as the engine rotation.
12 107E-1 Series
Measurement a If the crankpin journal of the crankshaft is out

of the specified value, polish the crankshaft
q Measure the crankshaft main journal and crank- again.
pin journal. 1] Machine the crankshaft to the specified
a Roundness: Max. 0.050 mm maximum value of the objective under-
a Taper: Max. 0.013 mm size bearing metal.
a If any journal is out of the specified value, polish 2] Finish the crankshaft to the standard
the crankshaft again. Even if only one journal is value of the objective undersize bearing
out of the specified value, be sure to polish all metal.
the journals. a Even if the diameter of only one jour-
nal is out of the specified value, be
sure to polish all the journals.
2. Measure the outside diameter of the main

journal.
a Outside diameter of main journal (Standard):
82.962 – 83.013 mm
1. Measure the outside diameter of the crankpin

journal.
a Outside diameter of crankpin journal (Stan-
dard):
68.962 – 69.013 mm
a Outside diameter of undersize main journal

Unit: mm
Undersize Min. Max.
0.25 US 82.712 82.763

0.50 US 82.462 82.513
0.75 US 82.212 82.263
1.00 US 81.962 82.013
a US: Undersize
a If the main journal of the crankshaft is out of

a Outside diameter of undersize crankpin jour- the specified value, polish the crankshaft
nal again.
Unit: mm 1] Machine the crankshaft to the specified
maximum value of the objective under-
Size Min. Max.
size bearing.
0.25 US 68.712 68.763 2] Finish the crankshaft to the standard
0.50 US 68.462 68.513 value of the objective undersize bearing.
0.75 US 68.212 68.263 a Even if the diameter of only one jour-
nal is out of the specified value, be
1.00 US 67.962 68.013
sure to polish all the journals.
a US: Undersize
107E-1 Series 13
3. Check the thrust faces for a damage and exces-

sive wear.
a A slight scratch is allowed. Polish the worked
surface with polish cloth of fine mesh.
a The thrust bearing surfaces are in the follow-
ing positions.
q 4D107E-1: 4th main journal
q 6D107E-1: 6th main journal
4. Measure the dimension of the thrust surface.

a End play of thrust surface: 0.065 – 0.432 mm
a If the end play of the thrust surface is out of
the specified value, a thrust bearing of 0.25
mm or 0.50 mm oversize can be used.
14 107E-1 Series
Replacement of connecting rod bushing

a Connecting rod bushing replacement tools 4. Install mandrel (3) to anvil (4).
Match the angle of the connecting rod to that of
anvil (4) so that the connecting rod will be hori-
K 795-799-1500 Push tool (KIT) zontal.
Removal
1. Insert mandrel (3) in the connecting rod pin hole.
5. Apply pressure over cap (5) to push out the

connecting rod bushing to the bore bottom.
2. Install removal ring (thin) (2) over mandrel (3).

Align the angled face accurately.
6. Remove cotter pin (6) and then remove cap (5)

and removal ring (thin) (2).
3. Put cap (5) over mandrel (3) and fix it with cotter
pin (6).
107E-1 Series 15
7. With the bushing removed, measure the Press fitting

connecting rod pin hole diameter.
a Connecting rod pin hole diameter (when 1. Before installing the connecting rod bushing,
bushing is removed): 42.987 – 43.013 mm soak it and the pin end of the connecting rod in
clean engine oil (EO15W-40).
2. Insert the connecting rod bushing in mandrel (3).
3. Install removal ring (thin) (2) and then install stop

ring (1).
4. Match the angles of removal ring (thin) (2) and

stop ring (1) to each other, set their angled ends
down, match the notch of the removal ring to the
pin in the stop ring, and install them over
mandrel (3).
16 107E-1 Series
5. Put cap (5) and fix it with cotter pin (6). 8. Place the connecting rod and mandrel on anvil
(4). (Match the angle of the connecting rod to
that of anvil (4) so that the connecting rod will be
horizontal.)
6. Insert the assembly of mandrel (3) in the cham-

fered side of the connecting rod and align the
angles of the bushing, connecting rod and stop
ring. 9. Using a hydraulic press, press fit the bushing to
the connecting rod from above the cap. Press fit
until the stop ring touches the connecting rod.
10. Check the clearance between the connecting

rod bushing and connecting rod.
a Using a feeler gauge of 0.025 mm, check that
the bushing is fitted to the rod hole normally.
a The feeler gauge of 0.025 mm must not go
between the bushing and connecting rod.
7. Press fit the assembly of mandrel (3) until it

touches the pin hole of the connecting rod.
107E-1 Series 17
Machining
q The inside of a new connecting rod bushing must

be finished.
a Machine the bushing with a rod boring machine
or equivalent.
a If SUNNEN PM-300 or equivalent connecting
rod boring machine is adjusted correctly, it can
be used to adjust the tolerance of bend, torsion,
etc.
a Do not use a honing machine of "floating rod"
type.
a Finished bushing bore: 40.019 – 40.033 mm
Check for bend and torsion
q Check the connecting rod for bend and torsion.

a Distance between centers of holes (large and
small):
191.975 – 192.025 mm
a Parallelism of bushing bore with large end hole
q In bend direction: 0.02 mm
q In torsion direction: 0.03 mm
18 107E-1 Series
107E-1 Series 19
©2009 KOMATSU
All Rights Reserved
20

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SEN00161-23

ENGINE 107E -1 SERIES

Engine 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00161-23

00 Index and foreword SEN00162-23

10 Structure, function and maintenance standard SEN00167-07

20 Standard value table SEN00247-16

30 Testing and adjusting SEN00249-09

50 Disassembly and assembly SEN00256-10

90 Repair and replacement of parts SEN05210-00

Foreword and general information SEN00164-06

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2 ........................................ 42

S-9 Oil becomes contaminated quickly.................................................................................... 18

50 Disassembly and assembly

Disassembly and assembly, Part 1 SEN00258-07

Disassembly and assembly, Part 2 SEN00259-10

90 Repair and replacement of parts

Parts related to cylinder head SEN05212-00

Parts related to cylinder block SEN05213-00

KOMATSU 107E-1 Series Diesel engine

Form No. SEN00163-23

Engine 1SHOP MANUAL

00 Index and foreword 1

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

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

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips