Komatsu 107E-2 Series Diesel Engine Shop Manual - PDF DOWNLOAD by www.heydownloads.com

SEN05623-06

ENGINE

107E

-2

SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

00 Index and foreword 1 00 Index and foreword

107E-2 SERIES

00-1

00 Index and foreword Index

Index

(ALL-0310-001-A-00-A)

00 Index and foreword ....................................................................................................................... 00-1 Index ......................................................................................................................................... 00-2 Foreword, safety and general information ..................................................................................... 00-5 Important safety notice ......................................................................................................... 00-5 How to read the shop manual.............................................................................................. 00-12 Explanation of terms for maintenance standard .................................................................... 00-14 Handling equipment of fuel system devices .......................................................................... 00-16 Handling of intake system parts........................................................................................... 00-17 Handling of hydraulic equipment.......................................................................................... 00-18 Method of disconnecting and connecting of push-pull type coupler ......................................... 00-20 Handling of electrical equipment.......................................................................................... 00-23 How to read electric wire code............................................................................................. 00-31 Precautions when performing operation ............................................................................... 00-34 Standard tightening torque table.......................................................................................... 00-39 List of abbreviation ............................................................................................................. 00-45 Conversion table ................................................................................................................ 00-50 01 Specification................................................................................................................................. 01-1 Table of contents ........................................................................................................................ 01-2 General information .................................................................................................................... 01-3 Exhaust gas regulation ......................................................................................................... 01-3 Specifications............................................................................................................................. 01-9 Applicable machines ............................................................................................................ 01-9 Specifications .................................................................................................................... 01-10 General view ..................................................................................................................... 01-18 Engine performance curve .................................................................................................. 01-43 10 Structure and function ................................................................................................................... 10-1 Table of contents ........................................................................................................................ 10-2 Components layout..................................................................................................................... 10-4 Components layout drawing (4D107) ..................................................................................... 10-4 Components layout drawing (6D107) ..................................................................................... 10-6 Intake and exhaust system parts .................................................................................................. 10-8 Intake and exhaust system layout drawing (4D107)................................................................. 10-8 Intake and exhaust system layout drawing (6D107)................................................................. 10-9 Intake and exhaust system circuit diagram (4D107) .............................................................. 10-10 Intake and exhaust system circuit diagram (6D107) .............................................................. 10-12 Air cleaner (4D107) ............................................................................................................ 10-14 Air cleaner (6D107) ............................................................................................................ 10-15 VFT (4D107)...................................................................................................................... 10-17 KVGT (6D107)................................................................................................................... 10-21 Aftercooler......................................................................................................................... 10-29 EGR system piping drawing (4D107) ................................................................................... 10-30 EGR system piping drawing (6D107) ................................................................................... 10-32 EGR system circuit diagram (4D107) ................................................................................... 10-34 EGR system circuit diagram (6D107) ................................................................................... 10-36 EGR valve (4D107) ............................................................................................................ 10-38 EGR valve (6D107) ............................................................................................................ 10-40 EGR cooler........................................................................................................................ 10-42 Layout of KCCV (4D107) .................................................................................................... 10-43 Layout of KCCV (6D107) .................................................................................................... 10-46 KCCV ventilator ................................................................................................................. 10-48 KDOC muffler (4D107) ....................................................................................................... 10-52 KDPF (6D107) ................................................................................................................... 10-54 Engine main body parts............................................................................................................. 10-59 Cylinder head .................................................................................................................... 10-59 Cylinder block .................................................................................................................... 10-61 Main moving parts.............................................................................................................. 10-63 Vibration damper (6D107)................................................................................................... 10-67

00-2

107E-2 SERIES

00 Index and foreword Index

Timing gear ....................................................................................................................... 10-68 Front cover ........................................................................................................................ 10-69 Valve system ..................................................................................................................... 10-70 Flywheel............................................................................................................................ 10-73 Lubrication system.................................................................................................................... 10-75 Lubrication system parts layout drawing (4D107) .................................................................. 10-75 Lubrication system parts layout drawing (6D107) .................................................................. 10-77 Lubrication system circuit diagram (4D107) .......................................................................... 10-79 Lubrication system circuit diagram (6D107) .......................................................................... 10-80 Oil pump ........................................................................................................................... 10-81 Boost oil pump (6D107) ...................................................................................................... 10-82 Oil filter.............................................................................................................................. 10-83 Oil cooler........................................................................................................................... 10-84 Regulator valve.................................................................................................................. 10-85 Safety valve....................................................................................................................... 10-86 Oil pan .............................................................................................................................. 10-87 Fuel system ............................................................................................................................. 10-88 Fuel system parts layout drawing......................................................................................... 10-88 Fuel system circuit diagram................................................................................................. 10-91 Supply pump ..................................................................................................................... 10-95 Fuel cooler ........................................................................................................................ 10-96 Pre-filter ............................................................................................................................ 10-97 Main filter .......................................................................................................................... 10-98 Cooling system......................................................................................................................... 10-99 Cooling system parts layout drawing.................................................................................... 10-99 Cooling system circuit diagram (4D107) ............................................................................. 10-100 Cooling system circuit diagram (6D107) ............................................................................. 10-101 Drive pulley ..................................................................................................................... 10-102 Water pump..................................................................................................................... 10-107 Thermostat ...................................................................................................................... 10-108 Electrical equipment................................................................................................................ 10-109 Alternator ........................................................................................................................ 10-109 Starting motor .................................................................................................................. 10-117 Intake air heater ............................................................................................................... 10-121 Engine wiring harness (4D107) ......................................................................................... 10-122 Engine wiring harness (6D107) ......................................................................................... 10-124 Engine controller (4D107) ................................................................................................. 10-126 Engine controller (6D107) ................................................................................................. 10-132 Sensor ............................................................................................................................ 10-138 20 Standard value tables.................................................................................................................... 20-1 Table of contents ........................................................................................................................ 20-2 Standard service value table........................................................................................................ 20-3 Standard value table for engine ............................................................................................. 20-3 Running-in standard and performance test standard ............................................................. 20-27 50 Disassembly and assembly ........................................................................................................... 50-1 Table of contents ........................................................................................................................ 50-2 Related information on disassembly and assembly ........................................................................ 50-3 How to read this manual ....................................................................................................... 50-3 Coating materials list ............................................................................................................ 50-5 Special tool list..................................................................................................................... 50-9 Sketch of special tool.......................................................................................................... 50-11 Disassembly and assembly ....................................................................................................... 50-12 General disassembly of engine ........................................................................................... 50-12 General assembly of engine................................................................................................ 50-34 Removal and installation procedure of supply pump unit alone............................................... 50-75 Engine front oil seal replacement procedure ......................................................................... 50-79 Engine rear oil seal replacement procedure.......................................................................... 50-82 60 Maintenance standard................................................................................................................... 60-1 Table of contents ........................................................................................................................ 60-2 107E-2 SERIES

00-3

00 Index and foreword Index

Intake and exhaust system parts .................................................................................................. 60-3 VFT (4D107)........................................................................................................................ 60-3 KVGT(6D107)...................................................................................................................... 60-4 Engine main body parts............................................................................................................... 60-5 Cylinder head ...................................................................................................................... 60-5 Cylinder block ...................................................................................................................... 60-7 Crankshaft........................................................................................................................... 60-9 Piston ............................................................................................................................... 60-11 Connecting rod .................................................................................................................. 60-12 Vibration damper (6D107)................................................................................................... 60-14 Timing gear ....................................................................................................................... 60-15 Camshaft .......................................................................................................................... 60-16 Valve and valve guide......................................................................................................... 60-18 Rocker arm........................................................................................................................ 60-20 Tappet............................................................................................................................... 60-21 Flywheel............................................................................................................................ 60-22 Lubrication system.................................................................................................................... 60-24 Oil pump ........................................................................................................................... 60-24 Index.................................................................................................................................................................... 1

00-4

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Foreword, safety and general information Important safety notice

(ALL-0370-001-A-00-A)

(ALL-1120-012-A-01-A)

(Rev. 2012/10) • Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. • The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. General precautions k Inappropriate

handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. • Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. • When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.

•

1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of "UNDER WORKING" in the operator's compartment. Only qualified workers must perform the work and operation which require license or qualification. Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc. If welding repairs is required, always have a trained and experienced welder with good

107E-2 SERIES

knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. • Before starting work, warm up your body thoroughly to start work under good condition. • Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place. Safety points 1 2 3 4 5 6 7 8 9 10

Good arrangement Correct work clothes Observance of work standard Practice of making and checking signals Prohibition of operation and handling by unlicensed workers Safety check before starting work Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Good physical condition and preparation Precautions against work which you are not used to or you are used to too much

Preparation • Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving. • Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them. • When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work. • Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of

00-5

00 Index and foreword Foreword, safety and general information

steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Precautions during work • For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first. • Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out. • When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit. • Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently. • Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, rotational speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment. • The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. • When removing the part which is under internal pressure or reaction force of the spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately and release the pressure, then, remove the part. • When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires.

00-6

• When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. • As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular. • Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated. • When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct. • When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly. • When aligning 2 holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole. • When measuring hydraulic pressure, check that the measuring tools are correctly installed. • Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track. • If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well. Precautions for slinging work and making signals • Only one appointed worker must make signals and co-worker must communicate with each other frequently. The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. 1. Do not stand under the load. 2. Do not step on the load. • Check the slings before starting sling work.

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

• Keep putting on the gloves during sling work. (Put on the leather gloves, if available.) • Measure the weight of the load by the eye and check its center of gravity. • Use the proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. • Do not sling a load with 1 wire rope only. If do so, the load may rotate or the sling gets loose and the sling may slip off. Install 2 or more wire ropes symmetrically.

• Apply wire ropes to the middle part of the hook. a Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The strength of the hook is maximum at its central part.

k Slinging

with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.

• Hanging angle must be 60 degrees or smaller as a rule. • When hanging a heavy load (25kg or heavier), the hanging angle of the rope must be narrower than that of the hook. a When slinging a load with 2 ropes or more, the larger the hanging angle is, the larger the tension of each rope. The figure bellow shows the variation of allowable load in kg when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000kg} a load vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 degrees. If the two ropes sling a 2000 kg load at a hanging angle of 150 degrees, each rope is subjected to a force as large as 4000 kg.

• Do not use twisted or kinked wire ropes. • When slinging up a load, observe the following. 1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught. 2. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. 3. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. 4. Do not lift up the load at an angle. • When lowering a load, pay attention to the following. 1. When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. 2. Check that the load is stable, and then remove the sling. 3. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane k The

• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. • Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc. 107E-2 SERIES

hoist or crane must be used to sling the components weighing 25 kg or heavier. A part weighing 25 kg or heavier in "disassembly and assembly" section is indicated with the symbol of 4 .

00-7

00 Index and foreword Foreword, safety and general information

• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing warning lamp, and check the following safety items. • Observe the signals for sling work. • Operate the hoist at a safe place. • Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button. • Do not sling a load at an angle. Do not move the crane while the slung load is swinging. • Do not raise or lower a load while the crane is moving longitudinally or laterally. • Do not drag a sling. • When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. • Consider the travel route in advance and lift up a load to a safe height. • Place the control switch in a position where it will not be an obstacle to work and passage. • After operating the hoist, do not swing the control switch. • Remember the position of the main switch so that you can turn off the power immediately in an emergency. • Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupter for electric shock prevention, check that the devices related to that switch are not in operating condition. • If you find an obstacle around the hoist, stop the operation. • After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 meters above the floor. Do not leave the sling attached to the hook. Selecting wire ropes • Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below Wire rope (JIS G3525, 6 x 37 - Type A) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope mm 10 12 14 16 18 20 25 30 40

00-8

Allowable load kN 8.8 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6

ton 0.9 1.3 1.7 2.3 2.9 3.6 5.6 8.1 14.4

Nominal diameter of rope mm 50 60

Allowable load kN 221.6 318.3

ton 22.6 32.4

a The allowable load is calculated as one sixth of the breaking load of the rope to be used (safety coefficient: 6). Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit Disconnection k When

replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.

a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). (Only registered persons can work.) a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. k If

refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.

• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut. Connection • When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and water into the hose. • Check that the O-rings are fitted to the joints when connecting the air conditioner piping. • Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. • When removing the O-rings, use a soft tool so that the piping is not damaged. • Check that the O-ring is not damaged or deteriorated. • Apply compressor oil for refrigerant (R134a) to the O-ring. a However, do not apply oil to the threaded portion of a bolt, nut or union.

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Manufacturer DENSO VALEO THERMAL SYSTEMS SANDEN

Part name ND-OIL8 ZXL100PG (equivalent to PAG46) SP-10

â&#x20AC;˘ When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). a Example of fitting of O-ring â&#x20AC;˘ An O-ring is fitted to every joint of the air conditioner piping.

For tightening torques, see "Others", "Precautions for disconnection and connection of air conditioner piping".

107E-2 SERIES

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00 Index and foreword Foreword, safety and general information

Precautions to prevent fire

(ALL-0000-17B-K-03-A)

• Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid.There is danger that they may catch fire. Always observe the following. • Do not smoke or use any flame near fuel or other flammable substances. • Shut down the engine before adding fuel. • Do not leave the machine when adding fuel or oil. • Tighten all the fuel and oil caps securely. • Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. • After adding fuel or oil, wipe up any spilled fuel or oil. • Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace. • When washing parts with oil, use a nonflammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire. • Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. • Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter. • When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.

•

9 J D 0 1 7 2 0

•

9 J D 0 1 7 2 1

• Fire caused by accumulation or attachment of flammable material

00-10

• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers. • To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover. Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. • Keep all the electric wiring connections clean and securely tightened. • Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring. Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death. Fire around the machine due to highly heated exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas.Its exhaust gas discharged during purification process (regeneration) can be at higher temperature than that from existing models. Do not bring any flammable material close to the outlet of the exhaust pipe. • When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas. See the operation and maintenance manual for the setting procedure. Explosion caused by lighting equipment • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine itself, follow the instructions in the operation and maintenance manual.

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Action if fire occurs

(ALL-0000-17A-K-01-A)

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

Dispose of waste materials

(ALL-0000-99A-K-

02-A)

To prevent pollution, pay full attention to the way to dispose of waste materials. • Always put the oil and coolant drained from the machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. • Observe the related laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.

Some kinds of rubber and plastics may produce poisonous gas harmful to human body when they are burned. • As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations.

107E-2 SERIES

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00 Index and foreword Foreword, safety and general information

How to read the shop manual

(ALL-0320-010-A-03-A)

(Rev. 2012/10) • Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. • Materials and specifications are subject to change without notice. • The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop manual for the same model of the engine as the one which is mounted on the machine. Composition of shop manual • This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use. 00. Index and foreword • This section includes the index, foreword, safety and basic information. 01. Specification • This section explains the specifications of the machine. 10. Structure and function • This section explains the structure and function of the machine. The section of "Structure and function" serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table • The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting. 50. Disassembly and assembly • This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained. 60. Maintenance standard • This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.

00-12

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically. Symbol

Item

Safety

Caution

Weight

Tightening torque

Coat

Oil, coolant

Drain

Remarks The special safety precautions required for performing work are described. The special technical precautions or other precautions for preserving standards required when performing work are described The weight of part or component and the cautions required when selecting hoisting wire or when working posture is important are indicated. The tightening torques that require special attention during assembly work are indicated. The places to be coated with adhesives, grease, etc. during assembling are indicated. The places where oil, coolant, etc. must be added and the quantity to be added are indicated. Places where oil, coolant, etc. must be drained and the quantity to be drained are indicated.

Unit â&#x20AC;˘ In this shop manual, the units are indicated with International System of units (SI). â&#x20AC;˘ For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

107E-2 SERIES

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00 Index and foreword Foreword, safety and general information

Explanation of terms for maintenance standard

(ALL-0330-006-A-01-A)

(Rev. 2012/10) • The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms. Standard dimension and tolerance • To be accurate, the finished dimension of a part is slightly different from one to another. • The finished dimension of a part specifies the allowable difference from the standard dimension which is set first. • The dimension set as the standard is called the standard dimension and the range of difference from this standard dimension is called the "tolerance". • An indication example of a standard dimension and tolerance is shown in the following table. (The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side) Example: Standard dimension

Tolerance -0.022 -0.126

120

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/lower limit of tolerance)." Example: 120(-0.022/-0.126) • Usually, the dimension of a hole and the dimension of a shaft to be inserted into the hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. • An indication example of a shaft and hole is shown in the following table. (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension 60

Tolerance Shaft -0.030 -0.076

Hole +0.046 0

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

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• When some parts are repaired, the value of performance/function is set to the standard value.

Standard interference • When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference". • Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is the "standard interference". • After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value or allowable dimension • The dimensions of parts change because of the wear or deformation while they are used. When the dimension changes exceeding certain value,

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the parts can not be used any longer. This value is called "repair limit". • If a part is worn to the repair limit, it must be replaced or repaired. • The performance and function of the products lower while they are used. When the value of the performance and function lowers exceeding a certain limit and it influences the operation etc., this value is called the allowable value or allowable dimension. • A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgement must be made in consideration of the operating condition and customer's requirement. Allowable clearance • Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "allowable clearance". • If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired. Allowable interference • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "allowable interference". • The allowable interference shows the repair limit of the part of smaller tolerance. • The parts whose interferences are out of the allowable interference must be replaced or repaired.

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Handling equipment of fuel system devices

(PC-AD00-2A4-K-00-A)

(Rev. 2012/01) • The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system. Use care for working environment • Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust. Sealing openings • Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself. How to clean parts when dirt is stuck • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge. • The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter element other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter element.

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Handling of intake system parts

(PC220-A900-2A4-K-00-A)

(Rev.2013/10) â&#x20AC;˘ The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system. Be careful of working environment â&#x20AC;˘ Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust. Sealing openings â&#x20AC;˘ Plug the pipes and the openings of the components which are removed, with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left open or plugged with rag since foreign material may enter.

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Handling of hydraulic equipment

(ALL-C000-2A4-P-01-A)

(Rev. 2012/10) • With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or when disassembling or assembling the hydraulic components. Be careful of working environment • Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust. Disassembly and maintenance work in the field • When disassembly or maintenance work of the hydraulic is performed in the field, there is danger of dust entering the components. It is also difficult to check the performance of the components after repairs, so it is desirable to use the component exchange service. The disassembly and assembly of the hydraulic components must be performed in the specially arranged dustproof workshop and the performance test of the components must be performed with the special testing equipment.

Plugging of opening (prevention of flowing out of oil) • Plug the pipes and the openings of the components which are removed (when plugs are not prepared, seal with caps, tapes, vinyl bags, etc.) to prevent entry of foreign material and flowing out of oil. Never leave the openings of the pipes and hoses without being covered or plugged with cloth as foreign material may enter them or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.

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Preventing intrusion of foreign materials during refilling operations. • Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible to remove the dirt that is collected during storage. It is a surer means.

Replacing hydraulic oil while its temperature is high • When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil.

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Flushing operations • After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them. Normally, flushing is performed twice. Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil.

Cleaning operations • After repairing the hydraulic equipment (pump, control valve, etc.) or when the machine is in operation, perform oil cleaning to remove the sludge or contaminant in the hydraulic oil circuit. The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device.

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Method of disconnecting and connecting of push-pull type coupler

(ALL-

C930-001-P-00-A)

(Rev. 2012/01) k Loosen

the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.

k Even

if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

(ALL-C930-925-P-01-A)

Disconnection 1. Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a It can be pushed in by approximately 3.5mm. a Do not hold rubber cap portion (4). 2. While pushing hose joint (2) into adapter (3), push rubber cap (4) against adapter (3) until "click" is heard. (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 container.

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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 part (4). 2. After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition. (Fig. 4) a When the hose fitting is pulled back, the rubber cap will move toward the hose, however, it is not a problem.

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Type 2

(ALL-C930-925-P-02-A)

Disconnection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side. (Fig. 6) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8)

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Connection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side to connect it. (Fig. 9)

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Type 3

(ALL-C930-925-P-03-A)

Disconnection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male side. (Fig. 10) 2. While keeping the condition of Step 1, push cover (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 11) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12)

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Connection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (a) at the hexagonal portion on the male side to connect them. (Fig. 13)

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Handling of electrical equipment

(ALL-E000-2A4-P-01-A)

(Rev. 2012/11) • To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment". Precautions for handling electric equipment Handling wiring harnesses and connectors • Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. • Compared with other electrical components fitted 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 the wiring harnesses.

Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female connectors) • Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.

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Defective crimping or soldering of connectors • The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joining area may become loose, which may result in a defective connection or breakage.

Disconnections in wiring • If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, the crimping of the connector may separate, or the soldering may be damaged, or the wiring harness may be broken.

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blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the oil and water from the compressed air completely before cleaning the connector with the compressed air.

High-pressure water entering connector • The connector is designed to make it difficult for water to enter (drip-proof structure), but if highpressure 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 spray water over the connector. The connector is designed to prevent water from entering, but once water does enter, it is difficult to drain it. If water should get into the connector, the pins will be short-circuited by the water. So if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors 1. Hold the connectors when disconnecting. • Disconnect connectors by holding the connector bodies. For the connectors held by a screw, loosen the screw fully, then hold the male and female connectors with each hand respectively and pull them apart horizontally. For the connectors with lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a connector • If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air. Oil, mud or dirt stuck to connector • If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or

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2. When removing from clips • Both of the connector and clip have stoppers, which are engaged with each other when the connector is connected.

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• Check that there is no oil, dirt or water stick to the connector pins (joint portion). • Check that the connector pins are free from deformation, defective contact, corrosion, or damage. • Check that external surfaces of the connectors are free from damage or breakage.

• When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the right and left, the housing may break.

a If any oil, water or dirt is stuck to the connector, wipe it off with a dry cloth. If any water is inside the connector, warm the connector and the inside of the wiring harness with a dryer. But be careful not to make it too hot as it causes short circuit. a If there is any damage or breakage, replace the connector. 2. Fix the connector securely. • Align the connectors correctly, and fit them securely. For the connectors with the lock stopper, push in the connectors until "click" is heard.

3. Action to take after removing connectors • After removing the connector, cover it with the vinyl bag to prevent entry of dust, dirt,oil or water in the contact portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

3. Correct the protrusion of the boot and misalignment of the wiring harness • For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the position, put it in its original position. a If the connector cannot be corrected easily, remove the clamp and adjust the position.

Connecting connectors 1. Check the connector visually.

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â&#x20AC;˘ If the connector clamp is removed, be sure to return it to its original position. And check that it is securely installed.

Drying wiring harness â&#x20AC;˘ If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing by using steam. If the wire harness must be washed in water, do not apply high pressure water or steam directly to the wiring harness. If water gets directly on the connector, do as follows. 1. Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown with dry compressed air, there is a risk that oil in the air may cause defective contact of the conditioner, remove oil and water in the air before starting air blow.

Handling of Deutsch connector (DT8-pin, DT12pin) Disconnection 1. While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector.

Connection 1. Push in female connector (2) horizontally until the lock clicks. (Arrow: x) 2. Since locks (a) and (b) may not be set completely, push in female connector (2) with curving movement until the locks are set normally. (Arrow: x, y, and z)

a Hot air from the dryer can be used, but regulate the time to use hot air in order to prevent the connector or related parts from becoming too hot, as it causes deformation or damage to the connector.

a Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.

3. Perform a continuity test on the connector. After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them.

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Handling of connectors used on engine

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

Slide, lock type (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right. 2. While pressing lock (L2), pull out connector (1) toward you. a In the case that even if lock (L2) is pressed, connector (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.

a Lock (L2) is located in the back of connector (1).

Connection 1. Insert the connector securely until a click is heard. (FRAMATOME-24) Disconnection 1. Slide down lock (red) (L1).

Connection 1. Insert the connector securely until a click is heard. Pull lock type (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

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Connection 1. Insert the connector securely until a click is heard. Push lock type (BOSCH-3) Disconnection 1. While pressing lock (C), pull out connector (3) in the direction of the arrow.

Connection 1. Insert the connector securely until a click is heard. (AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

â&#x20AC;˘ 114 series

Connection â&#x20AC;˘ 107 series

1. Insert the connector securely until a click is heard. (SUMITOMO-2) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

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

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Connection 1. Insert the connector securely until a click is heard. 107E-2 SERIES

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(SUMITOMO-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. a Pull the connector straight up.

Connection 1. Insert the connector to the end while aligning its grove to the other. 2. Turn housing (H1) in the direction of the arrow until it "clicks". Connection 1. Insert the connector securely until a click is heard. (SUMITOMO-4) Disconnection 1. While pressing lock (D), pull out connector (4) in the direction of the arrow.

Handling controller • The electronic circuits for control including the microcomputers are assembled in the controller. These electronic circuits in the controller must be handled with care as they control the machine. • Do not place objects on top of the controller. Connection 1. Insert the connector securely until a click is heard. Turn-housing type (Round green connector) (CANNON-4) Disconnection 1. Turn housing (H1) in the direction of the arrow. a Unlock the connector by turning housing (H1). When the lock is release the housing is felt tight to turn. 2. Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

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• Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts. • During rainy weather, do not leave the controller in a place where it is exposed to rain. • Do not place the controller on oil, water, or soil, or in a place that can be heated to a high

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temperature even for a short period of time. (Place it on a suitable dry stand.)

• Precautions when performing arc welding When performing arc welding on the machine body, disconnect all the wiring harness connectors connected to the controller. Put the arc welding ground to the place close to the welding point. Precautions for troubleshooting electrical circuits • Be sure to turn the starting switch to the "OFF" position before disconnecting or connecting the connectors. • Before performing troubleshooting, check all the related connectors for loose connection. a Check the related connectors for their performance by disconnecting and connecting them several times. • Be sure to connect all the disconnected connectors before proceeding to the next step. a If the starting switch is turned to the "ON" position with the connectors disconnected, the failure which is not related to the part which is actually failed. • When performing the troubleshooting for the circuit (measurement of voltage, resistance, continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. a If there is any value change on the multimeter, there may be a defective contact in the circuit.

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How to read electric wire code

(ALL-E500-030-P-00-A)

(Rev. 2012/10) • In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. AEX (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.) Indicates size of wire by nominal No. 0.85 Size (Nominal No.) is shown in Table 2. Indicates color of wire by color code. L Color codes are shown in Table 3. Type, symbol, and material • AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating. (Table 1) Type

Symbol

Low-voltage wire for AV automobile Thin-cover low-voltage wire for AVS automobile (Type 1) Thin-cover low-voltage wire for CAVS automobile (Type 2) Heatresistant lowvoltage wire AEX for automobile

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Conductor material

Insulator material

Temperature range (°C) in use

Example of use For large current wiring (nominal No. 5 and above)

Soft polyvinyl chloride

-30 to +60

Annealed copper for electric appliance

General wiring (nominal No. 3 and lower)

For mid- to small-size excavators (nominal No. 1.25 and lower)

Heat-resistant cross linked polyethylene

-50 to +110

General wiring for extremely cold weather specification Wiring at high ambient temperature place

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Dimensions (Table 2)

Coating D

(0.5) 0.75f (0.85) 1.25f (1.25) Nominal No. 0.5f Number of strands/ 20/ 30/ 11/ 50/ 16/ 7/0.32 Diameter of 0.18 0.18 0.32 0.18 0.32 strand Conductor Crosssectional 0.51 0.56 0.76 0.88 1.27 1.29 area (mm2) d (approx.) 1.0 1.2 1.5 AVS Standard 2.0 2.2 2.5 — — — AV Standard AEX

Standard

2.0

2.2

2.7

37/ 0.26

26/ 0.32

58/ 0.26

41/ 0.32

65/ 0.32

1.96

2.09

3.08

3.30

5.23

1.9 2.9 —

2.3 3.5 —

2.4 3.6 —

3.0 — 4.6

3.0

3.1

—

3.8

4.6

Coating D

Nominal No. 8 15 20 30 40 Number of strands/ 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 Diameter of strand Conductor Crosssectional 7.95 13.36 20.61 35.19 42.73 area (mm2) d (approx.) 3.7 4.8 6.0 8.0 8.6 — — — — — AVS Standard AV Standard 5.5 7.0 8.2 10.8 11.4 AEX

Standard

Coating D

Nominal No. Number of strands/ Diameter of strand Conductor Crosssectional area (mm2) d (approx.) CAVS

Standard

5.3

7.0

8.2

10.8

100

108/ 0.80

127/ 0.80

169/ 0.80

217/ 0.80

54.29

63.84

84.96

109.1

9.8 — 13.0

10.4 — 13.6

12.0 — 16.0

13.6 — 17.6

13.0

13.6

16.0

17.6

11.4

0.5f

0.5

0.75f

0.85

1.25f

1.25

—

7/round compression

—

11/round compression

—

16/round compression

—

0.56

—

0.88

—

1.29

—

0.9

—

1.1

—

1.4

—

1.6

—

1.8

—

2.1

a "f" of nominal No. denotes "flexible".

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Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White

a 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. Examples) GW means that the background is "Green" and marking is "White". Types of circuits and color codes Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

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R B R RW Y G L Br Lg O Gr P Sb Dg Ch

WG — — RB YR GW LW BrW LgR — — — — — —

AVS, AV, CAVS — — — — — — RY RG YB YG GR GY LR LY BrR BrY LgY LgB — — — — — — — — — — — —

AEX — — — RL YL GB LB BrB LgW — — — — — —

— — — — YW GL — — — — — — — — —

R B R D Y G L — — — — — — — —

— — — — Gr Br — — — — — — — — —

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Precautions when performing operation

(ALL-1160-927-A-00-A)

(Rev. 2012/11) • When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following general cautions. Precautions for removal and disassembly work • If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly. • After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering. • When draining oil, prepare a container with sufficient capacity. • Check the match marks which indicate the installing position, and put match marks on the places where they seem necessary before removal of the components to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing. • Check the number and thickness of the shims, and keep them in a safe place. • When hoisting the components, prepare the slings with sufficient strength. • When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately. • Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal. • After disconnecting the piping or removing a pipe joint, install the following plugs. a The O-rings in the table are emergency parts used for disassembly or transportation of the machine. When assembling, confirm the part numbers in the parts book and use the parts conforming to the using condition. Disconnection of face seal type hoses and tubes

Nominal No. 02 03 04 05 06

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Hose side Plug (1) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628

Pipe joint side Nut (2) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

O-ring (3) 02896-11008 02896-11009 02896-11012 02896-11015 02896-11018

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Disconnection of taper seal type hoses and tubes

Nominal No. 02 03 04 05 06 10 12 14

Hose side Plug (1) 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 07376-51443

Pipe joint side Nut (2) 07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219 07222-01422

Disconnection of split flange type hoses and tubes

No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737904 38.1 17.5 00400 0737905 42.9 19.8 00500 0737906 47.6 22.2 00640 0737910 52.4 26.2 01044 0737958.7 30.2 01250 12 0737966.7 31.8 01260 0737914 69.9 35.8 01460

107E-2 SERIES

Tube side Split flange Sleeve head O-ring (4) (2) (3) 07371-30400 07378-10400 07000-12021 07371-30500 07378-10500 07000-13022 07371-30640 07378-10600 07000-13025 07371-31049 07378-11000 07000-13032 07371-31255 07378-11200 07000-13038 07371-51260 07378-11210 07000-13038 07371-31465 07378-11400 07000-13048

Bolt (5) 0101080825 0101080830 0737251035 0737251035 0737251035 0101081245 0737251240

Washer (6) 01643-50823 01643-50823 01643-51032 01643-51032 01643-51032 01643-51232 01643-51232

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No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737979.4 36.5 01470 0737977.8 42.8 02071 20 0737996.8 44.5 02080 0737924 88.9 50.8 02484 0737930 106.4 62 03010 34

120.6

69.8

130.2

77.8

152.4

Tube side Split flange Sleeve head O-ring (4) (2) (3)

Bolt (5)

07371-51470 07378-11410 07000-13048 07371-32076 07378-12000 07000-12060 07371-52080 07378-12010 07000-12060 07371-12484 07378-12400 07000-12070 07371-13010 07378-13000 07000-12085

07379-03411 07371-13411 07378-13400 07000-12100 0737904012

07371-14012 07378-14000 07000-12110

07379-05011 07371-15011 07378-15000 07000-12135

0101081455 0737251240 0101081865 0737251240 0737251650 0737251650 0737251650 0737251655

Washer (6) 01643-31445 01643-51232 01643-31845 01643-51232 01643-51645 01643-51645 01643-51645 01643-51645

Removal of pipe joints of O-ring boss type

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Plug (1) 07040-10807 07040-11007 07040-11209 07040-11409 07040-11612 07040-11812 07040-12012 07040-12412 07041-13012 07040-13316 07041-13612 07040-14220 07040-15223

O-ring (2) 07002-10823 07002-11023 07002-11223 07002-11423 07002-11623 07002-11823 07002-12034 07002-12434 07002-13034 07002-13334 07002-13634 07002-14234 07002-15234

Removal of pipe joints of taper pipe thread type

00-36

107E-2 SERIES

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Nominal No. 01 02 03 04 06 10 12 14 20

Nominal thread size R 1/ 8 R 1/ 4 R 3/ 8 R 1/ 2 R 3/ 4 R1 R1 1/4 R1 1/2 R2

Plug (1) Square head type (A) 07042-00108 07042-00211 07042-00312 07042-00415 07042-00617 07042-01019 07042-01222 07042-01422 07042-02026

Hexagonal socket head (B) 07043-00108 07043-00211 07043-00312 07043-00415 07043-00617 07043-01019 07043-01222 07043-01422 07043-02026

Precautions for installation and assembly work • Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified. • Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are. • Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts. • Bend the cotter pins and lock plates securely. • When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded part. • When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage. • Clean all of the parts, and repair any damage, dents, burrs, or rust found on them. • Coat the rotating parts and sliding parts with engine oil. • Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P). • After installing the snap ring, check that the snap ring is settled in the ring groove completely. • When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then connect them securely. • Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook. • When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male screws which receives pressure. However, if the threaded part is difficult to degrease, you may use a seal tape. • When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing direction of the threads, seeing from the screw end and starting at the third thread. a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage.

107E-2 SERIES

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a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure. 1. Start the engine, and run it at low idle. 2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm before the stroke end 4 to 5 times. 3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke. a After the completion of repair and when operating the machine which is stored long term, perform the air bleeding with the same procedure as the one described above. Precautions at the time of completing work Refilling of coolant, oil and grease • When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again. • When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again. • If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to "Testing and adjusting". • Supply the specified amount of grease to the work equipment parts. Testing installed condition of cylinder heads and manifolds • Check the cylinder head and intake and exhaust manifold mountings for looseness. • If any bolt is loose, retighten it. a For the tightening torques, see the "Disassembly and assembly". Testing of engine piping for damage and looseness Check the piping for damage, the mounting bolts and nuts for looseness, and the joints Intake and exhaust for air suction and exhaust gas leakage. system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage. Cooling system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. Fuel system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check of KDPF or muffler and exhaust pipe for damage and looseness • Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. • Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts for looseness. If any part is loosely installed, retighten the bolts. Check of KDPF or muffler function • Check the KDPF or the muffler for unusual noise comparing to the noise when they are new. If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and assembly".

00-38

107E-2 SERIES

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Standard tightening torque table

(ALL-M140-03B-P-01-A)

(Rev. 2012/10) Table of tightening torque for bolts and nuts Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22 27 30 32 36 41 46 50 55 60

Tightening torque (Nm {kgm}) 11.8 to 14.7 {1.2 to 1.5} 27 to 34 {2.8 to 3.5} 59 to 74 {6.0 to 7.5} 98 to 123 {10.0 to 12.5} 157 to 196 {16 to 20} 245 to 309 {25 to 31.5} 343 to 427 {35 to 43.5} 490 to 608 {50 to 62} 662 to 829 {67.5 to 84.5} 824 to 1,030 {84 to 105} 1,180 to 1,470 {120 to 150} 1,520 to 1,910 {155 to 195} 1,960 to 2,450 {200 to 250} 2,450 to 3,040 {250 to 310} 2,890 to 3,630 {295 to 370}

*1: Split flange bolt. *2: Flanged bolt.

107E-2 SERIES

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a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the following table.

Thread diameter (mm) 6 8 10 12

Width across flats (mm) 10 12 14 17

Tightening torque (Nm {kgm}) 5.9 to 9.8 {0.6 to 1.0} 13.7 to 23.5 {1.4 to 2.4} 34.3 to 46.1 {3.5 to 4.7} 74.5 to 90.2 {7.6 to 9.2}

Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-20UNC 5/16-18UNC 3/8-16UNC 7/16-14UNC 1/2-13UNC 9/16-12UNC 5/8-11UNC 3/4-10UNC 7/8-9UNC 1-8UNC 1 1/8-7UNC 1 1/4-7UNC 1 1/2-6UNC

00-40

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5} 24.5 to 34.3 {2.5 to 3.5} 44.1 to 58.8 {4.5 to 6} 73.5 to 98.1 {7.5 to 10} 108 to 147 {11 to 15} 157 to 216 {16 to 22} 226 to 294 {23 to 30} 392 to 530 {40 to 54} 637 to 853 {65 to 87} 883 to 1,196 {90 to 122} 1,187 to 1,608 {121 to 164} 1,598 to 2,157 {163 to 220} 2,354 to 3,177 {240 to 324}

12.7 {1.3} 29.4 {3} 52.0 {5.3} 86.3 {8.8} 127 {13} 186 {19} 265 {27} 461 {47} 745 {76} 1,040 {106} 1,393 {142} 1,873 {191} 2,765 {282}

2.9 to 3.9 {0.3 to 0.4} 6.9 to 8.8 {0.7 to 0.9} 9.8 to 14.7 {1 to 1.5} 19.6 to 24.5 {2 to 2.5} 29.4 to 39.2 {3 to 4} 44.1 to 58.8 {4.5 to 6} 63.7 to 83.4 {6.5 to 8.5} 108 to 147 {11 to 15} 177 to 235 {18 to 24} 245 to 333 {25 to 34} 333 to 451 {34 to 46} 451 to 608 {46 to 62} 657 to 892 {67 to 91}

3.43 {0.35} 7.8 {0.8} 11.8 {1.2} 21.6 {2.2} 34.3 {3.5} 51.0 {5.2} 68.6 {7} 127 {13} 206 {21} 284 {29} 392 {40} 530 {54} 775 {79}

107E-2 SERIES

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Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-28UNF 5/16-24UNF 3/8-24UNF 7/16-20UNF 1/2-20UNF 9/16-18UNF 5/8-18UNF 3/4-16UNF 7/8-14UNF 1-14UNF 1 1/8-12UNF 1 1/4-12UNF 1 1/2-12UNF

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

14.7 to 19.6 {1.5 to 2} 34.3 to 39.2 {3.5 to 4} 53.9 to 68.6 {5.5 to 7} 83.4 to 108 {8.5 to 11} 127 to 167 {13 to 17} 186 to 245 {19 to 25} 255 to 343 {26 to 35} 441 to 598 {45 to 61} 716 to 961 {73 to 98} 1,020 to 1,373 {104 to 140} 1,353 to 1,844 {138 to 188} 1,804 to 2,432 {184 to 248} 2,707 to 3,658 {276 to 373}

17.7 {1.8} 37.3 {3.8} 61.8 {6.3} 96.1 {9.8} 147 {15} 216 {22} 294 {30} 520 {53} 843 {86} 1,196 {122} 1,598 {163} 2,118 {216} 3,177 {324}

3.9 to 4.9 {0.4 to 0.5} 7.8 to 9.8 {0.8 to 1} 14.7 to 19.6 {1.5 to 2} 24.5 to 29.4 {2.5 to 3} 34.3 to 49.0 {3.5 to 5} 49.0 to 68.6 {5 to 7} 73.5 to 98.1 {7.5 to 10} 127 to 167 {13 to 17} 196 to 265 {20 to 27} 284 to 382 {29 to 39} 382 to 520 {39 to 53} 510 to 686 {52 to 70} 765 to 1,030 {78 to 105}

4.41 {0.45} 8.8 {0.9} 16.7 {1.7} 26.5 {2.7} 41.2 {4.2} 58.6 {6} 83.4 {8.5} 147 {15} 226 {23} 333 {34} 451 {46} 598 {61} 892 {91}

Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.

Nominal No. 02 â&#x20AC;&#x201D; 03, 04 05, 06 107E-2 SERIES

Thread diameter (mm) 14 18 20 24

Width across flats (mm) Varies depending on type of connector.

Tightening torque (Nm {kgm}) Range

Target

35 to 63 {3.5 to 6.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0}

44 {4.5} 78 {8.0} 103 {10.5} 157 {16.0}

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00 Index and foreword Foreword, safety and general information

Nominal No. 10, 12 14

Thread diameter (mm) 33 42

Width across flats (mm)

Tightening torque (Nm {kgm}) Range

Target

363 to 480 {37.0 to 49.0} 746 to 1,010 {76.0 to 103}

422 {43.0} 883 {90.0}

Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter (mm) 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats (mm) 14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm}) Range

Target

5.88 to 8.82 {0.6 to 0.9} 9.8 to 12.74 {1.0 to 1.3} 14.7 to 19.6 {1.5 to 2.0} 19.6 to 24.5 {2.0 to 2.5} 24.5 to 34.3 {2.5 to 3.5} 34.3 to 44.1 {3.5 to 4.5} 44.1 to 53.9 {4.5 to 5.5} 58.8 to 78.4 {6.0 to 8.0} 93.1 to 122.5 {9.5 to 12.5} 107.8 to 147.0 {11.0 to 15.0} 127.4 to 176.4 {13.0 to 18.0} 181.3 to 240.1 {18.5 to 24.5} 274.4 to 367.5 {28.0 to 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the table below. a The table is applied to the threads coated with engine oil (wet threads)

00-42

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Nominal No. of hose

Width across flats (mm)

03 04 05 06 (10) (12) (14)

22 24 27 32 36 41 46 55

Tightening torque (Nm {kgm})

Taper seal

Range

Target

34 to 54 {3.5 to 5.5} 34 to 63 {3.5 to 6.5} 54 to 93 {5.5 to 9.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0} 177 to 245 {18.0 to 25.0} 177 to 245 {18.0 to 25.0} 197 to 294 {20.0 to 30.0} 246 to 343 {25.0 to 35.0}

44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Face seal Nominal No. - Thread root diameter Thread size threads per (mm) inch, type of (mm) (reference) thread 9/16-18UN — 14.3 — — 14 11/16-16UN — 17.5 — — 18 13 /16-16UN 20.6 22 24 1 -14UNS 25.4 30 1 3/16-12UN 30.2 — — 33 — — 36 — — 42

Table of tightening torque for face seal joints a The tightening torque table below applies to the seal joint (sleeve nut type) a The table is applied to the threads coated with engine oil (wet threads).

Width Outer diameter of across flats (mm) pipe (mm) 8 10 12 15 {16} 22 {20}

19 22 24 {27} 30 {32} 36

Tightening torque (Nm {kgm}) Range

Target

14 to 16 {1.4 to 1.6} 24 to 27 {2.4 to 2.7} 43 to 47 {4.4 to 4.8} 60 to 68 {6.1 to 6.8} 90 to 95 {9.2 to 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Nominal No. Thread root threads per inch, diameter (mm) type of thread (reference) 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1 -14UNS 25.4 30.2 1 3/16-12UN

Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification. Tightening torque table for bolts and nuts on 102,107 and 114 series engines a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the table below. Thread diameter (mm) 6 8 10 12 14

107E-2 SERIES

Tightening torque (Nm {kgm}) 10 ± 2 {1.02 ± 0.20} 24 ± 4 {2.45 ± 0.41} 43 ± 6 {4.38 ± 0.61} 77 ± 12 {7.85 ± 1.22} —

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00 Index and foreword Foreword, safety and general information

Tightening torque table for 102, 107, and 114 series engines (joint bolts) a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14

Tightening torque (Nm {kgm}) 8 ± 2 {0.81 ± 0.20} 10 ± 2 {1.02 ± 0.20} 12 ± 2 {1.22 ± 0.20} 24 ± 4 {2.45 ± 0.41} 36 ± 5 {3.67 ± 0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the table below. Material of female screw Nominal thread size 1/16 1/ 8 1/ 4 3/ 8 1/ 2 3/ 4

00-44

In cast iron or steel Tightening torque (Nm {kgm}) 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 55 ± 6 {5.61 ± 0.61} 75 ± 8 {7.65 ± 0.82}

In aluminum Tightening torque (Nm {kgm}) 5 ± 1 {0.51 ± 0.10} 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20} 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 45 ± 5 {4.59 ± 0.51}

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

List of abbreviation

(ALL-0360-005-A-00-A)

(Rev. 2013/03) • This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. • Abbreviations that are used in general society may not be included. • Special abbreviations which appear infrequently are noted in the text (marked with a). • This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams. List of abbreviations used in the shop manual Abbreviation

ABS

AISS

AJSS

ARAC

ARSC

ASR ATT BCV CAN CDR

CLSS

CRI

ECM

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Explanation

With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. Automatic Idling This function automatically sets the idle Engine Setting System speed. A lever is used to perform the steering Steering operations instead of a steering wheel. Advanced Joystick Steering System Moreover, it shifts gear and changes direction (WA) (FORWARD or REVERSE). When the accelerator pedal is released while Travel and brake the machine is traveling downhill, this function Automatic Retarder automatically applies the retarder with a Accelerator Control (HD, HM) constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function Travel and brake Automatic Retarder automatically applies the retarder to ensure Speed Control (HD, HM) that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, Travel and brake Automatic Spin this function automatically uses the optimum Regulator (HD, HM) braking force to drive both wheels. A device that can be fixed onto a machine in Work equipment Attachment order to enable it to do different jobs. When the retarder is not being used, this Brake Brake cooling oil valve bypasses part of the brake cooling oil to control valve (HD) reduce the load on the hydraulic pump. Controller Area Communication and One of communication standards that is used Network electronic control in the network on the machine. A regulator valve which is installed to KCCV Crankcase Depression Engine ventilator. It is written as CDR valve and it is Regulator not used independently. This system can simultaneously actuate multiple actuators regardless of the load Closed-center Load Hydraulic system (provides better combined operation than O.L. Sensing System S.S.). Engine controller electronically controls supply pump, common rail, and injector. This Common Rail Injection Engine function maintains optimum fuel injection amount and fuel injection timing. Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Electronic control system indicates the optimum actuation to the Module actuators. (Same as E.C.U.) Anti-skid Brake System

107E-2 SERIES

Travel and brake (HD, HM)

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00 Index and foreword Foreword, safety and general information

Abbreviation ECMV

ECSS

ECU

EGR

EMMS EPC

FOPS

F-N-R GNSS GPS

HSS

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. This system ensures smooth high-speed Electronically Travel travel by absorbing vibration of machine Controlled Suspension during travel with hydraulic spring effect of (WA) System accumulator. Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Unit Electronic control system indicates the optimum actuation to the actuators. (Same as E.C.M.) This function recirculates part of exhaust gas Exhaust Gas to combustion chamber in order to reduce Engine Recirculation combustion temperature, controls emission of NOx. This system allows data (filter, oil replacement Equipment interval, malfunctions on machine, failure Management Machine monitor code, and failure history) from each sensor on Monitoring System the machine to be checked on the monitor. Electromagnetic This mechanism allows actuators to be Hydraulic system Proportional Control operated in proportion to the current supplied. This structure protects the operator's head from falling objects. (Falling Object Protective Falling Object Structure) Cab and canopy Protective Structure This performance is standardized as ISO 3449. Forward-NeutralOperation Forward-Neutral-Reverse Reverse Global Navigation A general term for positioning system using Communication Satellite System satellites such as GPS, GALILEO, etc. Communication Global Positioning This system uses satellites to determine the (KOMTRAX, KOMTRAX current location on the earth. System Plus) This function uses a combination of hydraulic motor and bevel shaft to control difference in Steering Hydrostatic Steering travel speed of right and left tracks. System (D) Accordingly machine can turn without using Electronic Control Modulation Valve

Transmission (D, HD, WA, etc.)

HST

Hydro Static Transmission

Transmission (D, WA)

ICT

Information and Communication Technology

Intelligent Machine Control

IMA

Inlet Metering Actuator Engine

IMU

Inertial Measurement Unit

Intelligent Machine Control

IMV

Inlet Metering Valve

Engine

KCCV

00-46

Explanation

Komatsu Closed Engine Crankcase Ventilation

steering clutch. This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears. A general term for the engineering and its socially applied technology of information processing and communication. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. This is a device to detect the angular velocity and acceleration of the 3 axes that control motions. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. (I.M.A.) This mechanism separates oil in blowby gas and returns it to the intake side to afterburn it there. It primarily consists of filters. 107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

KCSF

Komatsu Catalyzed Soot Filter

Engine

KDOC

Komatsu Diesel Oxidation Catalyst

Engine

KDPF

Komatsu Diesel Particulate Filter

Engine

KTCS

Komatsu Traction Control System

Travel and brake (HM system)

KVGT

Komatsu Variable Geometry Turbocharger

Engine

LCD

Liquid Crystal Display

Machine monitor

LED

Light Emitting Diode

Electronic parts

LIN

Local Interconnect Network

Communication and electronic control

Load Sensing

Hydraulic system

LVDS

Low Voltage Differential Signaling

Communication and electronic control

MAF

Mass Air Flow

Engine

MMS

Multimedia Messaging Communication Service

Normally Closed

Electric and hydraulic systems

Normally Open

Electric and hydraulic systems

Open-center Load Sensing System

Hydraulic system

Pressure Compensation

Hydraulic system

OLSS PC

PCCS

PCV

Palm command control Steering system (D) Pre-stroke Control Valve

107E-2 SERIES

Engine

Explanation This filter captures soot in exhaust gas. It is built in to KDPF. The catalyst used for purifying exhaust gas. This is built in KDPF or assembled with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed in place of the conventional muffler. This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road. The turbocharger on which the cross-section area of the exhaust passage is made variable. Image display equipment such as a monitor which assembles in the liquid crystal element. It refers to semiconductor element that emits light when the voltage is applied in forward direction. One of communication standards that is used in the network on the machine Function that detects differential pressure of pump and controls discharge amount corresponding to load. One of communication standards that is used in the network on the machine This indicates engine intake air flow.It is not used independently but it is used as combined with sensor.Mass air flow sensor can be called as MAF sensor. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. A function used to correct oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharge amount of supply pump.

00-47

00 Index and foreword Foreword, safety and general information

Abbreviation PPC PPM PTO PTP

ROPS

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional Pressure Hydraulic system Control Piston Pump and Motor Power Take Off Power Tilt and power Pitch dozer

Hydraulic system (D, PC, etc.) Power transmission Work equipment (D)

Roll-Over Protective Structure

Cab and canopy

Le Systeme International dâ&#x20AC;&#x2122; Unites Unit (International unit system)

SOL

Solenoid

Electric system

TWV

2-Way Valve

Hydraulic and electric systems

VFT

Variable Flow Turbocharger

Engine

Explanation Used for controlling proportional pressure. This system moves actuators in proportion to the oil pressure. Piston pump and motor. Power take-off mechanism This function performs hydraulic control of the tilt and pitch of the bulldozer blade. If a machine tips over, this structure protects the operator with the seat belt fastened from being crushed. (Operator Protective Structure When Tipping) This performance is standardized as ISO 3471. Abbreviation for the "International System of Units". It is the universal unit system and "a single unit for a single quantity" is the basic principle applied. It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized. Solenoid valve that switches over direction of flow. Turbocharger variable in route of exhaust passage.

*1: Code for applicable machine family D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC

00-48

Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actuator No Connection 107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Abbreviation S/T STRG SIG SOL STD OPT OP PRESS SPEC SW TEMP T/C T/M

107E-2 SERIES

Actual word spelled out Steering Signal Solenoid Standard Option Pressure Specification Switch Temperature Torque Converter Transmission

00-49

00 Index and foreword Foreword, safety and general information

Conversion table

(ALL-2150-931-A-00-A)

(Rev. 2012/10) Method of using the conversion table â&#x20AC;˘ The unit conversion table enables the simple conversion in the figures between the different units. For further details of the method of use of the conversion table, see the examples given below. Example: Method of using the conversion table to convert a unit from millimeters to inches Conversion of 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 horizontal line from (A). 2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B). 3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from millimeters to inches. Therefore, 55 mm = 2.165 in. Conversion of 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 get 55 mm. 2. Then convert 55 mm to 2.165 in by the same procedure as above. 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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65 in. Millimeters to inches (B)

(A)

00-50

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.017 2.441 2.835 3.228 3.622

2.087 2.480 2.847 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

Millimeters to inches

0 10 20 30 40 50 60 70 80 90

0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.847 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.323 2.677 2.717 3.071 3.110 3.465 3.504 3.858 3.898

1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62

2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83

3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03

4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24

5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44

6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64

7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85

1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 130.07 149.91 152.12 171.96 174.17 194.01 196.21 216.05 218.26

1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040

2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304

3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568

4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832

5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096

6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361

1 l = 0.2642 U.S.Gal 7 8 9 1.849 2.113 2.378 4.491 4.755 5.019 7.133 7.397 7.661 9.774 10.039 10.303 12.416 12.680 12.944 15.058 15.322 15.586 17.700 17.964 18.228 20.341 20.605 20.870 22.983 23.247 23.511 25.625 25.889 26.153

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

Kilograms to pounds

0 10 20 30 40 50 60 70 80 90

0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

l to U.S. Gallons

0 10 20 30 40 50 60 70 80 90

0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775

107E-2 SERIES

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00 Index and foreword Foreword, safety and general information

l to U.K. Gallons

0 10 20 30 40 50 60 70 80 90

0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797

1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017

2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237

3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457

4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677

5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897

6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117

1 l = 0.21997 U.K.Gal 7 8 9 1.540 1.760 1.980 3.740 3.950 4.179 5.939 6.159 6.379 8.139 8.359 8.579 10.339 10.559 10.778 12.528 12.758 12.978 14.738 14.958 15.178 16.938 17.158 17.378 19.137 19.357 19.577 21.337 21.557 21.777

1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5

2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7

3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0

4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2

5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4

6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7

7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9

kgm to ft.lb

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

00-52

0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3

1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 426.8 491.8 499.1 564.2 571.4 636.5 643.7 708.8 716.1 781.2 788.4 853.5 860.7 925.8 933.1 998.2 1005.4 1070.5 1077.7 1142.8 1150.0 1215.1 1222.4 1287.5 1294.7 1359.8 1367.0 1432.1 1439.4

107E-2 SERIES

00 Index and foreword Foreword, safety and general information

kg/cm2 to lb/in22

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414

107E-2 SERIES

1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428

2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442

3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456

4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470

5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485

6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499

1 kg/cm2 = 14.2233 lb/in22 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 825.0 839.2 953.0 967.2 981.4 1,095 1,109 1,124 1,237 1,252 1,266 1,380 1,394 1,408 1,522 1,536 1,550 1,664 1,678 1,693 1,806 1,821 1,835 1,949 1,963 1,977 2,091 2,105 2,119 2,233 2,247 2,262 2,375 2,389 2,404 2,518 2,532 2,546 2,660 2,674 2,688 2,802 2,816 2,830 2,944 2,958 2,973 3,086 3,101 3,115 3,229 3,243 3,257 3,371 3,385 3,399 3,513 3,527 3,542

00-53

00 Index and foreword Foreword, safety and general information

Temperature Conversion of Fahrenheit to Celsius • A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures on the following table show the temperatures in both Fahrenheit and Celsius. • When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. • When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right. °C -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2

00-54

-40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

°F -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

°C -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

°F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

°C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

°F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

°C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4

1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0 86 186.8 87 188.6 88 190.4 89 192.2 90 194.0 91 195.8 92 197.6 93 199.4 94 201.2 95 203.0 96 204.8 97 206.6 98 208.4 99 210.2 100 212.0 105 221.0 110 230.0 115 239.0 120 248.0 125 257.0 130 266.0 135 275.0 140 284.0 145 293.0 150 302.0 155 311.0 160 320.0 165 329.0 170 338.0 175 347.0

107E-2 SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

01 Specification 2 01 Specification

107E-2 SERIES

01-1

01 Specification Table of contents

Table of contents

(ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1 Table of contents ........................................................................................................................ 01-2 General information .................................................................................................................... 01-3 Exhaust gas regulation ......................................................................................................... 01-3 Specifications............................................................................................................................. 01-9 Applicable machines ............................................................................................................ 01-9 Specifications .................................................................................................................... 01-10 General view ..................................................................................................................... 01-18 Engine performance curve .................................................................................................. 01-43

01-2

107E-2 SERIES

01 Specification Exhaust gas regulation

General information

(ALL-0000-001-A-00-A)

Exhaust gas regulation

(ENG-A000-017-K-00-A)

• The 3 main diesel engine emissions that adversely impact the human body and the environment are the following: 1. NOx (nitrogen oxides): causes breathing problems and acid rain 2. HC (hydrocarbons): causes photochemical smog 3. PM (particulates in air such as soot): causes cancer and breathing problems • NOx are produced when the nitrogen (N2) in air reacts with oxygen (O2) at high temperatures. These substances are produced when a diesel engine combustion takes place with too much air (nitrogen). To reduce NOx, it is necessary to lower the combustion temperature in the cylinder to suppress the oxidation of N (nitrogen). Therefore, an air-cooled aftercooler (2) is used for lowering the temperature of the air from turbocharger (1). • HC is the main component of fuel. HC in the blowby gas holds the most part of hazardous materials emitted from a diesel engine, however, this has been released into the air. • Incomplete combustion produces HC and also PM, which are solid particles adhering to soot, etc. Generally, there is a antinomy relation between NOx and PM (trying to reduce either results in increase of the other). To reduce PM, combustion has been improved by using common rail (3), microparticulating the fuel spray by using an electronically controlled high-pressure fuel injection system, reducing the injection period, and optimizing the injection timing. • Emission regulations are established in Japan, US, and various regions in Europe. The history of the USA regulations from the 1st (Tier 1) to 4th (Tier 4) is traced in the following table. (Transition of USA EPA(*1) emission regulations, for engine rated horsepowers 130 kW to 560 kW) The horizontal axis shows the NOx + NMHC(*2) level, and the vertical axis shows the PM level. In the 4th (Tier 4) regulation, both the NOx + NMHC and PM standards are tightened to levels approx. 1/7 of the 3rd (Tier 3) regulation. This 4th regulation is referred to as "Tier 4 regulation"(*3). *1: United States Environmental Protection Agency *2: General term for hydrocarbons (HC) that have a high photochemical reactivity. *3: There are 2 stages in Tier 4. The 1st stage is referred to as "Tier 4 Interim", for which actions are taken this time. The 2nd stage is referred to as "Tier 4 Final".

107E-2 SERIES

01-3

01 Specification Exhaust gas regulation

01-4

107E-2 SERIES

01 Specification Exhaust gas regulation

Actions taken to meet the Tier 4 regulation (4D107) Actions taken to meet the Tier 4 regulation

(ENG114-A000-001-K-00-A)

(ENG107-A000-018-K-00-A)

1. Engine 2. Air cleaner 3. Air cooled aftercooler 4. EGR cooler ECU(CM2250): Engine controller EGR EACT: EGR valve electric actuator MAF: Mass air flow and temperature sensor PAMB: Ambient pressure sensor PCCV: Crankcase pressure sensor PEX: Exhaust manifold pressure sensor PIM: Intake manifold pressure sensor T1: EGR orifice temperature sensor TIM: Intake manifold temperature sensor VFT EACT: VFT electric actuator â&#x20AC;˘ Compared to the actions for Tier 3, the following improvements have been made to meet Tier 4. 1. EGR (Exhaust Gas Recirculation) cooler (4) is adopted. (to reduce NOx). 2. Intake air flow at low engine speeds is increased by utilizing variable speed operation of the turbocharger (VFT) (PM reduced). 107E-2 SERIES

01-5

01 Specification Exhaust gas regulation

3. Oxygen density control is optimized for each driving condition by using a high precision EGR valve (VFT), mass air flow (MAF) and temperature sensor, engine controller, and by monitoring each part of the EGR circuit (NOx and PM reduced). 4. Common rail pressure is raised to increase fuel injection pressure and microparticulate the fuel spray (PM reduced). 5. Blowby gas reduction system (KCCV) is introduced to perform internal circulation of blowby gas (HC reduced). 6. Oxydation catalyzer (KDOC) is introduced (PM reduced). 7. Variations between injectors are averaged by engine controller (CM2250). 8. Combustion chamber is improved (NOx and PM reduced). 9. Fuel injection and VFT are automatically controlled according to the altitude by sensing high elevations with ambient pressure sensor (PAMB) (NOx and PM reduced).

01-6

107E-2 SERIES

01 Specification Exhaust gas regulation

Actions taken to meet the Tier 6 regulation (6D107) Actions taken to meet the Tier 4 regulation

(ENG114-A000-001-K-01-A)

(ENG-A000-018-K-00-A)

1. Engine 2. Air cleaner 3. Air cooled aftercooler 4. EGR cooler dP: KDPF differential pressure sensor and outlet pressure sensor ECU(CM2250): Engine controller EGRSOL: EPC valve (for EGR valve) EGRV: EGR valve MAF: Mass air flow and temperature sensor PAMB: Ambient pressure sensor PCCV: Crankcase pressure sensor PEX: Exhaust manifold pressure sensor PIM: Intake manifold pressure sensor REV: Turbocharger speed sensor SEGR: EGR valve lift sensor SVGT: KVGT position sensor T: KDPF inside temperature sensor 107E-2 SERIES

01-7

01 Specification Exhaust gas regulation

T1: EGR orifice temperature sensor TIM: Intake manifold temperature sensor VGTSOL: EPC valve (for KVGT) â&#x20AC;˘ Compared to the actions for Tier 3, the following improvements have been made to meet Tier 4. 1. EGR (Exhaust Gas Recirculation) cooler (4) is adopted. (to reduce NOx). 2. Intake air flow at low engine speeds is increased by utilizing variable speed operation of the turbocharger (KVGT) (PM reduced). 3. Oxygen density control is optimized for each driving condition by using a high precision EGR valve (EGRV), mass air flow (MAF) and temperature sensor, engine controller, and by monitoring each part of the EGR circuit (NOx and PM reduced). 4. Common rail pressure is raised to increase fuel injection pressure and microparticulate the fuel spray (PM reduced). 5. Blowby gas reduction system (KCCV) is introduced to perform internal circulation of blowby gas (HC reduced). 6. Soot collecting filter (KCSF) is introduced (PM reduced). 7. Oxydation catalyzer (KDOC) is introduced (NOx reduced). 8. Variations between injectors are averaged by engine controller (CM2250). 9. Combustion chamber is improved (NOx and PM reduced). 10.Fuel injection and KVGT are automatically controlled according to the altitude by sensing high elevations with ambient pressure sensor (PAMB) (NOx and PM reduced). 11.KVGT speed (REV) is monitored (to protect the KVGT). 12.When clogging of the soot collecting filter (KCSF) is detected by the differential pressure (dP) across the KDPF, the engine controller performs automatic regeneration(*), or prompts the operator to perform manual stationary regeneration on the machine monitor (to maintain the KDPF condition). *: A new feature to clean (oxidize) the soot accumulated in the soot collecting filter (KCSF) inside the KDPF.

01-8

107E-2 SERIES

01 Specification Applicable machines

Specifications

(ALL-2111-001-A-00-A)

Applicable machines Engine SAA4D107E-2

SAA6D107E-2

107E-2 SERIES

(ENG107-A000-00V-K-00-A)

Engine serial No. PC170LC-10 PC210I-10 PC210LC-10 PC210LCI-10 PC228USLC-10 PC240LC-10 PC290LC-10 WA270–7 WA320–7 WA380–7 D61EX-23 D61PX-23 D61EXI-23 D61PXI-23

Machine model Hydraulic excavator

Hydraulic excavator

Wheel loader

Bulldozer

01-9

01 Specification Specifications

Specifications

(ENG107-2110-001-A-00-A)

Applicable machines: PC170LC-10 Engine name Number of cylinders – bore x stroke Total displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimension pipe) Overall height (including exhaust pipe) Rated horsepower (gross) Max. torque (gross)

(ENG107-2110-030-A-11-A)

mm l {cc} – mm mm

SAA4D107E-2 4 – 107 x 124 4.46 {4,460} 1–3–4–2 1,160 825

–

1,504

kW{HP}/min–1 90.0 ± 4.5{121 ± 6.1} / 2,100 {2,100} {rpm} Nm{kgm}/min–1 484.4 ± 24.2 {49.4 ± 2.5} / 1,500 {rpm} {1,500}

Max. speed with no load min–1 {rpm} (High idle speed) Min. speed with no load min–1 {rpm} (Low idle speed) Fuel consumption ratio at rated point g/kWh {g/HPh} Dry weight (excluding KDPF) kg Fuel injection system – Fuel injection system control – Quantity of lubricating oil (Refill capacity) l Quantity of coolant l – Alternator Starting motor – VFT (turbocharger) – Performance

01-10

2,320 ± 30{2,320 ± 30} 1,050 ± 25 {1,050 ± 25} 220 {164} 457 High pressure common rail type Electronic control type 20 (18) 8.2 24 V, 35 A 24 V, 4.5 kW TD04M4t

107E-2 SERIES

01 Specification Specifications

Applicable machines: PC210I-10, PC210LC-10, PC210LCI-10, PC228USLC10 (ENG107-2110-030-A-04-A) Engine name Number of cylinders – bore x stroke Total displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimension pipe) Overall height (including exhaust pipe) Rated horsepower (gross) Max. torque (gross)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,136 740

1,210

–

kW{HP}/min–1 {rpm} Nm{kgm}/min–1 {rpm}

123.2 ± 6.16 {165 ± 8.25} / 2,000 {2,000} 648.4 ± 32.4 {66.2 ± 3.3} / 1,500 {1,500}

2,060 ± 50 {2,060 ± 50} 1,050 ± 25 {1,050 ± 25} 215 {160} 583 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 60 A [35 A] 24 V, 5.5 kW [4.5 kW] HE341Vh

[ ]：Shows for PC228USLC-10.

107E-2 SERIES

01-11

01 Specification Specifications

Applicable machines: PC240LC-10 Engine name Number of cylinders – bore x stroke Total displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimension pipe) Overall height (including exhaust pipe) Rated horsepower (gross) Max. torque (gross)

(ENG107-2110-030-A-00-A)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,136 740

1,207

–

kW{HP}/min–1 {rpm} Nm{kgm}/min–1 {rpm}

141 ± 7.06 {189 ± 9.47} / 2,000 {2,000} 744 ± 37.3 {75.9 ± 3.8} / 1,500 {1,500}

01-12

2,160 ± 50 {2,160 ± 50} 1,050 ± 25 {1,050 ± 25} 218 {163} 583 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 35 A 24 V, 4.5 kW HE341Vh

107E-2 SERIES

01 Specification Specifications

Applicable machines: PC290LC-10 Engine name Number of cylinders – bore x stroke Total displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimension pipe) Overall height (including exhaust pipe) Rated horsepower (gross) Max. torque (gross)

(ENG107-2110-030-A-01-A)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,136 740

1,207

–

kW{HP}/min–1 {rpm} Nm{kgm}/min–1 {rpm}

158.6 ± 7.9 {213 ± 10.6} / 2,050 {2,050} 819.3 ± 41.0 {83.6 ± 4.2} / 1,500 {1,500}

107E-2 SERIES

2,180 ± 50 {2,180 ± 50} 1,050 ± 25 {1,050 ± 25} 218 {163} 583 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 35 A 24 V, 4.5 kW HE341Vh

01-13

01 Specification Specifications

Applicable machines: WA270-7

(ENG107-2110-030-A-08-A)

Engine name Number of cylinders – bore x stroke Total displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimension pipe) Overall height (including exhaust pipe) Rated horsepower (gross) Max. torque (gross)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,045 861

1,458

–

kW{HP}/min–1 114.5 ± 5.7 {153.5 ± 7.7} / 2,000 {rpm} {2,000} Nm{kgm}/min–1 690 ± 34 {70.4 ± 3.5} / 1,300 {1,300} {rpm}

Max. speed with no load min–1 {rpm} (High idle speed) Min. speed with no load min–1 {rpm} (Low idle speed) Fuel consumption ratio at rated point g/kWh {g/HPh} Dry weight (Including KDPF and bracket) kg Fuel injection system – Fuel injection system control – Quantity of lubricating oil (Refill capacity) l Quantity of coolant l – Alternator Starting motor – KVGT (turbocharger) – Performance

01-14

2,250 ± 50 {2,250 ± 50} 825 ± 25 {825 ± 25} 220 {164} 680 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 60 A 24 V, 5.5 kW HE341Vh

107E-2 SERIES

01 Specification Specifications

Applicable machines: WA320-7

(ENG107-2110-030-A-09-A)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,045 861

1,458

–

kW{HP}/min–1 127.0 ± 6.4 {170.3 ± 8.5} / 2,100 {rpm} {2,100} Nm{kgm}/min–1 767 ± 38 {78.2 ± 3.9} / 1,400 {1,400} {rpm}

107E-2 SERIES

2,250 ± 50 {2,250 ± 50} 825 ± 25 {825 ± 25} 220 {164} 680 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 60 A 24 V, 5.5 kW HE341Vh

01-15

01 Specification Specifications

Applicable machines: WA380-7

(ENG107-2110-030-A-03-A)

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,100 861

1,530

–

kW{HP}/min–1 {rpm} Nm{kgm}/min–1 {rpm}

143.4 ± 7.2 {192.3 ± 9.6} / 2,100 {2,100}

01-16

941 ± 47 {96 ± 4.8} / 1,450 {1,450} 2,250 ± 50 {2,250 ± 50} 850 ± 25 {850 ± 25} 220 {164} 680 High pressure common rail type Electronic control type 25.4 (23.1) 12.4 24 V, 60 A 24 V, 5.5 kW HE341Vh

107E-2 SERIES

01 Specification Specifications

Applicable machines: D61EX-23,D61PX-23,D61EXI-23,D61PXI-23

(ENG107-2110-030-A-06-

mm l {cc} – mm mm

SAA6D107E-2 6 – 107 x 124 6.69 {6,690} 1–5–3–6–2–4 1,058 761

1,139

—

kW{HP}/min–1 127 ± 6.4 {170 ± 8.6} / 2,200 {2,200} {rpm} Nm{kgm}/min–1 767 ± 38.4{78.2 ± 3.9} / 1,400 {1,400} {rpm}

107E-2 SERIES

2,280 ± 30 {2,280 ± 30} 975 ± 25 {975 ± 25} 216 {161} 625 High pressure common rail type Electronic control type 33.3 (31.0) 12.4 24 V, 60 A 24 V, 5.5 kW HE341Vh

01-17

01 Specification General view

General view

(ENG107-2180-001-A-00-A)

Applicable machines: PC170LC-10

(ENG107-2180-041-A-07-A)

Left side a The shape is subject to machine models.

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

01-18

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-19

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-20

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-21

01 Specification General view

Applicable machines: PC210I-10, PC210LC-10, PC210LCI-10, PC228USLC-10, PC240LC-10, PC290LC-10 (ENG107-2180-041-A-00-A) Left side a The shape is subject to machine models.

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

01-22

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-23

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-24

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-25

01 Specification General view

Applicable machines: WA270-7

(ENG107-2180-041-A-05-A)

Left side a The shape is subject to machine models.

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

01-26

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-27

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-28

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-29

01 Specification General view

Applicable machines: WA320-7

(ENG107-2180-041-A-06-A)

Left side a The shape is subject to machine models.

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

01-30

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-31

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-32

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-33

01 Specification General view

Applicable machines: WA380-7

(ENG107-2180-041-A-02-A)

Left side a The shape is subject to machine models.

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

01-34

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-35

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-36

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-37

01 Specification General view

Applicable machines: D61EX-23,D61PX-23,D61EXI-23,D61PXI-23

(ENG107-2180-041-A-03-

Left side a The shape is subject to machine models.

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

01-38

107E-2 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

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

107E-2 SERIES

01-39

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-40

107E-2 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

107E-2 SERIES

01-41

01 Specification General view

Dimensions table

(ENG107-2110-2A4-A-00-A)

a These dimensions are given for reference when the engine is set on a test bench. Unit: mm Engine SAA4D107E-2

SAA6D107E-2

01-42

Machine model PC170LC-10 PC210I-10 PC210LC-10 PC210LCI-10 PC228USLC-10 PC240LC-10 PC290LC-10 WA270-7 WA320-7 WA380-7 D61EX-23 D61PX-23 D61EXI-23 D61PXI-23

A 1.160

Dimension of each part B C 1.453 392

D 781

1.136

1.159

429

740

1,136

1,156

429

740

1,045

1,458

409

861

1,100

1,530

409

861

1,058

1,139

377

761

107E-2 SERIES

01 Specification Engine performance curve

Engine performance curve

(ENG107-2170-001-A-01-A)

Applicable machines: PC170LC-10

(ENG107-2170-34E-A-11-A)

Rated horsepower: 90.0 ± 4.5 kW {121 ± 6.1 HP} / 2,100 min–1 {2,100 rpm} (Gross) Max. torque: 484.4 ± 24.2 Nm {49.4 ± 2.5 kgm} / 1,500 min–1 {1,500 rpm} (Gross)

107E-2 SERIES

01-43

01 Specification Engine performance curve

Applicable machines: PC210I-10, PC210LC-10, PC210LCI-10, PC228USLC10 (ENG107-2170-34E-A-04-A) Rated horsepower: 123.2 ± 6.16 kW {165 ± 8.25 HP} / 2,000 min–1 {2,000 rpm} (Gross) Max. torque: 648.4 ± 32.4 Nm {66.2 ± 3.3 kgm} / 1,500 min–1 {1,500 rpm} (Gross)

01-44

107E-2 SERIES

01 Specification Engine performance curve

Applicable machines: PC240LC-10

(ENG107-2170-34E-A-00-A)

Rated horsepower: 141 ± 7.06 kW {189 ± 9.46 HP} / 2,000 min–1 {2,000 rpm} (Gross) Max. torque: 744 ± 37.3 Nm {75.9 ± 3.8 kgm} / 1,500 min–1 {1,500 rpm} (Gross)

107E-2 SERIES

01-45

01 Specification Engine performance curve

Applicable machines: PC290LC-10

(ENG107-2170-34E-A-01-A)

Rated horsepower: 158.6 ± 7.9 kW {213 ± 10.6 HP} / 2,050 min–1 {2,050 rpm} (Gross) Max. torque: 819.3 ± 41.0 Nm {83.6 ± 4.2 kgm} / 1,500 min–1 {1,500 rpm} (Gross)

01-46

107E-2 SERIES

01 Specification Engine performance curve

Applicable machines: WA270-7

(ENG107-2170-34E-A-08-A)

Rated horsepower: 114.5 ± 5.7 kW {153.5 ± 7.7 HP} / 2,000 min–1 {2,000 rpm} (Gross) Max. torque: 690 ± 34 Nm {70.4 ± 3.5 kgm} / 1,300 min–1 {1,300 rpm} (Gross)

107E-2 SERIES

01-47

01 Specification Engine performance curve

Applicable machines: WA320-7

(ENG107-2170-34E-A-09-A)

Rated horsepower: 127.0 ± 6.4 kW {170.3 ± 8.5 HP} / 2,100 min–1 {2,100 rpm} (Gross) Max. torque: 767 ± 38 Nm {78.2 ± 3.9 kgm} / 1,400 min–1 {1,400 rpm} (Gross)

01-48

107E-2 SERIES

01 Specification Engine performance curve

Applicable machines: WA380-7

(ENG107-2170-34E-A-03-A)

Rated horsepower: 143.4 ± 7.2 kW {192.3 ± 9.6 HP} / 2,100 min–1 {2,100 rpm} (Gross) Max. torque: 941 ± 47 Nm {96 ± 4.8 kgm} / 1,450 min–1 {1,450 rpm} (Gross)

107E-2 SERIES

01-49

01 Specification Engine performance curve

Applicable machines: D61EX-23,D61PX-23,D61EXI-23,D61PXI-23

(ENG107-2170-34E-A-06-

Rated horsepower: 127 ± 6.4 kW {170 ± 8.6 HP} / 2,200 min–1 {2,200 rpm} (Gross) Max. torque: 767 ± 38.4 Nm {78.2 ± 3.9 kgm} / 1,400 min–1 {1,400 rpm} (Gross)

01-50

107E-2 SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

10 Structure and function 3 10 Structure and function

107E-2 SERIES

10-1

10 Structure and function Table of contents

Table of contents

(ALL-0310-002-A-00-A)

10 Structure and function ................................................................................................................... 10-1 Table of contents ........................................................................................................................ 10-2 Components layout..................................................................................................................... 10-4 Components layout drawing (4D107) ..................................................................................... 10-4 Components layout drawing (6D107) ..................................................................................... 10-6 Intake and exhaust system parts .................................................................................................. 10-8 Intake and exhaust system layout drawing (4D107)................................................................. 10-8 Intake and exhaust system layout drawing (6D107)................................................................. 10-9 Intake and exhaust system circuit diagram (4D107) .............................................................. 10-10 Intake and exhaust system circuit diagram (6D107) .............................................................. 10-12 Air cleaner (4D107) ............................................................................................................ 10-14 Air cleaner (6D107) ............................................................................................................ 10-15 VFT (4D107)...................................................................................................................... 10-17 KVGT (6D107)................................................................................................................... 10-21 Aftercooler......................................................................................................................... 10-29 EGR system piping drawing (4D107) ................................................................................... 10-30 EGR system piping drawing (6D107) ................................................................................... 10-32 EGR system circuit diagram (4D107) ................................................................................... 10-34 EGR system circuit diagram (6D107) ................................................................................... 10-36 EGR valve (4D107) ............................................................................................................ 10-38 EGR valve (6D107) ............................................................................................................ 10-40 EGR cooler........................................................................................................................ 10-42 Layout of KCCV (4D107) .................................................................................................... 10-43 Layout of KCCV (6D107) .................................................................................................... 10-46 KCCV ventilator ................................................................................................................. 10-48 KDOC muffler (4D107) ....................................................................................................... 10-52 KDPF (6D107) ................................................................................................................... 10-54 Engine main body parts............................................................................................................. 10-59 Cylinder head .................................................................................................................... 10-59 Cylinder block .................................................................................................................... 10-61 Main moving parts.............................................................................................................. 10-63 Vibration damper (6D107)................................................................................................... 10-67 Timing gear ....................................................................................................................... 10-68 Front cover ........................................................................................................................ 10-69 Valve system ..................................................................................................................... 10-70 Flywheel............................................................................................................................ 10-73 Lubrication system.................................................................................................................... 10-75 Lubrication system parts layout drawing (4D107) .................................................................. 10-75 Lubrication system parts layout drawing (6D107) .................................................................. 10-77 Lubrication system circuit diagram (4D107) .......................................................................... 10-79 Lubrication system circuit diagram (6D107) .......................................................................... 10-80 Oil pump ........................................................................................................................... 10-81 Boost oil pump (6D107) ...................................................................................................... 10-82 Oil filter.............................................................................................................................. 10-83 Oil cooler........................................................................................................................... 10-84 Regulator valve.................................................................................................................. 10-85 Safety valve....................................................................................................................... 10-86 Oil pan .............................................................................................................................. 10-87 Fuel system ............................................................................................................................. 10-88 Fuel system parts layout drawing......................................................................................... 10-88 Fuel system circuit diagram................................................................................................. 10-91 Supply pump ..................................................................................................................... 10-95 Fuel cooler ........................................................................................................................ 10-96 Pre-filter ............................................................................................................................ 10-97 Main filter .......................................................................................................................... 10-98 Cooling system......................................................................................................................... 10-99 Cooling system parts layout drawing.................................................................................... 10-99

10-2

107E-2 SERIES

10 Structure and function Table of contents

Cooling system circuit diagram (4D107) ............................................................................. 10-100 Cooling system circuit diagram (6D107) ............................................................................. 10-101 Drive pulley ..................................................................................................................... 10-102 Water pump..................................................................................................................... 10-107 Thermostat ...................................................................................................................... 10-108 Electrical equipment................................................................................................................ 10-109 Alternator ........................................................................................................................ 10-109 Starting motor .................................................................................................................. 10-117 Intake air heater ............................................................................................................... 10-121 Engine wiring harness (4D107) ......................................................................................... 10-122 Engine wiring harness (6D107) ......................................................................................... 10-124 Engine controller (4D107) ................................................................................................. 10-126 Engine controller (6D107) ................................................................................................. 10-132 Sensor ............................................................................................................................ 10-138

107E-2 SERIES

10-3

10 Structure and function Components layout drawing (4D107)

Components layout

(ALL-A000-001-K-04-A)

Components layout drawing (4D107)

(ENG107-A000-04D-K-02-A)

a The PC170LC-10 is shown as an example. The shape is subject to machine models.

10-4

107E-2 SERIES

10 Structure and function Components layout drawing (4D107)

1. KDOC muffler 2. KCCV ventilator 3. EGR valve 4. Crankshaft pulley 5. Air cleaner 6. Auto-tensioner 7. Starting motor 8. EGR cooler 9. Engine oil filter 10. VFT 11. Oil cooler 12. Supply pump 13. Fuel filter 14. Engine controller 15. Oil pan

107E-2 SERIES

10-5

10 Structure and function Components layout drawing (6D107)

Components layout drawing (6D107)

(ENG107-A000-04D-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. Starting motor 2. EGR cooler

10-6

107E-2 SERIES

10 Structure and function Components layout drawing (6D107)

3. Engine oil filter 4. KDPF 5. KCCV ventilator 6. Alternator 7. Vibration damper and crankshaft pulley 8. Auto-tensioner 9. Air cleaner 10. KVGT 11. Supply pump 12. Boost oil pump 13. Engine controller 14. Oil pan 15. Oil cooler

107E-2 SERIES

10-7

10 Structure and function Intake and exhaust system layout drawing (4D107)

Intake and exhaust system parts

(ENG107-A900-001-K-00-A)

Intake and exhaust system layout drawing (4D107)

(ENG107-A900-04D-K-02-A)

a The PC170LC-10 is shown as an example. The shape is subject to machine models.

1. VFT 2. EGR valve 3. Air intake connector 4. Mixing connector 5. Exhaust manifold 6. EGR cooler A: To KDOC muffler B: From EGR valve C: From aftercooler D: To intake manifold E: From air cleaner F: To aftercooler G: From exhaust manifold

10-8

107E-2 SERIES

10 Structure and function Intake and exhaust system layout drawing (6D107)

Intake and exhaust system layout drawing (6D107)

(ENG107-A900-04D-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. KVGT 2. EGR valve 3. Air intake connector 4. Exhaust manifold 5. EGR cooler A: To KDPF B: From EGR valve C: From aftercooler D: To intake manifold E: From air cleaner F: To aftercooler G: From exhaust manifold 107E-2 SERIES

10-9

10 Structure and function Intake and exhaust system circuit diagram (4D107)

Intake and exhaust system circuit diagram (4D107)

(ENG107-A900-052-K-01-A)

1. Air cleaner 2. VFT 3. Air cooled aftercooler 4. Intake air heater 5. Intake manifold 6. Exhaust manifold 7. EGR valve 8. KCCV ventilator 9. KDOC muffler 10. EGR cooler 11. Flywheel housing 12. Engine oil pan 13. Engine A: From atmosphere B: To atmosphere C: From KCCV

Function

(ENG95-A900-042-K-00-A)

• The engine employs the VFT (Variable Flow Turbocharger), EGR system (EGR valve and EGR cooler) which recirculates a part of the exhaust gas into the combustion chamber to control generation of NOx, KDOC (KOMATSU Diesel Oxidation Catalyst), and KCCV (KOMATSU Closed Crankcase Ventilation) system which recirculates the blowby gas. • The engine requires clean air to maintain its performance. If it takes in dirt or dust, it is damaged and its performance is lowered. • Air is sucked into the engine through air cleaner (1), VFT (2), and air-cooled aftercooler (3).

10-10

107E-2 SERIES

10 Structure and function Intake and exhaust system circuit diagram (4D107)

• If the VFT takes in foreign material, it may be damaged seriously since it has a variable mechanism which is not installed to the conventional turbocharger. Accordingly, the VFT always requires a high quality air cleaner. Therefore, clean or replace the air cleaner element according to the procedure described in the Operation and Maintenance Manual while taking care that foreign material does not enter it. • The intake air is sucked into the compressor side of VFT (2) through air cleaner (1). The air turbocharged by VFT (2) is cooled by air-cooled aftercooler (3). Then, the air is sucked into the cylinders through intake manifold (5) and used for combustion. • The exhaust gas flows through exhaust manifold (6) to the turbine of VFT (2) and drives the turbine impeller by using its energy. • The engine controller outputs signals to the EGR system so that EGR valve (7) opens properly according to the engine load to realize both clean exhaust gas and low fuel consumption. • If EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (6) into the EGR cooler through the EGR piping. • The exhaust gas cooled by EGR cooler (10) flows through EGR vale (7), merges with the intake air, and flows into intake manifold (5). • KDOC muffler (9) is installed to meet the emission regulations and composed of KDOC (oxidation catalyst) and muffler. • SOF (Soluble Organic Fraction) in PM (Particulate Matter) contained in the exhaust gas from the engine is oxidized to reduce the PM and clean the exhaust gas.

107E-2 SERIES

10-11

10 Structure and function Intake and exhaust system circuit diagram (6D107)

Intake and exhaust system circuit diagram (6D107)

(ENG107-A900-052-K-00-A)

1. Air cleaner 2. KVGT 3. Air cooled aftercooler 4. Intake air heater 5. Intake manifold 6. Exhaust manifold 7. EGR valve 8. KCCV ventilator 9. KDPF 10. EGR cooler 11. Flywheel housing 12. Engine oil pan 13. Engine A: From atmosphere B: To atmosphere C: From KCCV

Function

(ENG107-A900-042-K-00-A)

• A variable displacement turbocharger KVGT (KOMATSU Variable Geometry Turbocharger), EGR system (EGR valve and EGR cooler) which sends a part of exhaust gas back to the combustion chamber in order to suppress generation of NOx, KDPF (KOMATSU Diesel Particulate Filter) which purify the exhaust gas, and a blowby gas recirculation system KCCV (KOMATSU Closed Crankcase Ventilation) are introduced for this engine. • Clean air is necessary to maintain the engine performance. If dirt or dust enters, the engine can get damaged and the performance may be degraded. • Air flows through air cleaner (1), KVGT (2), and air cooled aftercooler (3) into the engine.

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10 Structure and function Intake and exhaust system circuit diagram (6D107)

• The KVGT has a variable geometry mechanism not found in conventional turbochargers. The KVGT can get seriously damaged if foreign material enters the KVGT. Therefore, a high quality air cleaner is essential for the engine. Follow the procedures in the Operation and Maintenance Manual to clean or replace the air cleaner element, and be careful not to let foreign material enter the system during replacement work. • Intake air flows from air cleaner (1) into the compressor side of KVGT (2). The air charged at KVGT (2) is cooled at air cooled aftercooler (3). The air then flows through air intake manifold (5) and then into the cylinders for combustion. • Exhaust gas is sent from exhaust manifold (6) to the turbine side of KVGT (2). Thus the turbine impeller is driven by the energy of the exhaust gas. • The engine controller outputs signals to the EGR system for opening EGR valve (7) most properly according to the load on the engine to attain both clean exhaust gas and low fuel consumption. • When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (6) through EGR piping to the EGR cooler. • The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air and then flows in the intake manifold (5). • KDPF (9) features a newly designed mechanism and is installed to meet the new exhaust gas regulations. The KDPF consists of KDOC (oxidation catalyzer) and KCSF (soot collecting filter). • Particulate soot in the exhaust gas are collected to purify the exhaust gas.

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10 Structure and function Air cleaner (4D107)

Air cleaner (4D107) Air cleaner

(ENG107-A910-001-K-00-A)

(ENG95-A910-041-K-00-A)

a The shape is subject to machine models.

1. Vacuator valve 2. Pre-cleaner 3. Inlet 4. Outlet 5. Outlet cover 6. MAF sensor 7. Body 8. Secondary element 9. Primary element 10. Cover A: Air intake inlet B: Air intake outlet Features • Since the intake air does not swirl largely or make a U-turn, the intake resistance is low. • Orifice of the element and the outlet straighten the flow effectively to stabilize the MAF sensor output. • Since the body is rectangular, it makes dead volume decrease when mounted on the machine.

Operation

(ENG95-A910-044-K-00-A)

• Air containing dust is sucked in from inlet (3) and the dust is separated by centrifugal force of pre-cleaner (2). • Furthermore, the dust is removed 99.9% or more by primary element (9) and the clean air is sucked into the engine through secondary element (8) and outlet (4). • On the other hand, the dust and water separated by pre-cleaner (2) swirl along the inside wall of precleaner (2), jump into vacuator valve (1), and go out automatically.

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10 Structure and function Air cleaner (6D107)

Air cleaner (6D107) Air cleaner

(ENG107-A910-001-K-01-A)

(ENG107-A910-041-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. Vacuator valve 2. Inlet 3. Air cleaner clogging sensor or dust indicator mounting 4. Outlet 5. Mass air flow, temperature sensor mounting 6. Rectifier wire net 7. Outer element 8. Guide vane 9. Inner element 10. Screen

Specifications

(ENG107-A910-030-K-00-A)

• Type: Cyclone pack type • Filtering area (outer element): 7.6 m2 • Filtering area (inner element): 1.4 m2

Operation

(ENG107-A910-044-K-00-A)

• Since inlet (2) is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vanes (8), not by guide plates. • Air containing dust is sucked in vertically through inlet (2) and the dust is separated by the centrifugal effect by guide vane (8). • More than 99.9% of the dust is removed by outer element (7) and clean air is sucked in the engine through inner element (9) and outlet (4). • The dust and water separated by guide vane (8) swirl along the inside wall of body and enter vacuator valve (1) and then are discharged out automatically. 107E-2 SERIES

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10 Structure and function Air cleaner (6D107)

â&#x20AC;˘ Rectifier wire net (6) rectifies the air flow to the mass air flow and temperature sensor which is important to the engine control.

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10 Structure and function VFT (4D107)

VFT (4D107)

(ENG107-AA10-001-K-00-A)

a This section corresponds to 4-cylinder engine.

VFT

(ENG95-AA10-041-K-00-A)

a VFT: Abbreviation for Variable Flow Turbocharger a The shape is subject to machine models.

A: Air intake inlet B: Air intake outlet C: Exhaust inlet D: Exhaust outlet

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10 Structure and function VFT (4D107)

1. VFT motor 2. Flange bolt 3. Bracket 4. Thrust sleeve

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10 Structure and function VFT (4D107)

5. Bracket 6. O-ring 7. Insert 8. Oil deflector 9. Thrust bearing 10. Thrust ring 11. Bearing housing 12. Bearing 13. Piston ring 14. Turbine wheel 15. Turbine insert 16. Turbine housing assembly 17. Pin 18. Seal ring 19. Snap ring 20. O-ring 21. Snap ring 22. Piston ring 23. Compressor cover assembly 24. Compressor wheel 25. Lock nut 26. Flange bolt 27. Flange bolt 28. Connector assembly 29. Snap ring 30. Snap ring 31. Lock plate 32. Flange bolt E: Oil inlet F: Oil outlet

Specifications

(PC160-AA10-030-K-00-A)

Turbocharger model: TD04M4t-VFT Rotation direction: Clockwise (seen from intake air inlet)

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10 Structure and function VFT (4D107)

Operation

(ENG95-AA10-044-K-00-A)

1. Large scroll 2. Small scroll 3. Fixed vane 4. Flow control valve A: When flow control valve is fully closed (small flow rate) B: When flow control valve is fully open (large flow rate) • The turbine housing of the VFT consists of large scroll (1) and small scroll (2). • Fixed vane (3) is installed between large scroll (1) and small scroll (2) for flow rectification. • The flow rate into large scroll (1) side is controlled by opening or closing the flow control valve (4). • The position of the flow control valve (4) is controlled by the actuator which is driven by the command from the engine controller.

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10 Structure and function KVGT (6D107)

KVGT (6D107)

(ENG107-AA10-001-K-01-A)

a This section corresponds to 6-cylinder engine.

KVGT

(ENG107-AA10-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and it is variable displacement turbocharger. a The PC240LC-10 is shown as an example. The shape is subject to machine models.

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10 Structure and function KVGT (6D107)

1. Blower housing 2. KVGT speed sensor 3. Hydraulic actuator 4. Turbine housing

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10 Structure and function KVGT (6D107)

5. Plate 6. Vane 7. Nozzle ring 8. Push rod 9. Shaft 10. Blower impeller 11. Turbine impeller 12. Piston A: Air intake inlet B: Air intake outlet C: Exhaust inlet D: Exhaust outlet

Operation

(ENG107-AA10-044-K-00-A)

1. Air cleaner 2. KVGT 3. KDPF 4. EGR cooler 5. EGR valve C: Blower impeller T: Turbine impeller • The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/ intake air flow) • To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas pressure hitting the turbine impeller (T) can be adjusted, is introduced. • The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to insufficient oxygen at low engine speeds. • The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the engine output increases. • Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be injected, and the engine output increases. a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when replacing oil or oil filter.

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10 Structure and function KVGT (6D107)

• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P) is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6). • The passage area changes when push rod (8) slides right or left. • The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8). • Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and sent out from (B). • When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push rod (8) slides to the right to narrow section (P). • Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases, and more air (oxygen) is inhaled. • The turbocharger speed is sensed by KVGT speed sensor (2). When nozzle ring is closed • At low engine speeds, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed) • When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine increases and the turbocharger speed increases.

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10 Structure and function KVGT (6D107)

When nozzle ring is open â&#x20AC;˘ At high engine speeds, exhaust gas inlet passage (P) is widened (L2). â&#x20AC;˘ As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).

a Nozzle ring (7), vane (6), and push rod (8) are integrated and slide together but do not rotate. a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the whole KVGT.

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10 Structure and function KVGT (6D107)

Hydraulic actuator operation • Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve (10). • The force for the movement is the oil pressure supplied from boost oil pump (12). a The shape in the following figure is subject to machine models.

• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to engine controller (7).

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10 Structure and function KVGT (6D107)

1. Air cleaner 2. Mass air flow and temperature sensor 3. KVGT 4. KVGT speed sensor 5. KVGT position sensor 6. Hydraulic actuator 7. Engine controller 8. EPC valve (for KVGT) 9. KDPF 10. EGR system (EGR cooler, EGR valve) 11. EGR orifice temperature sensor 12. Boost oil pump C: Blower impeller T: Turbine impeller KVGT control system • Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil pressure controlled by EPC valve (8), to move the piston. • A good response at high altitudes is maintained by sensing high elevations with the ambient pressure sensor, and automatically controlling the fuel injection and the KVGT. • The KVGT is protected by controlling its speed to prevent overspeeds. Lubrication • Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication. • Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing. • Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil pan.

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10 Structure and function KVGT (6D107)

Cooling â&#x20AC;˘ Coolant from the cylinder block enters the center housing to cool the KVGT. â&#x20AC;˘ Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows through the water inlet connector to the water pump.

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10 Structure and function Aftercooler

Aftercooler

(ENG107-A9A0-041-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. Core 2. Tank 3. Tube 4. Fin A: Intake air outlet B: Intake air inlet

Specifications • • • •

(ENG107-A9A0-030-K-00-A)

Cooling method: Air cooled Core type: Triangle plates Fin pitch: 4.0/2 Total heat dissipation area: 12.71 m2

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10 Structure and function EGR system piping drawing (4D107)

EGR system piping drawing (4D107) EGR system piping drawing

(ENG107-A9J0-001-K-00-A)

(PC160-A9J0-04D-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation a The shape is subject to machine models.

1. VFT 2. EGR valve 3. Air intake connector 4. Mixing connector 5. Exhaust manifold 6. EGR cooler

Function

(PC160-L541-042-K-00-A)

• EGR valve (driven with electric motor) Controls the gas flow from exhaust side to intake side. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows into the intake side. • EGR cooler Cools the exhaust gas. The engine coolant is used for cooling. • Mixing connector Returns the air from the air-cooled aftercooler and the exhaust gas from the EGR valve to the intake side. • Sensors Control the EGR according to the operating condition.

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10 Structure and function EGR system piping drawing (4D107)

Troubleshoot the system. â&#x20AC;˘ Control each part of the EGR circuit and control the EGR rate according to the operating condition to clean the exhaust gas constantly. â&#x20AC;˘ Monitor the condition of the EGR circuit and perform troubleshooting to prevent a serious failure.

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10 Structure and function EGR system piping drawing (6D107)

EGR system piping drawing (6D107) EGR system piping drawing

(ENG107-A9J0-001-K-01-A)

(ENG107-A9J0-04D-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation. a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. KVGT 2. EGR valve 3. Air intake pipe 4. Air intake connector 5. Exhaust manifold 6. EGR cooler

Function

(ENG107-A9J0-042-K-00-A)

â&#x20AC;˘ EGR valve (driven hydraulically) Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the air intake side.

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10 Structure and function EGR system piping drawing (6D107)

• EGR cooler Cools the exhaust gas. Engine coolant is used for cooling. • Air intake connector Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side. • Each sensor Controls the EGR according to the operating condition. Troubleshoots the system. • Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to ensure clean exhaust at all times. • Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.

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10 Structure and function EGR system circuit diagram (4D107)

EGR system circuit diagram (4D107) EGR system circuit diagram

(ENG107-A9J0-001-K-02-A)

(ENG107-A9J0-052-K-01-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner 2. KDOC muffler 3. Mass air flow and temperature sensor (MAF) 4. Electric actuator (VFT) 5. EGR cooler 6. EGR valve 7. Electric actuator (EGR valve) 8. Ambient pressure sensor 9. Aftercooler 10. Exhaust manifold 11. Air intake manifold 12. Charge (boost) pressure and temperature sensor 13. Engine controller 14. EGR orifice temperature sensor 15. Exhaust manifold pressure sensor C: Blower impeller T: Turbine impeller

Operation

(ENG95-A9J0-044-K-00-A)

â&#x20AC;˘ The engine controller outputs signals so that EGR valve (6) opens properly according to the engine load to realize both clean exhaust gas and low fuel consumption. â&#x20AC;˘ If EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10) into EGR cooler (5) through the EGR piping.

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10 Structure and function EGR system circuit diagram (4D107)

â&#x20AC;˘ The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6), merges with the intake air in the air intake connector, and flows into intake manifold (11).

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10 Structure and function EGR system circuit diagram (6D107)

EGR system circuit diagram (6D107) EGR system circuit diagram

(ENG107-A9J0-001-K-03-A)

(ENG107-A9J0-052-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner 2. KDPF 3. Ambient pressure sensor 4. Aftercooler 5. EGR orifice temperature sensor 6. EGR cooler 7. EGR valve 8. Hydraulic actuator (power piston) 9. EPC valve (for EGR valve) 10. EGR valve lift sensor 11. EPC valve (for KVGT) 12. Exhaust manifold 13. Boost oil pump 14. Air intake manifold 15. Charge (boost) pressure and temperature sensor 16. Engine controller 17. Mass air flow and temperature sensor(MAF) 18. Exhaust manifold pressure sensor C: Blower impeller T: Turbine impeller

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10 Structure and function EGR system circuit diagram (6D107)

Operation

(ENG107-A9J0-044-K-00-A)

• The engine controller outputs signals for opening EGR valve (7) most properly according to the load on the engine to attain both clean exhaust gas and low fuel consumption. • When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12) through EGR piping to EGR cooler (6). • The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in the air intake connector, and then flows in the air intake manifold (14).

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10 Structure and function EGR valve (4D107)

EGR valve (4D107) EGR valve

(ENG107-A9K1-001-K-00-A)

(ENG95-A9K1-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation a The shape is subject to machine models.

1. DC motor assembly (brushless motor with built-in position sensor) 2. DC motor shaft 3. Rod 4. Filter 5. Housing 6. Valve seat 7. Valve 8. Seal 9. Spring A: EGR gas inlet (from EGR cooler) B: EGR gas outlet (to intake manifold) Structure • Small-sized EGR valve driven with a DC motor. • The DC motor has a position sensor in it to sense the valve position. • Since 2 valves are combined to cancel the EGR gas pressure, the operating effort is small.

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10 Structure and function EGR valve (4D107)

Operation

(ENG95-A9K1-044-K-00-A)

A: EGR gas inlet (from EGR cooler) B: EGR gas outlet (to air intake manifold) â&#x20AC;˘ DC motor shaft (2) of the DC motor converts rotary motion into linear motion. Accordingly, valve (7) is opened or closed by turning the motor. Open valve: The DC motor is turned and DC motor shaft (2) is pushed out to push rod (3) and open valve (7). When valve (7) opens, the EGR gas flows into the air intake manifold. Close valve: The DC motor is turned in reverse and DC motor shaft (2) is pulled in, then rod (3) is pushed back by spring (9) and valve (7) closes.

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10 Structure and function EGR valve (6D107)

EGR valve (6D107) EGR valve

(ENG107-A9K1-001-K-01-A)

(ENG107-A9K1-041-K-00-A)

a The shape is subject to machine models.

1. Valve 2. Spring 3. Power piston 4. Spool 5. Spring 6. EGR valve lift sensor 7. EPC valve (for EGR valve) 8. EPC valve (for KVGT) A: EGR gas inlet (from EGR cooler) B: EGR gas outlet (to intake manifold) C: Servo drive oil inlet D: Servo drive oil outlet E: KVGT control oil pressure outlet F: KVGT drive oil pressure outlet Structure â&#x20AC;˘ The EGR valve consists of the EGR gas flow control mechanism and the EPC valves

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10 Structure and function EGR valve (6D107)

• There are two EPC valves, one for the EGR valves control and one for the KVGTcontrol.

Operation

(ENG107-A9K1-044-K-00-A)

• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve flows into port (E). • Spool (4) is pressed to the right by the reaction force of spring (5), and EGR valve (1) is closed by the reaction force of spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side. • To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a position whereat this control pressure and the force of spring (5) are balanced. • The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port (C) pushes power piston (3) to the left. • Oil from the boost oil pump acts on power piston (3) and generates force (Fp). • When force (Fp) becomes larger than reaction force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas will flow to the intake side. • Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at a position determined by spool (4). • The valve position is controlled by the engine controller by controlling the spool position with the control pressure of the EPC valve. • A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in contact with power piston (3). • Position of spool (4) is sensed by the EGR valve lift sensor.

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10 Structure and function EGR cooler

EGR cooler

(ENG107-A9L0-041-K-00-A)

a The shape is subject to machine models.

1. Tube A: EGR gas inlet B: Air vent C: Coolant outlet D: EGR gas outlet (to EGR valve) E: Coolant inlet

1. Flat tube 2. Inner fin

Operation

(ENG107-A9L0-044-K-00-A)

• The EGR gas enters from (A) and flows through 11 flat tubes (1). • Coolant enters from (E) and flows around flat tube (1) in shell and then goes out from (C). • The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet (D).

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10 Structure and function Layout of KCCV (4D107)

Layout of KCCV (4D107) KCCV layout drawing

(ENG107-A180-001-K-00-A)

(PC160-A180-04D-K-00-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation a The shape is subject to machine models.

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10 Structure and function Layout of KCCV (4D107)

1. KCCV ventilator 2. VFT 3. Blowby duct 4. Flywheel housing 5. Check valve 6. CDR valve 7. Crankcase pressure sensor A: Blowby gas (from flywheel housing) B: Blowby gas from which engine oil is removed (to VFT) C: Engine oil (to oil pan) â&#x20AC;˘ Blowby gas has been emitted to the atmosphere so far. Since the emission regulation has become strict and blowby gas must be controlled now, the blowby gas intake recirculation system is employed. â&#x20AC;˘ Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to VFT(2) as it is, it causes the following problems. To prevent this, a filter is installed to KCCV ventilator (1) to remove the engine oil. 1. Deterioration of turbocharger and aftercooler performance caused by sticking engine oil 2. Abnormal combustion in engine 3. Malfunction of each sensor caused by sticking engine oil

Operation

(PC160-A180-044-K-00-A)

a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere. The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV ventilator.

1. Air cleaner 2. VFT 3. Aftercooler 4. Cylinder block (crankcase) 5. Breather

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10 Structure and function Layout of KCCV (4D107)

6. KCCV ventilator 7. Oil pan â&#x20AC;˘ Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and then the cleaned gas (B) is recirculated to the intake side of the VFT. â&#x20AC;˘ Removed engine oil (C) flows through a check valve and falls to the oil pan.

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10 Structure and function Layout of KCCV (6D107)

Layout of KCCV (6D107) KCCV layout drawing

(ENG107-A180-001-K-01-A)

(ENG107-A180-04D-K-00-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. KCCV ventilator 2. KVGT 3. Blowby duct 4. Flywheel housing 5. Check valve 6. CDR valve 7. Crankcase pressure sensor A: Blowby gas (from flywheel housing) B: Engine oil-free blowby gas (to KVGT) C: Engine oil (to oil pan) â&#x20AC;˘ Formerly, blowby gas (A) has been released to the atmosphere. However, since the tightened exhaust gas regulation also regulates blowby gas, the blowby gas recirculation system is adopted. â&#x20AC;˘ Since blowby gas (A) contains engine oil mist, which may cause the following problems when recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil. 1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil 2. Abnormal engine combustion

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10 Structure and function Layout of KCCV (6D107)

3. Malfunction of sensors due to aherence of engine oil

Operation

(ENG107-A180-044-K-00-A)

a The figure on the left shows the flow of blowby gas released to the atmosphere from conventional engines. The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV ventilator.

1. Air cleaner 2. KVGT 3. Aftercooler 4. Cylinder block (crankcase) 5. Breather 6. KCCV ventilator 7. Oil pan â&#x20AC;˘ Engine oil mist is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and then the cleaned gas (B) is recirculated to the intake side of the KVGT. â&#x20AC;˘ Removed engine oil (C) flows through a check valve and falls to the oil pan.

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10 Structure and function KCCV ventilator

KCCV ventilator

(PC160-A18H-041-K-00-A)

a The shape is subject to machine models.

1. Case 2. CDR valve 3. Crankcase pressure sensor 4. Relief valve 5. Impactor 6. Filter 7. Heater tube A: Blowby gas inlet (from flywheel housing) B: Blowby gas outlet (to VFT intake side) C: Oil drain port (to oil pan) D: Coolant inlet E: Coolant outlet

Function

(PC160-A18H-042-K-00-A)

• If the blowby gas is returned to the intake side of VFT, inside of crank case becomes negative pressure and the dust may be sucked in through crank seal. To prevent this, the blowby pressure is controlled by CDR valve (regulator valve ) (2) and crank case pressure sensor. • If the filter of the KCCV ventilator is clogged, the crankcase pressure may increases to cause oil leakage. To prevent this, crankcase pressure sensor (3) senses clogging of filter (6). • There are 2 types of the filter; one is the top load type (taken out upward) and the other is the bottom load type (taken out downward). • Keep the KCCV ventilator warm with warmed-up engine coolant, and prevent clogging of blowby gas passage due to freeze.

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107E-2 SERIES

10 Structure and function KCCV ventilator

Operation

(PC160-A18H-044-K-00-A)

• Blowby gas enters (A) and large oil particles in the engine oil mist are separated when it flows through the hole of impactor (5) in filter (6). • Small oil particles are separated by filter (6). • The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan. • When the crankcase pressure becomes negative, CDR valve (2) operates to prevent the crankcase pressure from becoming excessively negative. • The crankcase pressure sensor (3) detects the blowby gas pressure (crankcase pressure). • If the engine controller judges from the value detected by the crankcase pressure sensor (3) that the filter is clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further. • Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when filter (6) is blocked.

CDR valve

(PC160-A18A-041-K-00-A)

CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm 2. Spring A: Crankcase side B: VFT side (intake side) • The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1). • Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to VFT side (intake side) (B). • When intake air flow at VFT side (intake side) (B) increases and crankcase pressure (P1) decreases, the reaction force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily blocks the flow. • After that, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is pushed up again and blowby gas starts to flow again.

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10 Structure and function KCCV ventilator

Forming of condensed water and emulsion

(ENG95-A18H-14H-K-00-A)

1. Air cleaner 2. VFT 3. Aftercooler 4. Engine 5. Breather 6. KCCV ventilator 7. Oil pan Outline â&#x20AC;˘ If operating the engine with low load while the ambient temperature is low, the moisture in the blowby gas is not vaporized but condensed and returned to oil pan (7) through KCCV ventilator (6). Its flow is as follows; 1. The moisture in the blowby gas is condensed in KCCV piping (A). 2. The condensed water flows into the oil pan through the drain circuit. 3. The water is vaporized inside the oil pan. 4. When the water is condensed again at a place in the engine where the temperature is relatively low, it is mixed with the oil and white solid material is generated. This solid material is called mayonnaise sludge (*). *: Emulsion made of oil and water which looks like mayonnaise. 5. The temperature of each part does not increase because of low-load operation and the mayonnaise sludge is piled up. â&#x20AC;˘ The mayonnaise sludge is generated at inside of breather (B), back of head cover (C), level gauge (D), etc. where temperature is low and water is condensed easily.

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10 Structure and function KCCV ventilator

â&#x20AC;˘ If the operation is increased and the engine oil temperature increases, the mayonnaise sludge disappears. â&#x20AC;˘ Mixing of the mayonnaise sludge into the oil is not a problem. However, if it mixes into the engine coolant, find out the cause of coolant leakage.

107E-2 SERIES

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10 Structure and function KDOC muffler (4D107)

KDOC muffler (4D107)

(ENG107-A9H2-001-K-00-A)

a This section corresponds to 4-cylinder engine.

KDOC muffler

(PC160-A9H2-041-K-00-A)

a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst a The shape is subject to machine models.

1. DOC unit 2. Silencer unit 3. To exhaust gas outlet piping 4. From exhaust gas inlet piping 5. Drain pipe Structure • The KDOC muffler consists of inlet piping (4) to lead in the exhaust gas from the engine, DOC unit (1) to store the oxidation catalyst, silencer unit (2) having silencing function and containing a "dam" to prevent rain water from flowing into the DOC unit from exhaust gas outlet piping, outlet piping (3) to discharge the exhaust gas, and drain piping (5) to drain water from the silencer unit. Those components are welded together into one unit. • DOC unit (1) consists of ceramic honeycomb with oxidation catalyst. • The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramic under the vibrations from the engine and chassis.

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10 Structure and function KDOC muffler (4D107)

Function

(PC160-A9H2-042-K-00-A)

A: Flow of exhaust gas 1. DOC unit 2. Silencer unit • The KDOC muffler is installed to meet the latest very severe emission regulations. It oxidizes SOF (soluble organic fraction in minute particle in exhaust gas), HC (hydrocarbon not combusted), and CO (carbon monoxide) contained in the engine exhaust gas to clean the exhaust gas. The silencer is also equipped to reduce the exhaust noise. • Function of DOC unit (1) Oxidization of SOF (soluble organic fraction in minute particle in exhaust gas) (2) Oxidization of HC (hydrocarbon not combusted) (3) Oxidization of CO (carbon monoxide) • Function of silencer unit Reduction of exhaust noise

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10 Structure and function KDPF (6D107)

KDPF (6D107)

(ENG107-A9H0-001-K-00-A)

a This section corresponds to 6-cylinder engine.

KDPF

(ENG107-A9H0-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. Inlet unit 2. KDOC inlet temperature sensor 3. KDOC outlet temperature sensor 4. KCSF unit 5. Connector box 6. KDPF outlet temperature sensor 7. Outlet unit 8. KDPF differential pressure sensor port 9. KDPF differential pressure sensor 10. KDPF differential pressure sensor port 11. KDOC unit 12. Hanger bracket 13. Sensor bracket 14. Sensor bracket band 15. Water drain port A: From KVGT B: Exhaust C: Water drain â&#x20AC;˘ The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11) that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and

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10 Structure and function KDPF (6D107)

• •

• • • • • • •

outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit (4). KDOC unit (11) consists of a ceramic honeycomb coated with oxidation calatyst material. The ceramic honeycomb supports the oxidization of NO (nitrogen monoxide) into NO 2 (nitrogen dioxide), and also contributes to burn the injected fuel during automatic regeneration (*1) and manual stationary regeneration. The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine and machine vibrations. The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the ceramic honeycomb during operation. KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the KDOC unit (11). This ceramic honeycomb collects soot. Inside the KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and cells plugged at the outlet side are alternately arranged. Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure and KDPF outlet pressure sensor) are installed to the KDPF. Temperature signals from the three temperature sensors are used in combination to monitor the KDOC and KCSF operations and to perform various troubleshootings. The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various troubleshootings.

*1: Soot is cleaned (oxidized) during the process. k During

engine operation and for a while after engine shutdown, the surface of the KDPF and adjacent pipings are very hot. When working near the KDPF, be careful not to get burned.

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10 Structure and function KDPF (6D107)

Function

(ENG107-A9H0-042-K-00-A)

A: Flow of exhaust gas 1 KDOC (oxidation catalyzer) 2 KCSF 3 Sealing (ceramic) 4 Cell 5 Ceramic honeycomb • KDPF is installed to meet the latest very severe emission regulations. It captures almost all PM (Particulate Matter) contained in the engine exhaust gas to clean the exhaust gas. • KCSF (2) is made of ceramic. Inside KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and cells plugged at the outlet side are alternately arranged. • The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1), in operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive regeneration".) • On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low load operations, the deposit of soot in KCSF (2) increases. • The engine controller continuously monitors the amount of deposited soot by estimating from the operating conditions and calculating from the signals of the differential pressure sensor installed to KCSF (2). • When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn (oxidize) the soot. • During automatic regeneration, the engine controller automatically controls the fuel injection timing and the KVGT to raise the exhaust temperature. This operation is called "exhaust temperature-raising control". • As the exhaust temperature increases, the engine controller automatically performs calculations based on the exhaust temperature at KDOC (1) inlet and flow of the exhaust gas, so that KCSF (2) can efficiently burn (oxidize) the soot. • KDOC (1) burns (oxidizes) the soot by utilizing the function of the catalyzer. • Automatic regeneration is not performed when regeneration is executed from the machine monitor, or when the outside air temperature is extremely low, and when the exhaust gas temperature is not high

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10 Structure and function KDPF (6D107)

enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in the KCSF (2) will increase. • If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual stationary regeneration" to burn away (oxidize) the soot in the KCSF (2). • If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase fuel consumption, degrade engine combustion, or cause other problems. • If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and replacement becomes unavoidable. Make sure to follow the procedures in the Operation and Maintenance Manual when performing "manual stationary regeneration"

Types of regeneration

(ENG107-A9H0-042-K-01-A)

a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter (KCSF) inside the KDPF. 1. Passive regeneration When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be stronger and the soot deposit in the KCSF will be naturally burned away. 2. Active regeneration 1) Automatic regeneration If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperatureraising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process. Another type of automatic regeneration is performed by the engine controller at certain intervals, regardless of the amount of soot deposited in the KCSF. *1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature. *2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No. 1, 2, and 3 injectors are used for fuel dosing. 2) Manual stationary regeneration (*3) When the exhaust temperature does not reach a certain level due to the machine operating condition, or when regeneration is disabled by the operator, automatic regeneration will not be performed and the soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual stationary regeneration request on the screen. The operator must perform regeneration by operating the machine monitor on its screen. A regeneration feature is also provided for the technician who should use this feature from the machine monitor menu after engine controller replacement, KDPF replacement, and KCSF ash cleaning. (= Regeneration for service (*3)) *3:For details, see the Shop Manual for the applicable machine. • A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF when the machine is operated for a long time with low exhaust temperature. • When certain conditions are met, the engine controller automatically switches control to increase the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met, manual stationary regeneration may be requested. a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF regeneration. a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure. a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure. a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF, leading to a failure. a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a ceramic honeycomb, which can be damaged by strong impacts. a The engine controller performs automatic regeneration even when the amount of soot deposit is low. Since this is programmed to maintain the KDPF performance, this is normal. a During automatic regeneration and manual stationary regeneration, the KVGT automatically operates and the engine sound changes. The flow of exhaust gas through the KDPF changes and the exhaust sound changes, but this is normal.

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10 Structure and function KDPF (6D107)

a During automatic regeneration and manual stationary regeneration, especially at low temperatures, white smoke may come out from the exhaust pipe for a short time, but this is normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can be produced. a During automatic regeneration and manual stationary regeneration, a strange odor may be smelled from the exhaust pipe, but this is normal. a During automatic regeneration and manual stationary regeneration, the exhaust temperature at the exhaust pipe can exceed 650 째C. Make sure that there is no flammable material near the exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe, and pay sufficient attention to safety of the environment. a KDPF temperature values are shown below for reference.

Not regenerating (idling) Regenerating (under exhaust temperature-raising control: 1,000 rpm)

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DOC_In (KDOC inlet temperature sensor)

DOC_Out (KDOC outlet KDPF_Out (KDPF outlet temperature sensor) temperature sensor) 100 to 250 째C

100 to 250 째C

400 to 550 째C

107E-2 SERIES

10 Structure and function Cylinder head

Engine main body parts Cylinder head

(ENG107-R402-001-K-00-A)

(ENG107-A100-041-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. Cylinder head 2. Cylinder head cover 3. Oil filler cap 4. Head bolt 5. Injector assembly

Specifications

(ENG107-A100-030-K-00-A)

Cylinder head • Direct fuel injection type • Integral type • 4-valve 107E-2 SERIES

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10 Structure and function Cylinder head

Valve seat • Intake side: Valve seat inserts are press fitted • Exhaust side: Valve seat inserts are press fitted Injector assembly • Installation: Dry type (without sleeve)

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10 Structure and function Cylinder block

Cylinder block

(ENG107-A300-041-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. Main bearing cap 2. Main bearing cap bolt 3. Camshaft bushing 4. Cylinder block a: Center of crankshaft b: Cylinder block back side

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10 Structure and function Cylinder block

Specifications

(ENG107-A300-030-K-00-A)

Cylinder block Engine Number of crankshaft bearing Number of camshaft bearing Liner

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4D107 5 5 Without liner

6D107 7 7 Without liner

107E-2 SERIES

10 Structure and function Main moving parts

Main moving parts

(ENG107-R403-001-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. Crankshaft 2. Front crankshaft gear (36 teeth) 3. Connecting rod 4. Cylinder block 5. Piston 6. Piston pin 7. Thrust bearing 8. Rear crankshaft gear (36 teeth) 9. Main bearing 10. Top ring 11. Second ring 107E-2 SERIES

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10 Structure and function Main moving parts

12. Oil ring 13. Connecting rod bushing 14. Connecting rod cap 15. Connecting rod cap bolt 16. Main cap bolt 17. Main cap 18. Connecting rod bearing

Specifications

(ENG107-R403-030-K-00-A)

Crankshaft • Closed die forging • Journal, induction hardened Piston • Direct fuel injection type toroidal combustion chamber • Aluminum pistons (shaker-shaped) Piston rings

• Top ring (1): Barrel face, keystone, hard chrome plated • Second ring (2): Taper • Oil ring (3): With coil expander, M-shaped steel ring, hard chrome plated

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10 Structure and function Main moving parts

Crankshaft and main bearing

(ENG107-A530-041-K-00-A)

The crankshaft is a balanced forging steel and it has 5 journals (6D107 has 7 journals). The lower bearing shells of the 5 main bearings (6D107 has 7 journals) are all identical. The upper bearing shells are identical except the second last journal. The flanged upper bearing shells are attached to the second last journal. These flanges determine the end thrust of the crankshaft. a The figure indicates 6-cylinder engine.

There are two holes in the upper bearing. The larger hole receives oil from the main oil line. The smaller hole is connected to the camshaft journal, and acts as an orifice for the oil flowing to the journal.

Piston and connecting rod The body of the piston is made of cast aluminum and has piston cooling oil passages and three ring grooves. The pistons have three rings. The top ring has a trapezoidal cross-section shape, and is supported by the NiResist insert cast in the piston.

The piston and connecting rod are connected with a free floating, hollow piston pin. The pin and journals are lubricated by the oil sprayed for piston cooling.

107E-2 SERIES

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10 Structure and function Main moving parts

The piston end of the connecting rod is shaped in a tapered form to obtain a wide bearing surface. A bronze bushing is press fitted in the connecting rod pin hole.

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107E-2 SERIES

10 Structure and function Vibration damper (6D107)

Vibration damper (6D107)

(ENG107-A5E0-041-K-00-A)

a This section corresponds to 6-cylinder engine. a The shape is subject to machine models.

1. Vibration damper 2. Dowel pin 3. Mounting bolt 4. Crankshaft pulley

Function

(ENG107-A5E0-042-K-00-A)

â&#x20AC;˘ The vibration damper absorbs the torsional vibration that acts on the crankshaft and prevents damage and abnormal wear of the crankshaft and gears.

107E-2 SERIES

10-67

10 Structure and function Timing gear

Timing gear

(ENG107-A5A0-041-K-00-A)

a The shape is subject to machine models.

1. Supply pump gear (27 teeth) 2. Camshaft gear (72 teeth) 3. Timing (crankshaft ) gear (36 teeth) 4. Boost oil pump gear (36 teeth)(only for 6D107) a: Match marks b: Chamfered tooth

Function

(ENG107-A5A0-042-K-00-A)

â&#x20AC;˘ Timing (crankshaft) gear (3) and camshaft (2) gear are in mesh to to time the opening-closing of the intake and exhaust valves to the up-down of the pistons. â&#x20AC;˘ When assembling, align match mark (a) with chamfered tooth (b).

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107E-2 SERIES

10 Structure and function Front cover

Front cover

(ENG107-A5B2-041-K-00-A)

a The shape is subject to machine models.

1. Front seal 2. Front gear housing 3. Engine oil pressure switch mounting hole 4. Bkup (camshaft) speed sensor mounting hole 5. Ne (crankshaft) speed sensor mounting hole

107E-2 SERIES

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10 Structure and function Valve system

Valve system

(ENG107-A700-041-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. Exhaust valve

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10 Structure and function Valve system

2. Intake valve 3. Valve seal 4. Valve spring 5. Valve cotter 6. Camshaft gear (72 teeth) 7. Camshaft 8. Thrust plate 9. Adjustment screw 10. Locknut 11. Rocker arm 12. Push rod 13. Tappet

Camshaft, tappet, and push rod

(ENG107-A700-042-K-00-A)

The camshaft is driven by the crankshaft via gears. Cam bushings are used at the journal on both ends to support the side load from the accessory drive. The other journals are supported by the cast iron bores in the cylinder block, however, bushings can be installed to these bores when the engine is sent to the repair shop for reconditioning.

The camshaft has cam lobes to operate intake and exhaust valves. The cam lobes are in contact with the tappets which move the push rods up/down.

Mushroom head tappets are used. Since the surface of the tappet in contact with the cam lobe is convex, the tappet rotates as it lifts the push rod.

107E-2 SERIES

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10 Structure and function Valve system

The spherical end at the bottom of the push rod is placed in the ball socket of the tappet. The socket at the top of the push rod accepts the spherical end of the rocker arm adjustment screw.

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107E-2 SERIES

10 Structure and function Flywheel

Flywheel

(ENG107-A560-041-K-00-A)

a The shape is subject to machine models.

1. Flywheel housing 2. Flywheel 3. Starting motor 4. Ring gear 5. Rear seal

107E-2 SERIES

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10 Structure and function Flywheel

Specifications

(ENG107-A560-030-K-00-A)

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

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107E-2 SERIES

10 Structure and function Lubrication system parts layout drawing (4D107)

Lubrication system

(ENG107-AB00-001-K-00-A)

Lubrication system parts layout drawing (4D107)

(ENG107-AB00-04D-K-02-A)

a The PC170LC-10 is shown as an example. The shape is subject to machine models.

107E-2 SERIES

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10 Structure and function Lubrication system parts layout drawing (4D107)

1. VFT 2. Engine oil pan 3. Engine oil filter

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107E-2 SERIES

10 Structure and function Lubrication system parts layout drawing (6D107)

Lubrication system parts layout drawing (6D107)

(ENG107-AB00-04D-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. EGR valve 2. Engine oil pan 107E-2 SERIES

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10 Structure and function Lubrication system parts layout drawing (6D107)

3. Boost oil pump 4. KVGT 5. Engine oil filter

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107E-2 SERIES

10 Structure and function Lubrication system circuit diagram (4D107)

Lubrication system circuit diagram (4D107)

(ENG107-AB00-052-K-01-A)

1. Strainer 2. Oil pump 3. Regulator valve 4. Oil cooler 5. Oil filter 6. Safety valve 7. VFT lubrication 8. Main gallery 9. Lubrication of bearings 10. Piston cooling gallery 11. Piston cooling 12. Oil pan

107E-2 SERIES

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10 Structure and function Lubrication system circuit diagram (6D107)

Lubrication system circuit diagram (6D107)

(ENG107-AB00-052-K-00-A)

1. Strainer 2. Oil pump 3. Regulator valve 4. Oil cooler 5. Oil filter 6. Safety valve 7. KVGT lubrication 8. Main gallery 9. Lubrication of bearings 10. Boost oil pump 11. Regulator valve 12. EPC valve (for KVGT) 13. KVGT 14. EPC valve (for EGR valve) 15. EGR valve 16. Piston cooling gallery 17. Piston cooling 18. Oil pan

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107E-2 SERIES

10 Structure and function Oil pump

Oil pump

(ENG107-AB50-041-K-00-A)

a The shape is subject to machine models.

1. Bushing 2. Drive shaft 3. Back plate 4. Housing 5. Idler shaft 6. Idler gear (22 teeth) 7. Drive gear (24 teeth) 8. Inner rotor (drive rotor) 9. Outer rotor (planetary rotor)

Specifications

(ENG107-AB50-030-K-00-A)

• Type: Trochoid pump • Speed: Engine speed x 1.5

Function

(ENG107-AB50-042-K-00-A)

• The oil pump feeds engine oil which lubricates the inside of the engine. • The pump is installed between the oil pan and regulator valve circuit, and is driven by the camshaft.

107E-2 SERIES

10-81

10 Structure and function Boost oil pump (6D107)

Boost oil pump (6D107)

(ENG107-A9N0-041-K-00-A)

a This section corresponds to 6-cylinder engine. a The shape is subject to machine models.

1. Regulator valve a: Center of drive shaft b: Discharge port c: Suction port d: Pump drive gear

Specifications

(ENG107-A9N0-030-K-00-A)

Oil pump • Type: Gear pump • Speed: Engine speed x 1.0 Regulator valve • Cracking pressure: 1.43 ± 0.1 MPa {14.6 ± 1 kg/cm2}

Function

(ENG107-A9N0-042-K-00-A)

• The boost oil pump feeds engine oil which drives the EGR valve and the KVGT. • The pump is installed between the main gallery and EGR valve and KVGT circuit, and is driven by the camshaft. • The pump feeds oil pressure to the EGR valve drive, EGR valve control, KVGT drive, and KVGT control circuits.

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107E-2 SERIES

10 Structure and function Oil filter

Oil filter

(ENG107-ABC0-041-K-00-A)

a The shape is subject to machine models.

1. Filter cartridge 2. Safety valve 3. Plug 4. Filter head A: Oil outlet B: Oil inlet

Function

(ENG107-ABC0-042-K-00-A)

• During the engine lubrication process, impurities such as carbon, sludge, and wear particles will mix in the engine oil. The filter removes these impurities. • A safety valve is provided to bypass the engine oil when the filter gets clogged. • To make filter cartridge replacement easier, this is remotely mounted on some machines.

107E-2 SERIES

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10 Structure and function Oil cooler

Oil cooler

(ENG107-B810-041-K-00-A)

a The shape is subject to machine models.

1. Oil cooler core assembly 2. Regulator valve 3. Safety valve 4. Oil pump a: Oil pump gear b: Crankshaft gear

Specifications

(ENG107-B810-030-K-00-A)

Oil cooler â&#x20AC;˘ Number of element steps: 7

Function

(ENG107-B810-042-K-00-A)

â&#x20AC;˘ This is installed in the circuit between the regulator valve and oil filter to cool the engine oil.

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107E-2 SERIES

10 Structure and function Regulator valve

Regulator valve

(ENG107-ABD4-041-K-00-A)

a The oil filters layout, shape of oil pan and piping are subject to machine models.

1. Oil pump 2. From oil pump 3. Regulator valve closed 4. Regulator valve open 5. To oil cooler 6. To oil pan 7. Oil cooler 8. Safety valve 9. Safety valve closed 10. Safety valve open 11. To oil filter 12. Oil filter 13. From oil filter 14. To main gallery

Specifications

(ENG107-ABD4-030-K-00-A)

Regulator valve â&#x20AC;˘ Cracking pressure: 449 kPa {4.58 kg/cm2}

Function

(ENG107-ABD4-042-K-00-A)

â&#x20AC;˘ The regulator valve regulates (reduces) the engine oil pressure sent from the oil pump.

107E-2 SERIES

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10 Structure and function Safety valve

Safety valve

(ENG107-ABD0-041-K-00-A)

a The oil filters layout, shape of oil pan and piping are subject to machine models.

Specifications

(ENG107-ABD0-030-K-00-A)

Safety valve • Cracking pressure: 344 kPa {3.51 kg/cm2}

Function

(ENG107-ABD0-042-K-00-A)

• The safety valve regulates the engine oil pressure for engine lubrication. • The valve is installed between the oil cooler and oil filter circuit. • Normally, when the differential pressure across the oil filter is within the cracking pressure setting, oil flows through the oil filter. If the differential pressure exceeds the cracking pressure due to oil filter clogging or other reason, the oil will be bypassed to the main gallery without flowing through the oil filter, to secure the engine lubrication.

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107E-2 SERIES

10 Structure and function Oil pan

Oil pan

(ENG107-AB20-041-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. Oil suction pipe (with strainer) 2. Oil level sensor 3. Dipstick 4. Drain valve 5. Oil pan

107E-2 SERIES

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10 Structure and function Fuel system parts layout drawing

Fuel system

(ENG107-AD00-001-K-00-A)

Fuel system parts layout drawing

(ENG107-AD00-04D-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

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107E-2 SERIES

10 Structure and function Fuel system parts layout drawing

1. Main filter 2. Injector 3. Inlet connector 4. Check valve 107E-2 SERIES

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10 Structure and function Fuel system parts layout drawing

5. Supply pump 6. Common rail 7. High-pressure pipe 8. Pressure limiter valve 9. Feed pump A: From pre-filter B: To oil cooler

10-90

107E-2 SERIES

10 Structure and function Fuel system circuit diagram

Fuel system circuit diagram

(ENG107-AD00-052-K-00-A)

a The part of diagram in the fuel system circuit diagram indicates the 6-cylinder engine. Basic operation is the same as the 4-cylinder engine.

1. Main filter 2. Supply pump 3. Injector 4. Common rail 5. Check valve 6. Pressure limiter valve 7. Fuel cooler 8. Fuel tank 9. Water separator 10. Pre-filter 11. Priming pump 12. Feed pump

107E-2 SERIES

10-91

10 Structure and function Fuel system circuit diagram

Operation

(ENG107-AD00-044-K-00-A)

• The fuel system is of an electronically controlled high-pressure common rail type. The high-pressure common rail system consists of four main components: • Feed pump (low pressure pump) (12), supply pump (high-pressure pump) (2), common rail (4), and injectors (3). • The fuel system uses injectors (3) driven by solenoids. • The engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to the injector (3). • By controlling the solenoids electronically, the flow and timing are precisely controlled.

2. Supply pump 3. Injector 4. Common rail EC: Engine controller PS: Common rail pressure sensor • Supply pump (2) sends high-pressure fuel to common rail (4). High-pressure fuel is held in common rail (4). • The engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to the injector (3). • Fuel flows through the pre-filter (with a water separator) to feed pump (12). • Fuel discharged from feed pump (12) is filtered at main filter (1) and then enters supply pump (2).

• Fuel in supply pump (2) is pressurized in the three radial pumping chambers. • Common rail (4) holds fuel and acts as a fuel manifold to distribute fuel to the supply line of each injector (3). • Engine controller (EC) monitors the pressure sent from supply pump (2) to common rail (4) by using common rail pressure sensor (PS) provided inside common rail (4). • The pressure detected by common rail pressure sensor (PS) is used by engine controller (EC) to regulate the fuel output from supply pump (2). • Pressure limiter valve (6) (common rail pressure relief valve) is also installed in common rail (4).

10-92

107E-2 SERIES

10 Structure and function Fuel system circuit diagram

• Pressure limiter valve (6) is a safety valve to release pressure if the common rail pressure exceeds the threshold setting. • Fuel released from pressure limiter valve (6) flows from common rail (4) through a fuel return line to the fuel tank. • High-pressure fuel flows to the side of injector (3), and when the solenoid is energized, the needle inside is lifted and fuel is injected.

Injector and inlet connector • Since the clearance inside the injector nozzle is extremely small, dirt will cause sticking of the injector nozzle. Before servicing the fuel system, it is important to clean all fuel connections. • Before starting the repair work of the fuel system, cap or cover all open fuel connections.

• High-pressure fuel is supplied from common rail (7) through high-pressure pipe (11) and inlet connector (1) to injector (17). • By tightening retaining nut (18) of inlet connector (1), inlet connector (1) is pressed against the body of injector (17). High-pressure pipe (11) is connected to inlet connector (1) by tightening the sleeve nut. • Connection between inlet connector (1) and high-pressure pipe (11) is extremely important. If the tightening of retaining nut (18) is insufficient, the connecting surfaces are not sealed, and high-pressure fuel will leak. • If the tightening torque of retaining nut (18) is excessive, inlet connector (1) and injector (17) will be deformed, also leading to a leak of high-pressure fuel. • Since these leaks occur inside the parts, they cannot be found visually. This can result in failure codes, low engine output, and engine starting problems.

107E-2 SERIES

10-93

10 Structure and function Fuel system circuit diagram

• Inlet connector (1) contains an edge filter to break small foreign materials in the fuel. The edge filter uses high pulsation pressure to break particles into smaller pieces so that they can flow through the injector fuel passages.

• All injectors return fuel to a common return circuit in the cylinder head. • Excessive fuel flows from the return circuit through the spill tube installed to the rear of the cylinder head to the fuel tank. • A check valve is installed to the rear of the cylinder head, where the spill tube is installed. • The cylinder head and spill tube are connected with a quick disconnect fitting or an eye joint.

10-94

107E-2 SERIES

10 Structure and function Supply pump

Supply pump

(ENG107-AD70-041-K-00-A)

a The shape is subject to machine models.

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

Specifications

(ENG107-AD70-030-K-00-A)

• Type: Rotary plunger pressure feed • Lubrication method: lubricated by fuel

Function

(ENG107-AD70-042-K-00-A)

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

107E-2 SERIES

10-95

10 Structure and function Fuel cooler

Fuel cooler

(ENG107-B7W0-041-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. Core 2. Fin 3. Cup plate 4. Inner fin A: From supply pump B: To fuel tank Structure • Some models are equipped with the fuel cooler which is mounted to the machine.

Specifications • • • •

(ENG107-B7W0-030-K-00-A)

Cooling method: Cooling with air Core type: Drawn cup Fin pitch: 4.0/2 Total heat dissipation area: 0.59 m2

10-96

107E-2 SERIES

10 Structure and function Pre-filter

Pre-filter

(ENG107-AEA0-041-K-00-A)

a The shape is subject to machine models.

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

Function

(ENG107-AEA0-042-K-00-A)

• Fuel from the fuel tank flows through the pre-filter to the supply pump. • The pre-filter is a fuel filter with a water separator and collects the water removed from the fuel. • A water-in-fuel sensor is provided to detect the amount of separated water.

107E-2 SERIES

10-97

10 Structure and function Main filter

Main filter

(ENG107-AED0-041-K-00-A)

a The shape is subject to machine models.

1. Pressure pickup plug 2. Filter head 3. Filter head adapter 4. Cartridge

Function

(ENG107-AED0-042-K-00-A)

• Fuel from the feed pump (low-pressure pump) flows through the main filter to the supply pump (highpressure pump). • The main filter removes impurities from the fuel. • To make cartridge replacement easier, this is remotely mounted on some machines.

10-98

107E-2 SERIES

10 Structure and function Cooling system parts layout drawing

Cooling system

(ENG107-B110-001-K-00-A)

Cooling system parts layout drawing

(ENG107-B110-04D-K-00-A)

a The shape is subject to machine models. a The figure indicates 6-cylinder engine.

1. EGR cooler 2. VFT(4D107) ă&#x20AC;&#x20AC; KVGT(6D107) 3. Water pump 4. Oil cooler A: From radiator B: To radiator

107E-2 SERIES

10-99

10 Structure and function Cooling system circuit diagram (4D107)

Cooling system circuit diagram (4D107)

(ENG107-B110-052-K-01-A)

1. Radiator 2. Thermostat 3. Cylinder head 4. VFT 5. Cylinder block 6. EGR cooler 7. Engine oil cooler 8. Water pump a: Flow when thermostat is open b: Flow when thermostat is closed

10-100

107E-2 SERIES

10 Structure and function Cooling system circuit diagram (6D107)

Cooling system circuit diagram (6D107)

(ENG107-B110-052-K-00-A)

1. Radiator 2. Thermostat 3. Cylinder head 4. KVGT 5. EGR cooler 6. Cylinder block 7. Engine oil cooler 8. Water pump a: Flow when thermostat is open b: Flow when thermostat is closed

107E-2 SERIES

10-101

10 Structure and function Drive pulley

Drive pulley

(ENG107-B110-041-K-00-A)

Water pump drive For wheel loaders

(ENG107-B400-001-K-00-A)

(ENG107-B400-041-K-00-A)

a The shape is subject to machine models.

1. Poly V-belt 2. Tension pulley 3. Water pump 4. Auto-tensioner 5. Alternator 6. Fan pulley 7. Crankshaft pulley A: To radiator (coolant) B: From radiator (coolant) Outside diameter of pulleys a, b, c, d, and e • Auto-tensioner (4) automatically maintains the Poly V-belt (1) tension at a constant level by means of tensioner pulley (2).

Specifications

(ENG107-B400-030-K-00-A)

Outside diameter of pulley

Machine model WA270–7 WA320–7 WA380–7

10-102

a (Water pump)

b (Alternator)

c (Tension)

d (Crankshaft)

174

Unit: mm e (Idler) 129

107E-2 SERIES

10 Structure and function Drive pulley

For Bulldozers

(ENG107-B400-041-K-02-A)

a The shape is subject to machine models.

1. Poly V-belt 2. Tension pulley 3. Water pump 4. Auto-tensioner 5. Alternator 6. Air conditioner compressor 7. Idler pulley 8. Crankshaft pulley A: To radiator (coolant) B: From radiator (coolant) Outside diameter of pulleys a, b, c, d, e, and f â&#x20AC;˘ Auto-tensioner (4) automatically maintains the Poly V-belt (1) tension at a constant level by means of tensioner pulley (2).

107E-2 SERIES

10-103

10 Structure and function Drive pulley

Specifications

(ENG107-B400-030-K-03-A)

Outside diameter of pulley

Machine model D61EX-23 D61PX-23 D61EXI-23 D61PXI-23

10-104

a (Water pump)

b (Alternator)

c (Tension)

d (Crankshaft)

e (Idler)

174

Unit: mm f (Air conditioner compressor) 120

107E-2 SERIES

10 Structure and function Drive pulley

Water pump drive, fan drive

(ENG107-B400-041-K-01-A)

a The shape is subject to machine models.

1. Poly V-belt 2. Tension pulley 3. Water pump 4. Auto-tensioner 5. Alternator 6. Fan pulley 7. Fan 8. Crankshaft pulley A: To radiator (coolant) B: From radiator (coolant) Outside diameter of pulleys a, b, c, d, and e â&#x20AC;˘ Auto-tensioner (4) automatically maintains the Poly V-belt (1) tension at a constant level by means of tensioner pulley (2).

107E-2 SERIES

10-105

10 Structure and function Drive pulley

Specifications

(ENG107-B400-030-K-01-A)

Outside diameter of pulley

Machine model PC170LC-10 PC210I-10 PC210LC-10 PC210LCI-10 PC228USLC-10 PC240LC-10 PC290LC-10

10-106

a (Water pump)

Unit: mm e (Fan)

c (Tension)

b (Alternator) 78

d (Crankshaft) 174

174

200

88 88 88

78 78 78

73 73 73

174 174 174

183 169 158

169

107E-2 SERIES

10 Structure and function Water pump

Water pump

(ENG107-BA10-041-K-00-A)

a The shape is subject to machine models.

1. Impeller 2. Water seal 3. Pump body 4. Pulley 5. Drive shaft A: Coolant inlet B: Coolant outlet (to engine)

Specifications

(ENG107-BA10-030-K-00-A)

• Type: Centrifugal type, poly V-belt drive

Function

(ENG107-BA10-042-K-00-A)

• The water pump circulates coolant through the entire engine to prevent engine from overheating. • Engine power is transmitted to the pulley via a fan belt to drive the impeller.

107E-2 SERIES

10-107

10 Structure and function Thermostat

Thermostat

(ENG107-BA30-041-K-00-A)

a The shape is subject to machine models.

1. Thermostat A: To radiator

Specifications

(ENG107-BA30-030-K-00-A)

• Cracking temperature: 79.4 to 83.3 °C • Fully open temperature: 95 °C • Valve lift: Min. 9.1 mm

10-108

107E-2 SERIES

10 Structure and function Alternator

Electrical equipment Alternator

(ENG107-AK50-001-K-00-A)

(ENG-AKK0-001-K-00-A)

Alternator with built-in regulator (Open type, 35A)

(ENG107-AKK0-041-K-00-A)

a The shape is subject to machine models.

1. Alternator pulley 2. Terminal B 3. Connector 4. Internal electrical circuit diagram 4A. Alternator assembly 4B. Regulator 4C. Terminal L load 4D. Starting switch 4E. Battery

107E-2 SERIES

10-109

10 Structure and function Alternator

Specifications Engine

(ENG107-AKK0-030-K-00-A)

Machine model

Type

PC228USLC-10 Open type, SAA6D107E-2 PC240LC-10 manufactured by DENSO PC290LC-10

10-110

Specifications 24 V, 35 A

Pulley Weight (kg) Number of Outside stage diameter (mm) Poly V-ribbed with 8 ribs

77.5

5.4

107E-2 SERIES

10 Structure and function Alternator

Alternator with built-in regulator (Open type, 60A)

(ENG107-AKK0-041-K-01-A)

a The shape is subject to machine models.

1. Alternator (Body) 2. Alternator pulley 3. Terminal B 4. Internal electrical circuit diagram 4A. Alternator assembly 4B. Regulator 4C. Terminal L load 4D. Starting switch 4E. Battery 5. Connector

107E-2 SERIES

10-111

10 Structure and function Alternator

Specifications

(ENG107-AKK0-030-K-01-A)

Pulley Engine

Machine model

Type

Specification

Number of stage

Outside diameter (mm)

Weight (kg)

SAA4D107E-2 PC170LC-10

Open type, manufactured by DENSO

24 V, 60 A Poly V-ribbed with 8 ribs

77.5

6.3

PC210I-10 PC210LC-10 PC210LCI-10 SAA6D107E-2 WA270–7 WA320–7 WA380-7

Open type, manufactured by DENSO

24 V, 60 A Poly V-ribbed with 8 ribs

77.5

6.3

10-112

107E-2 SERIES

10 Structure and function Alternator

Alternator with built-in regulator (Open type, 60A)

(ENG107-AKK0-041-K-03-A)

a The shape is subject to machine models.

1. Alternator (Body) 2. Alternator pulley 3. Terminal E 4. Terminal B 5. Terminal R 6. Internal electrical circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator

107E-2 SERIES

10-113

10 Structure and function Alternator

Specifications Engine

SAA6D107E-2

10-114

(ENG107-AKK0-030-K-03-A)

Machine model D61EX-23 D61PX-23 D61EXI-23 D61PXI-23

Type

Specification

Pulley Outside Number diameter of stage (mm)

Open type, Poly Vmanufactured by 24 V, 60 A ribbed Nikko Electric Industry with 8 ribs

Weight (kg)

11.0

107E-2 SERIES

10 Structure and function Alternator

Alternator with built-in regulator (Open type, 90A)

(ENG107-AKK0-041-K-04-A)

a The shape is subject to machine models.

1. Alternator (Body) 2. Alternator pulley 3. Terminal R 4. Terminal B 5. Terminal E 6. Internal electrical circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator

107E-2 SERIES

10-115

10 Structure and function Alternator

Specifications Engine

SAA6D107E-2

10-116

(ENG107-AKK0-030-K-04-A)

Machine model D61EX-23 D61PX-23 D61EXI-23 D61PXI-23

Type

Specification

Pulley Outside Number diameter of stage (mm)

Open type, Poly Vmanufactured by 24 V, 90 A ribbed Nikko Electric Industry with 8 ribs

Weight (kg)

19.0

107E-2 SERIES

10 Structure and function Starting motor

Starting motor For 4.5kW

(ENG-AK70-001-K-00-A)

(ENG107-AK70-041-K-00-A)

a The shape is subject to machine models.

1. Pinion gear 2. Water drain hole 3. Magnetic switch 4. Ventilation pipe 5. Jump start prevention cover 6. 30 (terminal B) 7. 50 (terminal C) 8. Internal electrical circuit diagram 8A. Relay 8B. Starting switch 8C. Battery 8D. 30 (terminal B) 8E. 50 (terminal C)

107E-2 SERIES

10-117

10 Structure and function Starting motor

Specifications

(ENG107-AK70-030-K-00-A)

Engine

Machine model

Type

Specifications

SAA4D107E-2

PC170LC-10

Drip proof, oil proof type, manufactured by DENSO

24 V, 4.5 kW

8.4

SAA6D107E-2

PC228USLC-10 PC240LC-10 PC290LC-10

Drip proof, oil proof type, manufactured by DENSO

24 V, 4.5 kW

8.4

10-118

Number of pinion Weight (kg) teeth

107E-2 SERIES

10 Structure and function Starting motor

For 5.5kW

(ENG107-AK70-041-K-01-A)

a The shape is subject to machine models.

1. Pinion gear 2. Magnetic switch 3. Starting motor assembly 4. Jump start prevention warning plate 5. Jump start prevention cover 6. 50 (terminal C) 7. 30 (terminal B) 8. Internal electrical circuit diagram 8A. Relay 8B. Starting switch 8C. Battery 8D. 30 (terminal B) 8E. 50 (terminal C)

107E-2 SERIES

10-119

10 Structure and function Starting motor

Specifications Engine

(ENG107-AK70-030-K-01-A)

Machine model

PC210I–10 PC210LC–10 PC210LCI–10 WA270–7 WA320–7 SAA6D107E-2 WA380–7 D61EX–23 D61PX–23 D61EXI–23 D61PXI–23

10-120

Type

Specifications

Number of pinion teeth

Weight (kg)

Drip proof, oil proof type, manufactured by DENSO

24 V, 5.5 kW

10.5

107E-2 SERIES

10 Structure and function Intake air heater

Intake air heater

(ENG107-AM51-041-K-00-A)

1. Intake air heater 2. Air intake connector 3. Heater coil 4. Housing 5. Internal electrical circuit diagram

Specifications

(ENG107-AM51-030-K-00-A)

• Type of heater: Electrical intake air heater (ribbon heater) • Rated voltage: 22 V (DC) • Load current: 100 A

107E-2 SERIES

10-121

10 Structure and function Engine wiring harness (4D107)

Engine wiring harness (4D107)

(ENG107-AK51-041-K-02-A)

a The PC170LC-10 is shown as an example. The shape is subject to machine models.

1. To oil pressure switch 2. To EGR valve actuator 3. To injector (No. 1 and 2) wiring harnesses 4. To coolant temperature sensor 5. To VFT actuator 6. To EGR orifice temperature sensor 7. To exhaust manifold pressure sensor 8. To injector (No. 3 and 4) wiring harnesses 9. To common rail pressure sensor 10. To ambient pressure sensor 11. To charge (boost) pressure and temperature sensor 12. To supply pump

10-122

107E-2 SERIES

10 Structure and function Engine wiring harness (4D107)

13. To engine controller 14. To machine wiring harness 15. To Ne (crankshaft) speed sensor 16. To CAN terminating resistor 17. To Bkup (camshaft) speed sensor

107E-2 SERIES

10-123

10 Structure and function Engine wiring harness (6D107)

Engine wiring harness (6D107)

(ENG107-AK51-041-K-00-A)

a The PC240LC-10 is shown as an example. The shape is subject to machine models.

1. To oil pressure switch 2. To ambient pressure sensor 3. To injector (No. 1 and 2) wiring harnesses 4. To coolant temperature sensor 5. To exhaust manifold pressure sensor 6. To EGR orifice temperature sensor 7. To connector box 8. To KVGT speed sensor 9. To KVGT position sensor 10. To EGR valve lift sensor 11. To injector (No. 5 and 6) wiring harnesses 12. To common rail pressure sensor

10-124

107E-2 SERIES

10 Structure and function Engine wiring harness (6D107)

13. To charge (boost) pressure and temperature sensor 14. To supply pump 15. To injector (No. 3 and 4) wiring harnesses 16. To CAN terminating resistor 17. To engine controller 18. To machine wiring harness 19. To Ne (crankshaft) speed sensor 20. To Bkup (camshaft) speed sensor

107E-2 SERIES

10-125

10 Structure and function Engine controller (4D107)

Engine controller (4D107) Engine controller

Function

(ENG107-AP70-001-K-00-A)

(PC220-AP70-041-K-00-A)

(ENG107-AP70-042-K-00-A)

• The engine controller CM2250, co-developed by Komatsu and Cummins, is adopted. • It performs calculations based on input signals from various sensors to output signals for optimized engine control. • The engine controller shares information with other controllers on the machine through the network (CAN) and optimally controls the engine according to the machine conditions. • By mounting the controller on the engine, serviceability in the field is improved. • The controller is mounted with rubber vibration isolators to reduce the effect of vibration.

10-126

107E-2 SERIES

10 Structure and function Engine controller (4D107)

Engine controller system diagram

(ENG107-AP70-052-K-01-A)

Input and output signals of engine controller

(PC160-AP70-03C-K-00-A)

• The symbols in the signal classification column in the Input/output signal table are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication DRC26–60P(1) [ECM J1(CN-CE01)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 107E-2 SERIES

Signal name (*1) (*1) Crankcase pressure sensor (*1) Charge temperature sensor Mass air flow (MAF) temperature sensor (*1) CAN_B(+)(KOMNET/r) Bkup (camshaft) speed sensor (+) (*1) (*1) (*1) GND Coolant temperature sensor Charge pressure sensor Ambient pressure sensor (*1)

Signal classification — — B — B B — E B — — — C B B B —

10-127

10 Structure and function Engine controller (4D107)

Pin No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name CAN_B(+)(KOMNET/r) (*1) (*1) Sensor power supply (12 V) GND Mass air flow (MAF) sensor Water-in-fuel sensor (*1) Ne (crankshaft) speed sensor (+) (*1) (*1) (*1) IMV (+) Engine oil pressure switch GND (*1) (*1) (*1) Sensor power supply (5 V) Ne (crankshaft) speed sensor (-) (*1) (*1) IMV (-) (*1) (*1) (*1) Injector #3 (-) Injector #2 (-) Injector #4 (-) (*1) Injector #1 (-) (*1) (*1) (*1) (*1) (*1) Injector #3 (-) Injector #2 (-) Injector #4 (-) (*1) Injector #1 (-) GND Sensor power supply (5 V)

Signal classification E — — A C B B — B — — — D B C — — — A C — — C — — — D D D — D — — — — — C C C — C C A

*1: Never connect these pins. Malfunctions or failures may occur. DRC26–60P(2) [ECM J2(CN-CE02)] Pin No. 1 2 3 4 5

10-128

Signal name VFT motor (V) VFT motor (U) EGR valve motor (W) EGR valve motor (V) EGR valve motor (U)

Signal classification B B B B B 107E-2 SERIES

10 Structure and function Engine controller (4D107)

Pin No. 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 107E-2 SERIES

Signal name (*1) (*1) (*1) (*1) (*1) VFT motor (W) (*1) (*1) (*1) (*1) (*1) (*1) GND (*1) (*1) GND (*1) (*1) CAN_B(+) CAN_B(-) (*1) (*1) (*1) (*1) Sensor power supply (5 V) Sensor power supply (5 V) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) EGR valve hall sensor (V) EGR valve hall sensor (W) VFT hall sensor (V) Common rail pressure sensor: (*1) (*1) GND (*1) (*1) (*1) EGR valve hall sensor (U) VFT hall sensor (U) VFT hall sensor (W) (*1) (*1) (*1) (*1)

Signal classification — — — — — B — — — — — — C — — C — — E E — — — — A A — — — — — — — — — D D D B — — C — — — D D D — — — —

10-129

10 Structure and function Engine controller (4D107)

Pin No. 58 59 60

Signal name (*1) (*1) (*1)

Signal classification — — —

*1: Never connect these pins. Malfunctions or failures may occur. DRC26–60P(3) [CN-CE03] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

10-130

Signal name Continuous power supply (24 V) Continuous power supply (24 V) ACC signal from starting switch Intake air heater relay (+) (*1) (*1) (*1) (*1) System operating lamp (*1) Continuous power supply (24 V) Continuous power supply (24 V) GND (*1) (*1) (*1) CAN_A(+) (KOMNET/c) CAN_A(-) (KOMNET/c) GND (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND Sensor power supply (5 V) GND (*1) (*1)

Signal classification A A B D — — — — D — A A C — — — E E C — C C — — — — — — — — C C — — — — — — — — C A C — — 107E-2 SERIES

10 Structure and function Engine controller (4D107)

Pin No. 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name (*1) (*1) (*1) Idle validation signal 1 Idle validation signal 2 Throttle signal Sensor power supply (5 V) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1)

Signal classification — — — B B B A — — — — — — — —

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

107E-2 SERIES

10-131

10 Structure and function Engine controller (6D107)

Engine controller (6D107) Engine controller

Function

(ENG107-AP70-001-K-02-A)

(PC220-AP70-041-K-00-A)

(ENG107-AP70-042-K-00-A)

10-132

107E-2 SERIES

10 Structure and function Engine controller (6D107)

Engine controller system diagram

Input and output signals

(ENG107-AP70-052-K-00-A)

(PC-AP70-03C-K-00-A)

• The following is the list of the symbols used for signal category in the input/output signal table. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication DRC26-60P(1)[ECM J1(CN-CE01)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 107E-2 SERIES

Signal name (*1) (*1) Crankcase pressure sensor (*1) Charge temperature sensor Intake air temperature (MAF) sensor CAN_C (+) CAN_B (+) (KOMNET/r) Bkup (camshaft) speed sensor (+) (*1) (*1) (*1) GND Coolant temperature sensor Charge pressure sensor Ambient pressure sensor

Signal category — — B — B B E E B — — — C B B B

10-133

10 Structure and function Engine controller (6D107)

Pin No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name CAN_C (-) CAN_B (-) (KOMNET/r) (*1) (*1) Sensor power supply (12 V) GND Mass air flow and temperature sensor Water-in-fuel sensor (*1) Ne (crankshaft) speed sensor (+) (*1) (*1) (*1) IMV(+) Engine oil pressure switch GND (*1) (*1) (*1) Sensor power supply (5 V) NE (crankshaft) speed sensor (-) (*1) (*1) IMV (-) (*1) (*1) Injector #4 (+) Injector #5 (+) Injector #6 (+) Injector #3 (+) Injector #2 (+) Injector #1 (+) (*1) (*1) (*1) (*1) Injector #4 (-) Injector #5 (-) Injector #6 (-) Injector #3 (-) Injector #2 (-) Injector #1 (-) GND Sensor power supply (5 V)

Signal category E E — — A C B B — B — — — D B C — — — A C — — C — — D D D D D D — — — — C C C C C C C A

*1: Never connect these pins. Malfunctions or failures may occur. DRC26-60P(2)[ECM J2(CN-CE02)] Pin No. 1 2 3 4

10-134

Signal name (*1) (*1) (*1) (*1)

Signal category — — — — 107E-2 SERIES

10 Structure and function Engine controller (6D107)

Pin No. 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 107E-2 SERIES

Signal name (*1) EGR actuator (+) (*1) (*1) (*1) KVGT actuator (+) (*1) (*1) (*1) (*1) (*1) EGR actuator (-) (*1) GND (*1) KVGT actuator (-) GND (*1) (*1) CAN_B (+) CAN_B (-) (*1) (*1) (*1) (*1) Sensor power supply (5 V) Sensor power supply (5 V) KVGT speed sensor (+) KVGT speed sensor (-) Exhaust manifold pressure sensor (*1) (*1) (*1) KVGT position sensor (*1) (*1) (*1) (*1) (*1) Common rail pressure sensor (*1) GND GND EGR orifice temperature sensor (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1)

Signal category — D — — — D — — — — — C — C — C C — — E E — — — — A A B C B — — — B — — — — — B — C C B — — — — — — — —

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10 Structure and function Engine controller (6D107)

Pin No. 57 58 59 60

Signal name (*1) (*1) EGR valve lift sensor (*1)

Signal category — — B —

*1: Never connect these pins. Malfunctions or failures may occur. DRC26-60P(3)[CN-CE03] *1: Never connect these pins. Malfunctions or failures may occur. Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

10-136

Signal name Continuous power supply (24 V) Continuous power supply (24 V) Starting switch ACC signal Intake air heater relay (+) (*1) (*1) (*1) (*1) System operating lamp (*1) Continuous power supply (24 V) Continuous power supply (24 V) GND (*1) (*1) (*1) CAN_A (+) (KOMNET/c) CAN_A (-) (KOMNET/c) GND (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND Sensor power supply (5 V)

Signal category A A B D — — — — D — A A C — — — E E C — C C — — — — — — — — C C — — — — — — — — C A 107E-2 SERIES

10 Structure and function Engine controller (6D107)

Pin No. 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

107E-2 SERIES

Signal name GND (*1) KDOC inlet temperature sensor (*1) (*1) KDOC outlet temperature sensor Idle validation signal 1 Idle validation signal 2 Throttle signal Sensor power supply (5 V) (*1) KDPF outlet temperature sensor KDPF differential pressure sensor (*1) (*1) KDPF outlet pressure sensor (*1) (*1)

Signal category C — B — — B B B B A — B B — — B — —

10-137

10 Structure and function Sensor

Sensor

(ALL-E700-001-P-00-A)

Sensors layout drawing

(ENG107-AK50-04D-K-00-A)

a Followings are Table for sensors and Sensors layout drawing Table for sensors a No. in table indicate number in Sensors layout drawing. Applicable engine No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 —

10-138

Sensor Exhaust manifold pressure sensor EGR orifice temperature sensor Charge (boost) pressure and temperature sensor Common rail pressure sensor Ambient pressure sensor Crankcase pressure sensor Ne (crankshaft) speed sensor Bkup (camshaft) speed sensor Oil pressure switch Mass air flow and temperature sensor (MAF) Air cleaner clogging sensor Coolant temperature sensor VFT motor (with built-in position sensor) EGR valve (with built-in position sensor) Engine oil level sensor KVGT speed sensor KVGT position sensor KDOC inlet temperature sensor KDPF differential pressure and outlet pressure sensor KDOC outlet temperature sensor KDPF outlet temperature sensor EGR valve lift sensor Water-in-fuel sensor

Connector label name

4D107

6D107

EXHAUST PRESSURE EXHAUST GAS TEMPARATURE

● ●

BOOST PRESS. & INT

●

FUEL RAIL PRESS AMB. AIR PRESSURE P57 CRANK SENSOR CAM SENSOR OIL PRESSURE SWITCH

● ● ● ● ● ●

P55

●

E26[TOUT] COOLANT TEMP VFT ACTUATOR EGR VALVE ACTUATOR P44 VGT_REV SVGT TEMP1

● ● ● ● ● — — —

● ● — — ● ● ● ●

E25

—

●

TEMP2 TEMP3 SEGR P47

— — — ●

● ● ● ●

107E-2 SERIES

10 Structure and function Sensor

Sensors layout drawing(4D107) a The shape is subject to machine models.

107E-2 SERIES

10-139

10 Structure and function Sensor

Sensors layout drawing(6D107) a The shape is subject to machine models.

10-140

107E-2 SERIES

10 Structure and function Sensor

KVGT speed sensor

(ENG-AAQ4-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. Sensor 2. O-ring 3. Connector

Function

(ENG-AAQ4-042-K-00-A)

â&#x20AC;˘ This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT turbine. a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only, and it has no pin No. 3.

107E-2 SERIES

10-141

10 Structure and function Sensor

VFT motor (with built-in position sensor)

(ENG95-AA56-041-K-00-A)

a VFT: Abbreviation for Variable Flow Turbocharger a The shape is subject to machine models.

1. VFT motor (brushless motor with built-in position sensor) 2. Turbine part 3. Connector

Function

(ENG95-AA56-042-K-00-A)

â&#x20AC;˘ Controls the flow control valve with a DC motor. â&#x20AC;˘ The VFT motor has a position sensor in it to sense the valve position.

10-142

107E-2 SERIES

10 Structure and function Sensor

KVGT position sensor

(ENG-AAQ3-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. O-ring (small) 2. O-ring (large) 3. Sensor 4. Connector

Function

(ENG-AAQ3-042-K-00-A)

â&#x20AC;˘ This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT to output the corresponding variable voltage. Output characteristics â&#x20AC;˘ The relation between stroke and output voltage is as shown in the following graph.

107E-2 SERIES

10-143

10 Structure and function Sensor

KDOC inlet temperature sensor

(ENG-A9HG-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor 2. Connector

Function

(ENG-A9HG-042-K-00-A)

• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

KDPF differential pressure and outlet pressure sensor

(ENG-A9HL-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. High-pressure port 2. Low-pressure port 3. Connector 4. Sensor

Function

(ENG-A9HL-042-K-00-A)

• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the corresponding variable voltage. • The output pressure difference is the difference between the KDPF inlet pressure which is detected at high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2). • The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).

10-144

107E-2 SERIES

10 Structure and function Sensor

Crankcase pressure sensor

(ENG-A18C-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG-A18C-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby pressure) to output the corresponding variable voltage.

EGR valve (with built-in position sensor)

(ENG95-AA57-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation a The shape is subject to machine models.

1. EGR valve motor (with built-in position sensor) 2. Connector 3. Body 107E-2 SERIES

10-145

10 Structure and function Sensor

Function

(ENG95-AA57-042-K-00-A)

• Small-sized EGR valve driven with a DC motor. • The EGR valve motor has a position sensor in it to sense the valve position.

EGR orifice temperature sensor

(ENG-A9U5-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Connector 2. Sensor 3. Washer

Function

(ENG-A9U5-042-K-00-A)

• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

Exhaust manifold pressure sensor

(ENG-AAN5-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AAN5-042-K-00-A)

• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects the exhaust pressure to output the corresponding variable voltage.

10-146

107E-2 SERIES

10 Structure and function Sensor

Coolant temperature sensor

(ENG-BA87-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG-BA87-042-K-00-A)

â&#x20AC;˘ This sensor, installed on the cylinder head of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

Engine oil level sensor

(ENG-AB45-041-K-00-A)

1. Connector 2. Bracket 3. Float 4. Switch

Function

(ENG-AB45-042-K-00-A)

â&#x20AC;˘ This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level becomes lower than specified.

107E-2 SERIES

10-147

10 Structure and function Sensor

Air cleaner clogging sensor

(PC-A968-041-K-01-A)

1. Adapter 2. Hood 3. Indicator 4. Connector

Function

(PC-A968-042-K-00-A)

â&#x20AC;˘ This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air cleaner is clogged and the pressure level drops to the specified level (negative pressure).

KDOC outlet temperature sensor

(ENG-A9HH-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor 2. Connector

Function

(ENG-A9HH-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

KDPF outlet temperature sensor

(ENG-A9HJ-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

10-148

107E-2 SERIES

10 Structure and function Sensor

1. Sensor 2. Connector

Function

(ENG-A9HJ-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

Common rail pressure sensor

(ENG-AE28-041-K-00-A)

1. Connector 2. Sensor

Function

(ENG-AE28-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the common rail in the engine, detects the fuel pressure to output the corresponding variable voltage.

Charge (boost) pressure and temperature sensor

(ENG-AAM7-041-K-00-A)

1. Connector 2. Sensor

107E-2 SERIES

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10 Structure and function Sensor

3. O-ring

Function

(ENG-AAM7-042-K-00-A)

â&#x20AC;˘ This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for temperature. a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and temperature". Output characteristics

Ambient pressure sensor

(ENG-AAP2-041-K-00-A)

1. Connector 2. Sensor

Function

(ENG-AAP2-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output the corresponding variable voltage.

10-150

107E-2 SERIES

10 Structure and function Sensor

Output characteristics

Ne (crankshaft) speed sensor

(ENG-AG42-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AG42-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to the gear rotation.

107E-2 SERIES

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10 Structure and function Sensor

Bkup (camshaft) speed sensor

(ENG-AG62-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AG62-042-K-00-A)

â&#x20AC;˘ This sensor, installed to the ring of camshaft on the engine front cover, outputs the pulse voltage due to the gear rotation.

Engine oil pressure switch

(PC-ABK6-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Specifications

(PC220-ABK6-030-K-00-A)

Contact type: Normally closed

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107E-2 SERIES

10 Structure and function Sensor

Function

(PC-ABK6-042-K-00-A)

• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the switch to "ON" position when the pressure goes below the specified value.

Mass air flow and temperature sensor

(ENG-A96H-041-K-00-A)

1. Connector 2. O-ring 3. Sensor

Function

(ENG-A96H-042-K-00-A)

• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and temperature into the resistance variation, and outputs the corresponding signals. a The "MAF (Mass Air Flow)" means the "intake air flow".

EGR valve lift sensor

(ENG-A9S2-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. O-ring (small) 2. O-ring (large) 3. Sensor 4. Connector

Function

(ENG-A9S2-042-K-00-A)

• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the corresponding variable voltage. 107E-2 SERIES

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10 Structure and function Sensor

Output characteristics • The relation between stroke and output voltage is as shown in the following graph.

Water-in-fuel sensor

(PC-AEB3-041-K-00-A)

1. Connector 2. Tube 3. Sensor 4. O-ring

Function

(PC-AEB3-042-K-00-A)

• This sensor is installed to the cup of fuel prefilter. • This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.

10-154

107E-2 SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

20 Standard value tables 4 20 Standard value tables

107E-2 SERIES

20-1

20 Standard value tables Table of contents

Table of contents

(ALL-0310-002-A-00-A)

20 Standard value tables.................................................................................................................... 20-1 Table of contents ........................................................................................................................ 20-2 Standard service value table........................................................................................................ 20-3 Standard value table for engine ............................................................................................. 20-3 Running-in standard and performance test standard ............................................................. 20-27

20-2

107E-2 SERIES

20 Standard value tables Standard value table for engine

Standard service value table

(ALL-A000-001-K-00-A)

Standard value table for engine

(ENG107-A000-033-K-00-A)

Applicable machines: PC170LC-10

(ENG107-A000-033-K-11-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA4D107E-2 Standard value Repair limit for new machine 2,320 ± 30 2,320 ± 30 1,050 ± 25 1,050 ± 25

Air intake and exhaust system Engine Item Air intake resistance

Measurement condition Whole speed range

Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) • Engine coolant temperature: 60 to 102 °C KDOC outlet • Arm curl relief, Exhaust gas color swing lock ON (exhaust pipe outlet) • After kept for 5 sec. at normal condition Intake valve Valve clearance Exhaust valve

Unit kPa {mmH 2O} kPa {mmHg}

SAA4D107E-2 Standard value Repair limit for new machine Max. 3.73 {380}

Max. 7.45 {760}

Min. 140 {1,050}

Min. 113{850}

°C

Max. 650

Max. 700

Bosch index

–

Max. 0.5

mm mm

0.25 0.51

0.152 to 0.381 0.381 to 0.762

Engine itself Engine Item

Measurement condition

Compression pressure

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm

Blowby pressure

At rated horsepower (when KCCV is disconnected)

107E-2 SERIES

SAA4D107E-2 Standard value Repair limit Unit for new machine MPa {kg/ Min. 2.41 Min. 1.69 {17.2} cm2} {24.6} kPa Max. 0.98 {mmH2Max. 1.96 {200} {100} O}

20-3

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Differential pressure across main filter Return circuit pressure Negative pressure circuit pressure Supply pump discharge Return rate from supply pump

Return rate from injector

Leakage from pressure limiter valve

Measurement condition At high idle During cranking At high idle During cranking At high idle During cranking At high idle During cranking speed (30 sec.) At low idle (30 sec.) During cranking (min. 150 rpm, 30 sec.) At low idle (30 sec.) During cranking (min. 150 rpm, 30 sec.) At low idle (30 sec.) During cranking (min. 150 rpm, 30 sec.)

SAA4D107E-2 Standard value Repair limit Unit for new machine 207 to 650 207 to 650 kPa {kg/ 2 cm } {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 kPa {kg/ cm2} {2.11 to 5.1} {2.11 to 5.1} kPa {kg/ cm2} Max. 81 {0.83} Max. 81 {0.83} kPa {kg/ cm2} kPa {kg/ cm2} Max. 18.6 Max. 18.6 {0.19} {0.19} kPa {kg/ cm2} mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Oil pressure

Oil temperature Oil consumption

20-4

Measurement condition At rated horsepower Engine oil SAE15W-40 temperature: Min. 80° C At low idle Engine oil SAE15W-40 temperature: Min. 80° C Whole speed range (inside oil pan) At continuous rated horsepower (Ratio to fuel consumption)

Unit

SAA4D107E-2 Standard value Repair limit for new machine

MPa {kg/ Min. 0.29 {3.0} cm 2}

Min. 0.25 {2.5}

MPa {kg/ Min. 0.10 {1.0} cm2}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

107E-2 SERIES

20 Standard value tables Standard value table for engine

Cooling system Engine Item

Measurement condition

Radiator pressure Cracking pressure (Differential pressure) valve Fan speed At rated speed Fan and alternator belt tension

107E-2 SERIES

Deflection when pressed with finger force of 98 N {10 kg}

Unit kPa {kg/ cm2} rpm mm

SAA4D107E-2 Standard value Repair limit for new machine â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

2,163 2,163 Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

20-5

20 Standard value tables Standard value table for engine

Applicable machines: PC210I-10, PC210LC-10, PC210LCI-10, PC228USLC10 (ENG107-A000-033-K-05-A) Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,060 ± 50 2,060 ± 50 1,050 ± 25 1,050 ± 25

Air intake and exhaust system Engine Item Air intake resistance

Measurement condition Whole speed range

Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and KDPF inlet) Exhaust gas color • Arm curl relief, swing lock ON • After kept for 5 KDPF outlet sec. at normal (exhaust pipe outlet) condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit

SAA6D107E-2 Standard value Repair limit for new machine

kPa Max. 3.73 {mmH Max. 7.45 {760} {380} 2O} kPa Min. 120 {900} Min. 93 {700} {mmHg} °C

Max. 650

Max. 700

Bosch index

–

Max. 2.7

Bosch index

–

Max. 0.5

mm 0.25 mm 0.51 MPa {kg/ Min. 1.2 {12.2} cm2} MPa {kg/ 0.3 to 1.0 {3.1 cm2} to 10.2}

0.152 to 0.381 0.381 to 0.762 Min. 1.2 {12.2} 0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Compression pressure

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm

Blowby pressure

At rated horsepower (when KCCV is disconnected)

20-6

SAA6D107E-2 Standard value Repair limit Unit for new machine MPa {kg/ Min. 2.41 Min. 1.69 {17.2} cm2} {24.6} kPa Max. 0.98 {mmH2Max. 1.96 {200} {100} O}

107E-2 SERIES

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Differential pressure across main filter Return circuit pressure Negative pressure circuit pressure Supply pump discharge Return rate from supply pump

Return rate from injector

Leakage from pressure limiter valve

SAA6D107E-2 Standard value Repair limit Unit for new machine 207 to 650 207 to 650 kPa {kg/ 2 cm } {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 kPa {kg/ cm2} {2.11 to 5.1} {2.11 to 5.1} kPa {kg/ cm2} Max. 81 {0.83} Max. 81 {0.83} kPa {kg/ cm2} kPa {kg/ cm2} Max. 18.6 Max. 18.6 {0.19} {0.19} kPa {kg/ cm2} mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Oil pressure

Oil temperature Oil consumption

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/ Min. 0.29 {3.0} cm 2}

Min. 0.25 {2.5}

MPa {kg/ Min. 0.10 {1.0} cm2}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

20-7

20 Standard value tables Standard value table for engine

Cooling system Engine Item

Measurement condition

Radiator pressure Cracking pressure (Differential pressure) valve Fan speed At rated speed Fan and alternator belt tension

20-8

Deflection when pressed with finger force of 98 N {10 kg}

Unit kPa {kg/ cm2} rpm mm

SAA6D107E-2 Standard value Repair limit for new machine â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

1,740 1,740 Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

107E-2 SERIES

20 Standard value tables Standard value table for engine

Applicable machines: PC240LC-10

(ENG107-A000-033-K-01-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,160 ± 50 2,160 ± 50 1,050 ± 25 1,050 ± 25

Air intake and exhaust system Engine Item

Measurement condition

Air intake Whole speed range resistance Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and • Arm curl relief, Exhaust gas KDPF inlet) swing lock ON color • After kept for 5 KDPF outlet sec. at normal (exhaust pipe outlet) condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit

SAA6D107E-2 Standard value Repair limit for new machine

kPa Max. 3.73 {380} Max. 7.45 {760} {mmH2O} kPa Min. 120 {900} Min. 93 {700} {mmHg} °C

Max. 650

Max. 700

Bosch index

–

Max. 2.2

Bosch index

–

Max. 0.5

mm mm MPa {kg/cm2} MPa {kg/cm2}

0.25 0.51

0.152 to 0.381 0.381 to 0.762

Min. 1.2 {12.2}

0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower Blowby pressure (when KCCV is disconnected) Compression pressure

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa Min. 2.41 {24.6} Min. 1.69 {17.2} {kg/cm2} kPa Max. 0.98 {100} Max. 1.96 {200} {mmH2O}

20-9

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Measurement condition

kPa {kg/cm2}

At high idle During cranking

At high idle Differential pressure across main filter During cranking Return circuit pressure Negative pressure circuit pressure Supply pump discharge

Unit

At high idle During cranking At high idle During cranking speed (30 sec.)

At low idle Return rate from (30 sec.) supply pump During cranking (min. 150 rpm, 30 sec.) At low idle Return rate from (30 sec.) injector During cranking (min. 150 rpm, 30 sec.) At low idle Leakage from (30 sec.) pressure limiter During cranking valve (min. 150 rpm, 30 sec.)

kPa {kg/cm2} kPa {kg/ cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}

SAA6D107E-2 Standard value Repair limit for new machine 207 to 650 207 to 650 {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 {2.11 to 5.1} {2.11 to 5.1} Max. 81 {0.83}

Max. 81 {0.83}

Max. 18.6 {0.19}

mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Measurement condition

At rated horsepower Engine oil SAE15W-40 temperature: Min. 80° C Oil pressure At low idle Engine oil SAE15W-40 temperature: Min. 80° C Oil temperature Whole speed range (inside oil pan) At continuous rated horsepower Oil consumption (Ratio to fuel consumption)

20-10

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/cm2}

Min. 0.29 {3.0}

Min. 0.25 {2.5}

MPa {kg/cm2}

Min. 0.10 {1.0}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

107E-2 SERIES

20 Standard value tables Standard value table for engine

Cooling system Engine Item Radiator pressure valve Fan speed Fan and alternator belt tension

107E-2 SERIES

Measurement condition Cracking pressure (Differential pressure) At rated speed Deflection when pressed with finger force of 98 N {10 kg}

Unit kPa {kg/cm2} rpm mm

SAA6D107E-2 Standard value Repair limit for new machine â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

2,059 Auto-tensioner (automatic adjustment)

20-11

20 Standard value tables Standard value table for engine

Applicable machines: PC290LC-10

(ENG107-A000-033-K-02-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,180 ± 50 2,180 ± 50 1,050 ± 25 1,050 ± 25

Air intake and exhaust system Engine Item Air intake resistance

Measurement condition Whole speed range

Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and • Arm curl relief, KDPF inlet) Exhaust gas color swing lock ON • After kept for 5 KDPF outlet sec. at normal (exhaust pipe outlet) condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit kPa {mmH 2O} kPa {mmHg}

SAA6D107E-2 Standard value Repair limit for new machine Max. 3.73 {380}

Max. 7.45 {760}

Min. 133 {1,000}

Min. 106 {800}

°C

Max. 650

Max. 700

Bosch index

–

Max. 2.2

Bosch index

–

Max. 0.5

mm 0.25 mm 0.51 MPa {kg/ Min. 1.2 {12.2} cm2} MPa {kg/ 0.3 to 1.0 {3.1 cm2} to 10.2}

0.152 to 0.381 0.381 to 0.762 Min. 1.2 {12.2} 0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Compression pressure

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm

Blowby pressure

At rated horsepower (when KCCV is disconnected)

20-12

SAA6D107E-2 Standard value Repair limit Unit for new machine MPa {kg/ Min. 2.41 Min. 1.69 {17.2} cm2} {24.6} kPa Max. 0.98 {mmH2Max. 1.96 {200} {100} O}

107E-2 SERIES

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Differential pressure across main filter Return circuit pressure Negative pressure circuit pressure Supply pump discharge Return rate from supply pump

Return rate from injector

Leakage from pressure limiter valve

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Oil pressure

Oil temperature Oil consumption

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/ Min. 0.29 {3.0} cm 2}

Min. 0.25 {2.5}

MPa {kg/ Min. 0.10 {1.0} cm2}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

20-13

20 Standard value tables Standard value table for engine

Cooling system Engine Item

Measurement condition

Radiator pressure Cracking pressure (Differential pressure) valve Fan speed At rated speed Fan and alternator belt tension

20-14

Deflection when pressed with finger force of 98 N {10 kg}

Unit kPa {kg/ cm2} rpm mm

SAA6D107E-2 Standard value Repair limit for new machine â&#x20AC;&#x201C;

â&#x20AC;&#x201C;

2,258 2,258 Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

107E-2 SERIES

20 Standard value tables Standard value table for engine

Applicable machines: WA270-7

(ENG107-A000-033-K-09-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,250 ± 50 2,250 ± 50 825 ± 25 825 ± 25

Air intake and exhaust system Engine Item

Measurement condition

Air intake Whole speed range resistance Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and • HST stall + KDPF inlet) Exhaust gas Hydraulic stall (full color stall) KDPF outlet • After kept for 5 (exhaust pipe outlet) sec. at normal condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit

SAA6D107E-2 Standard value Repair limit for new machine

kPa Max. 3.73 {380} Max. 7.45 {760} {mmH2O} kPa Min. 120 {900} Min. 93 {700} {mmHg} °C

Max. 650

Max. 700

Bosch index

–

Max. 2.7

Bosch index

–

Max. 0.5

mm mm MPa {kg/cm2} MPa {kg/cm2}

0.25 0.51

0.152 to 0.381 0.381 to 0.762

Min. 1.2 {12.2}

0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower Blowby pressure (when KCCV is disconnected) Compression pressure

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa Min. 2.41 {24.6} Min. 1.69 {17.2} {kg/cm2} kPa Max. 0.98 {100} Max. 1.96 {200} {mmH2O}

20-15

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Measurement condition

kPa {kg/cm2}

At high idle During cranking

At high idle Differential pressure across main filter During cranking Return circuit pressure Negative pressure circuit pressure Supply pump discharge

Unit

At high idle During cranking At high idle During cranking speed (30 sec.)

kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}

SAA6D107E-2 Standard value Repair limit for new machine 207 to 650 207 to 650 {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 {2.11 to 5.1} {2.11 to 5.1} Max. 81 {0.83}

Max. 81 {0.83}

Max. 18.6 {0.19}

mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Measurement condition

20-16

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/cm 2}

Min. 0.29 {3.0}

Min. 0.25 {2.5}

MPa {kg/ cm2}

Min. 0.10 {1.0}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

107E-2 SERIES

20 Standard value tables Standard value table for engine

Cooling system Engine Item Radiator pressure valve

Measurement condition Cracking pressure (Differential pressure)

Unit kPa {kg/cm2}

Fan speed

At rated speed

rpm

Fan and alternator belt tension

Deflection when pressed with finger force of 98 N {10 kg}

107E-2 SERIES

SAA6D107E-2 Standard value Repair limit for new machine –

–

– – Hydraulically Hydraulically driven by to driven by to which engine is which engine is installed installed Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

20-17

20 Standard value tables Standard value table for engine

Applicable machines: WA320-7

(ENG107-A000-033-K-10-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,250 ± 50 2,250 ± 50 825 ± 25 825 ± 25

Air intake and exhaust system Engine Item

Measurement condition

Air intake Whole speed range resistance Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and • HST stall + KDPF inlet) Exhaust gas Hydraulic stall (full color stall) KDPF outlet • After kept for 5 (exhaust pipe outlet) sec. at normal condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit

SAA6D107E-2 Standard value Repair limit for new machine

kPa Max. 3.73 {380} Max. 7.45 {760} {mmH2O} kPa Min. 120 {900} Min. 93 {700} {mmHg} °C

Max. 650

Max. 700

Bosch index

–

Max. 2.7

Bosch index

–

Max. 0.5

mm mm MPa {kg/cm2} MPa {kg/cm2}

0.25 0.51

0.152 to 0.381 0.381 to 0.762

Min. 1.2 {12.2}

0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower Blowby pressure (when KCCV is disconnected) Compression pressure

20-18

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa Min. 2.41 {24.6} Min. 1.69 {17.2} {kg/cm2} kPa Max. 0.98 {100} Max. 1.96 {200} {mmH2O}

107E-2 SERIES

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Measurement condition

kPa {kg/cm2}

At high idle During cranking

At high idle Differential pressure across main filter During cranking Return circuit pressure Negative pressure circuit pressure Supply pump discharge

Unit

At high idle During cranking At high idle During cranking speed (30 sec.)

kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}

SAA6D107E-2 Standard value Repair limit for new machine 207 to 650 207 to 650 {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 {2.11 to 5.1} {2.11 to 5.1} Max. 81 {0.83}

Max. 81 {0.83}

Max. 18.6 {0.19}

mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Measurement condition

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/cm 2}

Min. 0.29 {3.0}

Min. 0.25 {2.5}

MPa {kg/cm2}

Min. 0.10 {1.0}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

20-19

20 Standard value tables Standard value table for engine

Cooling system Engine Item Radiator pressure valve

Measurement condition Cracking pressure (Differential pressure)

Unit kPa {kg/cm2}

Fan speed

At rated speed

rpm

Fan and alternator belt tension

Deflection when pressed with finger force of 98 N {10 kg}

20-20

SAA6D107E-2 Standard value Repair limit for new machine –

–

– – Hydraulically Hydraulically driven by to driven by to which engine is which engine is installed installed Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

107E-2 SERIES

20 Standard value tables Standard value table for engine

Applicable machines: WA380–7

(ENG107-A000-033-K-04-A)

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,250 ± 50 2,250 ± 50 850± 25 850 ± 25

Air intake and exhaust system Engine Item

Measurement condition

Air intake Whole speed range resistance Boost pressure At rated horsepower (aftercooler inlet) Exhaust temperature Whole speed range (20 °C) (turbine outlet) Engine outlet • Engine coolant temperature: 60 to (between 102 °C turbocharger and • At torque Exhaust gas KDPF inlet) converter stall color • After kept for 5 KDPF outlet sec. at normal (exhaust pipe outlet) condition Intake valve Valve clearance Exhaust valve EGR valve and KVGT pressure

Drive pressure

At low idle

KVGT control pressure

At low idle

Unit

SAA6D107E-2 Standard value Repair limit for new machine

kPa Max. 3.73 {380} Max. 7.45 {760} {mmH2O} kPa Min. 120 {900} Min. 93 {700} {mmHg} °C

Max. 650

Max. 700

Bosch index

–

Max. 2.2

Bosch index

–

Max. 0.5

mm mm MPa {kg/cm2} MPa {kg/cm2}

0.25 0.51

0.152 to 0.381 0.381 to 0.762

Min. 1.2 {12.2}

0.3 to 1.0 {3.1 to 10.2}

Engine itself Engine Item

Measurement condition

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower Blowby pressure (when KCCV is disconnected) Compression pressure

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa Min. 2.41 {24.6} Min. 1.69 {17.2} {kg/cm2} kPa Max. 0.98 {100} Max. 1.96 {200} {mmH2O}

20-21

20 Standard value tables Standard value table for engine

Fuel system Engine Item

Low-pressure circuit pressure

Measurement condition

kPa {kg/cm2}

At high idle During cranking

At high idle Differential pressure across main filter During cranking Return circuit pressure Negative pressure circuit pressure Supply pump discharge

Unit

At high idle During cranking At high idle During cranking speed (30 sec.)

kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}

SAA6D107E-2 Standard value Repair limit for new machine 207 to 650 207 to 650 {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 {2.11 to 5.1} {2.11 to 5.1} Max. 81 {0.83}

Max. 81 {0.83}

Max. 18.6 {0.19}

mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Measurement condition

20-22

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/cm2}

Min. 0.29 {3.0}

Min. 0.25 {2.5}

MPa {kg/cm2}

Min. 0.10 {1.0}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

107E-2 SERIES

20 Standard value tables Standard value table for engine

Cooling system Engine Item Radiator pressure valve

Measurement condition Cracking pressure (Differential pressure)

Unit kPa {kg/cm2}

Fan speed

At rated speed

rpm

Fan and alternator belt tension

Deflection when pressed with finger force of 98 N {10 kg}

107E-2 SERIES

SAA6D107E-2 Standard value Repair limit for new machine –

–

– – Hydraulically Hydraulically driven by to driven by to which engine is which engine is installed installed Auto-tensioner Auto-tensioner (automatic (automatic adjustment) adjustment)

20-23

20 Standard value tables Standard value table for engine

Applicable machines: D61EX-23,D61PX-23,D61EXI-23,D61PXI-23

(ENG107-A000-033-K-07-

Performance Engine Item Engine speed

Measurement condition Max. speed with no load Min. speed with no load

Unit rpm rpm

SAA6D107E-2 Standard value Repair limit for new machine 2,280 ± 30 2,280 ± 30 975 ± 25 975 ± 25

Air intake and exhaust system Engine Item

Measurement condition

Air intake Whole speed range resistance Boost pressure (aftercooler inlet At rated horsepower pressure) Exhaust temperature Whole speed range (20°C) (turbine outlet) • Coolant temperature: 60 to 102° Engine outlet C (between • Hydraulic oil temperature: 40 to turbocharger 60°C and KDPF Exhaust gas • HST stall (stall pressure test inlet) color mode) and work equipment KDPF outlet relief (exhaust pipe • After kept for 5 seconds at outlet) normal condition

SAA6D107E-2 Standard value for Repair limit Unit new machine kPa {mmH Max. 3.73 Max. 7.45 {760} {380} 2O} kPa {mmHg}

Min. 113 {850}

Min. 87 {650}

°C

Max. 650

Max. 700

Bosch index

—

Max. 2.7

Bosch index

—

Max. 0.5

Intake valve

0.25

Exhaust valve

0.51 Min. 1.2 {12.2} 0.3 to 1.0 {3.1 to 10.2}

Valve clearance

EGR valve oil pressure and KVGT oil pressure

Driving oil pressure

At low idle

MPa {kg/ cm2}

KVGT control oil pressure

At low idle

MPa {kg/ cm2}

0.152 to 0.381 0.381 to 0.762 Min. 1.2 {12.2} 0.3 to 1.0 {3.1 to 10.2}

Main body Engine Item

Measurement condition

Compression pressure

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm

Blowby pressure

At rated horsepower (when KCCV is disconnected)

20-24

SAA6D107E-2 Standard value Repair limit Unit for new machine MPa {kg/ Min. 2.41 Min. 1.69 {17.2} cm2} {24.6} kPa Max. 0.98 {mmH Max. 1.96 {200} {100} 2O}

107E-2 SERIES

20 Standard value tables Standard value table for engine

Fuel system Engine Item Pressure in lowpressure circuit

Measurement condition At high idle During cranking

Pressure At high idle difference in front and behind main During cranking filter Pressure in return circuit

At high idle During cranking

Pressure in negative pressure At high idle circuit Supply pump During cranking (30 seconds) discharge At low idle Return rate from (For 30 seconds) supply pump During cranking (Min. 150 rpm, 30 seconds) At low idle Return rate from (For 30 seconds) injector During cranking (Min. 150 rpm, 30 seconds) At low idle Leakage from (For 30 seconds) pressure limiter During cranking valve (Min. 150 rpm, 30 seconds)

SAA6D107E-2 Standard value Repair limit Unit for new machine 207 to 650 207 to 650 kPa {kg/ cm2} {2.11 to 6.63} {2.11 to 6.63} 207 to 500 207 to 500 kPa {kg/ cm2} {2.11 to 5.1} {2.11 to 5.1} kPa {kg/ 81 81 cm2} kPa {kg/ Max. {0.83} Max. {0.83} cm2} kPa {kg/ 18.6 kPa 18.6 kPa cm2} kPa {kg/ Max. {0.19} Max. {0.19} cm2} mmHg

Max. -305

Min. 70

Max. 575

Max. 125

Max. 45

Max. 8

–

Max. 5 drops

Lubrication system Engine Item

Oil pressure

Oil temperature Oil consumption

107E-2 SERIES

Unit

SAA6D107E-2 Standard value Repair limit for new machine

MPa {kg/ Min. 0.29 {3.0} cm2}

Min. 0.25 {2.5}

MPa {kg/ Min. 0.10 {1.0} cm2}

Min. 0.07 {0.7}

°C

80 to 110

Max. 120

Max. 0.15

Max. 0.3

20-25

20 Standard value tables Standard value table for engine

Cooling system Engine Item

Measurement condition

Radiator pressure Cracking pressure (differential pressure) valve Fan speed Tension of fan and alternator belt

20-26

Unit kPa {kg/ cm2}

At rated speed

rpm

Deflection when pressed with finger force of 98 N {10 kg}

SAA6D107E-2 Standard value Repair limit for new machine â&#x20AC;&#x201D;

â&#x20AC;&#x201D;

Driving Driving hydraulic motor hydraulic motor Automatic Automatic adjustment adjustment (Auto(Auto-tensioner) tensioner)

107E-2 SERIES

20 Standard value tables Running-in standard and performance test standard

Running-in standard and performance test standard Applicable machines: PC170LC-10

(ENG107-A000-034-K-00-A)

(ENG107-A000-034-K-12-A)

Running-in standard Engine

min. rpm

1 2 1,050

2 10 1,000

SAA4D107E-2 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

147 { 15 }

245 {25}

545 {55,6}

kW {HP}

0 {0}

7.4 {10}

13,2 {17,7}

29,4 {39,4}

90 {121}

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 3 2,100

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine Test item Specification value (Gross)

–

Engine speed

rpm

Dynamometer load

N {kg}

Output (Gross)

kW {HP}

Torque (Gross) Fuel consumption Coolant temperature Lubricating oil temperature Lubricating oil pressure Exhaust temperature

Nm {kgm}

Rated horsepower 90 ± 4.5kW/ 2,100 rpm {121 ± 6.0 HP/ 2,100 rpm} 2,100 571 {58.3} 90

SAA4D107E-2 Max. speed with Min. speed with Max. torque no load no load 484.4 Nm/1,500 ± 50 rpm 2,320 ± 30 rpm 1,050 ± 25 rpm {49.4 kgm/1,500 ± 50 rpm} 1,500 ± 50 2,320 ± 30 1,050 ± 25 676 – – {68.9} –

–

484.4 {49.4}

–

sec/300 cc

–

°C

75 to 94

°C

80 to 110

kPa {kg/cm2}

Min. 261.8 {Min. 2.67}

Min. 193.2 {Min. 1.97}

Min. 261.8 {Min. 2.67}

Min. 54.9 {Min. 0.56}

°C

Max. 650

–

{121}

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 different from the specification values. a This table shows the standard values with an air cleaner installed, KDPF installed, alternator under no load. a The dynamometer load in this table shows the value at an dynamometer arm’s length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 oil for the lubricating oil.

107E-2 SERIES

20-27

20 Standard value tables Running-in standard and performance test standard

Applicable machines: PC210I-10, PC210LC-10, PC210LCI-10, PC228USLC10 (ENG107-A000-034-K-05-A) Running-in standard Engine

min. rpm

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

821 {83.8}

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

123.2 {165}

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 3 2,000

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine Test item Specification value (Gross) Engine speed Dynamometer load Output (Gross) Torque (Gross) Fuel consumption Coolant temperature Lubricating oil temperature Lubricating oil pressure Exhaust temperature

– rpm N {kg} kW {HP} Nm {kgm}

SAA6D107E-2 Rated Max. speed with Min. speed with Max. torque horsepower no load no load 123.2 ± 6.16 kW/ 648.4 Nm/1,500 2,000 rpm ± 50 rpm 2,060 ± 50 rpm 1,050 ± 25 rpm {165 ± 8.25 HP/ {66.2 kgm/1,500 2,000 rpm} ± 50 rpm} 2,000 1,500 ± 50 2,060 ± 50 1,050 ± 25 821 907 – – {83.8} {92.5} 123.2 – – – {165} 648.4 – – – {66.2}

sec/300 cc

–

°C

75 to 94

°C

80 to 110

kPa {kg/cm2}

Min. 261.8 {Min. 2.67}

Min. 193.2 {Min. 1.97}

Min. 261.8 {Min. 2.67}

Min. 54.9 {Min. 0.56}

°C

Max. 650

–

20-28

107E-2 SERIES

20 Standard value tables Running-in standard and performance test standard

Applicable machines: PC240LC-10

(ENG107-A000-034-K-01-A)

Running-in standard Engine

min. rpm

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

941 {96}

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

141 {189}

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 3 2,000

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Rated Max. speed with Min. speed with Max. torque Test item horsepower no load no load 743.4 Nm/1,500 141 ± 7 kW/ Specification 2,000 rpm ± 50 rpm value 2,160 ± 50 rpm 1,050 ± 25 rpm – {189 ± 9.47 HP/ {75.8 kgm/1,500 (Gross) 2,000 rpm} ± 50 rpm} rpm Engine speed 2,000 1,500 ± 50 2,160 ± 50 1,050 ± 25 941 1,038 N Dynamometer – – load {kg} {96} {105.4} 141 kW Output – – – {HP} (Gross) {189} Torque Nm 743.4 – – – (Gross) {kgm} {75.8} Fuel – – – sec/300 cc 35 consumption Coolant °C 75 to 94 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9 Lubricating oil pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56} Exhaust – – °C Max. 650 Max. 650 temperature 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 different from the specification values. a This table shows the standard values with an air cleaner installed, KDPF installed, alternator under no load. a The dynamometer load in this table shows the value at an dynamometer arm’s length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 oil for the lubricating oil.

107E-2 SERIES

20-29

20 Standard value tables Running-in standard and performance test standard

Applicable machines: PC290LC-10

(ENG107-A000-034-K-02-A)

Running-in standard Engine Item Running time min. rpm Engine speed Dynamometer N {kg} load Output kW {HP}

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

0 {0}

98 {10}

245 {25}

440 {45}

1,033 {105}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

141 {189}

4 3 1,600

5 3 2,050

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Max. speed with Rated horsepower Max. torque Test item no load 743.4 Nm/1,500 ± 158.6 ± 7.9 kW/ Specification 50 rpm 2,050 rpm value 2,180 ± 50 rpm – {212.6 ± 10.5 HP/ {75.8 kgm/1,500 ± (Gross) 50 rpm} 2,050 rpm} rpm Engine speed 2,050 1,500 2,180 ± 50 N 1,033 1,144 Dynamometer – load {kg} {105} {116.8} kW Output 158.6 – – {HP} (Gross) {215.7} Torque Nm 819.3 – – (Gross) {kgm} {83.6} Fuel – – 31 consumption sec/300 cc Coolant °C 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Lubricating oil pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} Exhaust – °C Max. 650 Max. 650 temperature

Min. speed with no load 1,050 ± 25 rpm 1,050 ± 25 – – – – 75 to 94 80 to 110 Min. 54.9 {Min. 0.56} –

20-30

107E-2 SERIES

20 Standard value tables Running-in standard and performance test standard

Applicable machines: WA270-7

(ENG107-A000-034-K-09-A)

Running-in standard Engine Item Running time min. rpm Engine speed Dynamometer N {kg} load Output kW {HP}

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

0 {0}

98 {10}

245 {25}

440 {45}

765 {78}

0 {0}

7.4 {10}

22 {30}

53 {71}

114.5 {153.5}

4 3 1,600

5 3 2,000

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Max. speed with Rated horsepower Max. torque Test item no load 114.5 ± 5.7 kW/ Specification 690 Nm/1,300 rpm 2,000 rpm value 2,250 ± 50 rpm – {70.4 kgm/1,300 {153.5 ± 7.7 HP/ rpm} (Gross) 2,000 rpm} rpm Engine speed 2,000 1,300 2,250 ± 50 N 764 964 Dynamometer – load {kg} {78} {98} kW Output 114.5 – – {HP} (Gross) {153.5} Torque Nm 690 – – (Gross) {kgm} {70.4} Fuel – – 43 consumption sec/300 cc Coolant °C 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Lubricating oil pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} Exhaust – °C Max. 650 Max. 700 temperature

Min. speed with no load 825 ± 25 rpm 825 ± 25 – – – – 75 to 94 80 to 110 Min. 54.9 {Min. 0.56} –

107E-2 SERIES

20-31

20 Standard value tables Running-in standard and performance test standard

Applicable machines: WA320-7

(ENG107-A000-034-K-10-A)

Running-in standard Engine Item Running time min. rpm Engine speed Dynamometer N {kg} load Output kW {HP}

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

0 {0}

98 {10}

245 {25}

440 {45}

807 {82}

0 {0}

7.4 {10}

22 {30}

53 {71}

127.0 {170.3}

4 3 1,600

5 3 2,100

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Max. speed with Rated horsepower Max. torque Test item no load 127.0 ± 6.4 kW/ Specification 767 Nm/1,400 rpm 2,100 rpm value 2,250 ± 50 rpm – {78.2 kgm/1,400 {170.3 ± 8.5 HP/ rpm} (Gross) 2,100 rpm} rpm Engine speed 2,100 1,400 2,250 ± 50 N 807 1,071 Dynamometer – load {kg} {82} {109} kW Output 127.0 – – {HP} (Gross) {170.3} Torque Nm 767 – – (Gross) {kgm} {78.2} Fuel – – 39 consumption sec/300 cc Coolant °C 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Lubricating oil pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} Exhaust – °C Max. 650 Max. 700 temperature

Min. speed with no load 825 ± 25 rpm 825 ± 25 – – – – 75 to 94 80 to 110 Min. 54.9 {Min. 0.56} –

20-32

107E-2 SERIES

20 Standard value tables Running-in standard and performance test standard

Applicable machines: WA380-7

(ENG107-A000-034-K-04-A)

Running-in standard Engine Item Running time min. rpm Engine speed Dynamometer N {kg} load Output kW {HP}

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

0 {0}

98 {10}

245 {25}

440 {45}

910 {93}

0 {0}

7.4 {10}

22 {30}

53 {71}

143.4{192.3}

4 3 1,600

5 3 2,100

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Max. speed with Rated horsepower Max. torque Test item no load 143.4 ± 7.2 kW/ Specification 941 Nm/1,450 rpm 2,100 rpm value 2,250 ± 50 rpm – {96 kgm/1,450 {192.3 ± 9.6 HP/ rpm} (Gross) 2,100 rpm} rpm Engine speed 2,100 1,500 ± 50 2,250 ± 50 N 910 1,314 Dynamometer – load {kg} {93} {134} kW Output 143.4 – – {HP} (Gross) {192.3} Torque Nm 941 – – (Gross) {kgm} {96} Fuel – – 34 consumption sec/300 cc Coolant °C 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Lubricating oil pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} Exhaust – °C Max. 650 Max. 710 temperature

Min. speed with no load 850 ± 25 rpm 850 ± 25 – – – – 75 to 94 80 to 110 Min. 54.9 {Min. 0.56} –

107E-2 SERIES

20-33

20 Standard value tables Running-in standard and performance test standard

Applicable machines: D61EX-23,D61PX-23,D61EXI-23,D61PXI-23

(ENG107-A000-034-K-07-

Running-in standard Engine

min. rpm

1 2 1,050

2 10 1,000

SAA6D107E-2 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

775 { 78.5 }

kW {HP}

0 {0}

7.4 {10}

22 {29.6}

53 {71}

127 {170 }

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 3 2,200

a This table shows the values when the fan is not installed. a The loads for the dynamometer are at an arm's length of 716 mm. Performance test standard Engine SAA6D107E-2 Rated Max. speed with Min. speed with Max. torque Test item horsepower no load no load 767 ± 38.4 Nm/ 127 ± 6.4 kW/ Specification 2,200 rpm 1,400 rpm value 2,280 ± 30 rpm 975 ± 25 rpm — {170 ± 8.6 HP/ {78.2 ± 3.9 kgm/ (Gross) 2,200 rpm} 1,400 rpm} rpm Engine speed 2,200 1,400 2,280 ± 30 975 ± 25 775 N 1,071 Dynamometer — — load { 78.5 } {kg} { 109.2 } kW Output 127 — — — {HP} (Gross) { 170 } Torque Nm 767 — — — (Gross) {kgm} { 78.2 } Fuel — — — sec/300 cc 39 consumption Coolant °C 75 to 94 75 to 94 75 to 94 75 to 94 temperature Lubricating oil °C 80 to 110 80 to 110 80 to 110 80 to 110 temperature kPa Min. 261.8 Min. 193.2 Min. 261.8 Min. 54.9 Lubricating oil 2 pressure {kg/cm } {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56} Exhaust — — °C Max. 650 Max. 650 temperature 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 different from the specification values. a This table shows the standard values with an air cleaner installed, KDPF installed, alternator under no load. a The dynamometer load in this table shows the value at an dynamometer arm’s length of 716 mm. a Use ASTM D975 diesel oil as the fuel. a Use SAE15W-40 oil for the lubricating oil.

20-34

107E-2 SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

50 Disassembly and assembly 5 50 Disassembly and assembly

107E-2 SERIES

50-1

50 Disassembly and assembly Table of contents

Table of contents

(ALL-0310-002-A-00-A)

50 Disassembly and assembly ........................................................................................................... 50-1 Table of contents ........................................................................................................................ 50-2 Related information on disassembly and assembly ........................................................................ 50-3 How to read this manual ....................................................................................................... 50-3 Coating materials list ............................................................................................................ 50-5 Special tool list..................................................................................................................... 50-9 Sketch of special tool.......................................................................................................... 50-11 Disassembly and assembly ....................................................................................................... 50-12 General disassembly of engine ........................................................................................... 50-12 General assembly of engine................................................................................................ 50-34 Removal and installation procedure of supply pump unit alone............................................... 50-75 Engine front oil seal replacement procedure ......................................................................... 50-79 Engine rear oil seal replacement procedure.......................................................................... 50-82

50-2

107E-2 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Related information on disassembly and assembly How to read this manual

(ALL-3851-001-A-00-A)

(ALL-0320-011-A-00-A)

(Rev.2013.05) Removal and installation of TTTT assembly Special tools • The special tools required for removal and installation work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described. • Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools. • For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools." Removal • In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. • The general tools required for "Removal" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in "Removal" section are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

• The general tools required for "Installation" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in "Installation" section are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

a : This mark gives knowledge or precautions when performing the work. 4 : This mark shows the weight of the part or equipment. 2 : This mark shows a specific coating agent to be used. 3 : This mark shows the specified tightening torque. 5 : This mark shows the amount of oil or coolant to be added. • For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants". Disassembly and assembly of TTTT assembly Special tools

Installation

• The special tools required for disassembly and assembly work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described. • Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools. • For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."

• The work procedure of "Installation" is in the reversed order to removal unless otherwise specified. • For knowledge and precautions required for "Installation", a [*1] mark is assigned to the "Removal" work procedure to indicate the work item of the installation knowledge or precaution.

Disassembly • "Disassembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and coolant required for the work. • The general tools required for "Disassembly" are listed as [1], [2], ..., without description of part number, part name, and quantity.

a : This mark gives knowledge or precautions when performing the work. [*1]: This mark indicates that knowledge or precautions for the assembly installation work are given in the "Installation" section. 6 : This mark shows the amount of oil or coolant to be drained. 4 : This mark shows the weight of the part or equipment.

107E-2 SERIES

50-3

50 Disassembly and assembly Related information on disassembly and assembly

• Marks used in the section of "Disassembly" are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

a : This mark gives knowledge or precautions when performing the work. 6 : This mark shows the amount of oil or coolant to be drained. 4 : This mark shows the weight of the part or equipment. Assembly • "Assembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and water required for the work. • The general tools required for "Assembly" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in the section of "Assembly" are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

50-4

107E-2 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Coating materials list

(ALL-3540-071-A-00-A)

(Rev.2012.11) a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Adhesive Komatsu code

Part No.

Capacity

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (contained 2 pieces)

Polyethylene container

LT-2

790-129–9180

50 g

Polyethylene container

Main features and applications • Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. • Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and nonmetal parts which require immediate and strong adhesion. • Features: Resistance to heat and chemicals • Use to prevent bolts and plugs from coming loose and as sealant.

LT-3

790-129-9060 Set of adhesive and hardener

Adhesive: 1 kg Hardener: 500 g

Can

• Use to bond and seal metal, glass and plastics.

LT-4

790-129-9040

250 g

Polyethylene container

Holts MH705

790-129-9120

75 g

Tube

ThreeBond 1735

790-129-9140

50 g

Polyethylene container

Aron Alpha 201

790-129-9130

2g (contained 5 pieces)

Polyethylene container

Loctite 499

428-99-80070

20 cc

Tube

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

107E-2 SERIES

• Use to seal plugs for blank holes. • Heat-resistant seal used to repair engines • Instantaneous adhesive • Curing time: From 5 sec. to 3 min. • Use mainly to bond metals, rubbers, plastics, and woods. • Instantaneous adhesive • Quick-curing type (max. strength is obtained after 30 minutes) • Use mainly to bond rubbers, plastics, and metals. • General-purpose instantaneous adhesive with excellent resistance to heat and impact • Use on the bushing mounting faces of axle supports. • Features: Resistance to heat and chemicals • Use to bond high-temperature fit parts.

50-5

50 Disassembly and assembly Related information on disassembly and assembly

Liquid gasket Komatsu code LG-5 ThreeBond 1110F

Part No. 790-129-9080

Capacity

Container

1 kg

Polyethylene container

• • •

LG-6 ThreeBond 1215

790-129-9160

250 g

Tube

• • •

LG-7 ThreeBond 1207C

790-129-9170

150 g

Tube

LG-8 ThreeBond 1207B

419-15-18131

100 g

Tube

LG-9 ThreeBond 1206D

790-129-9310

• • • •

200 g

Tube • •

LG-10 ThreeBond 1206E

790-129-9320

200 g

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

•

ThreeBond 1211

790-129-9090

100 g

Tube

•

Tube • •

Main features and applications Use to seal various threaded parts, pipe joints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and coldresistant sealant. Use to seal flange surface and threaded parts. Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based heat, vibration, and shock-resistant sealant. Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint. Use as lubricant or sealant when the radiator hoses are put on. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc. Liquid gasket used to repair engine

Molybdenum disulfide lubricant Komatsu code

Part No.

Capacity

Container

LM-P

09940-00040

200 g

Tube

LM-S

09995-00250

190 g

Can

50-6

Main features and applications • Use to prevent galling and seizure of press-fitted parts, shrinkage-fitted parts, and threaded parts. • Use to lubricate linkages, bearings, etc. • Spray type • Thin molybdenum disulfide films are made on metal surfaces to prevent the metals from galling. • Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.

107E-2 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Seizure prevention compound Komatsu code

Part No.

Capacity

Container

LC-G NEVER-SEEZ

—

Can

Capacity

Container

Various

• Lithium grease with extreme pressure lubrication performance, general purpose type.

400 g x 10 400 g x 20 16 kg

Bellowstype container Can

• Use for parts under heavy load. Caution: • Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. • Use this grease for work equipment pins only when installing them, but do not use it afterward. • Higher seizure resistance, heat resistance, and waterproof than molybdenum disulfide grease • Not conspicuous on machine since color is white.

• Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.

Main features and applications • Feature: Seizure and galling prevention compound with metallic super-finegrain, etc. • Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Grease Komatsu code

Part No. SYG2-400LI-A G2-LI SYGA-16CNLI G0-LI(*) SYG0-400LI-A *: For cold districts (*) SYG0-16CNLI (*)

Molybdenum disulfide grease LM-G(G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper white grease G2-T G0-T(*) *: For cold districts Biogrease G2-B G2-BT(*) *: For use at high temperature and under high load

SYG2-400T SYG2-16CNT SYG0-400T(*) SYG0-16CNT(*)

400 g 16 kg

Bellowstype container Can

SYG2-400B SYGA-16CNB SYG2-400BT(*) SYGA-16CNBT (*)

400 g 16 kg

Bellowstype container Can

G2-S ThreeBond 1855

—

200 g

Tube

G2-U-S ENS grease

427-12-11871

2 kg

Can

107E-2 SERIES

Main features and applications

• Feature: Silicon-based grease with wider operating temperature range and superior thermal oxidative stability to prevent deterioration of rubber and plastic. • Use for oil seals of the transmission, etc. • Feature: Urea (organic) grease with heat resistance and long life, inclusion type. • Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

50-7

50 Disassembly and assembly Related information on disassembly and assembly

Primer Loctite 712

Part No.

Capacity

428-99-80080

100 ml

SUNSTAR Paint Surface Primer 580 SUPER SUNSTAR Glass Primer 580 SUPER

417-926-3910

SUNSTAR Paint Surface Primer 435-95

Container Glass container

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

SUNSTAR PRIMER 435-41 for glass

22M-54-27240

150 ml

Steel can

SUNSTAR sash primer GP-402

22M-54-27250

20 ml

Glass container

Komatsu code

Part No.

Capacity

Container

SUNSTAR Penguin Seal 580 SUPER "S" or "W"

417-926-3910

320 ml

Polyethylene container

Sika Japan Sikaflex 256HV

20Y-54-39850

310 ml

Cartridge

SUNSTAR Penguin Super 560

22M-54-27210

320 ml

Ecocart (special container)

Part No.

Capacity

Container

417-926-3920

330 ml

Cartridge

20Y-54-55130

333 ml

Cartridge

Main features and applications • Use to accelerate hardening of instantaneous adhesive. • Use as primer for cab side. (Effective period: 4 months after manufacture) • Use as primer for glass side. (Effective period: 4 months after manufacture) • Use as primer for painted cab sheet metal surface. (Effective period: 4 months after manufacture) • Use as primer for black ceramiccoated glass surface and for hard polycarbonate-coated surface. (Effective period: 4 months after manufacture) • Use as primer for sash (alumite surface treatment). (Effective period: 4 months after manufacture)

For adhered window glass

Komatsu code

For adhered window glass

Adhesive Main features and applications • Use "S" as adhesive for glass in high temperature months (during summer) and "W" in low temperature months (during winter). (Effective period: 4 months after manufacture) • Use as adhesive for glass. (Effective period: 6 months after manufacture) • Use as adhesive for glass. (Effective period: 6 months after manufacture)

Komatsu code SUNSTAR Penguin Seal No.2505 SEKISUI Silicone Sealant 83 GE TOSHIBA SILICONES TOSSEAL381

50-8

22M-54-27220

333 ml

Cartridge

For adhered window glass

Caulking material Main features and applications • Use to seal glass-to-glass joint. (Effective period: 4 months after manufacture) • Use to seal front window. (Effective period: 6 months after manufacture) • Translucent white seal used for joint seals between glasses (Effective period: 12 months after manufacture)

107E-2 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Special tool list

(ENG107-3530-061-A-00-A)

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured). a Necessity t:Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tool. a New/Redesign N: Tools with new part numbers, newly developed for this model. R: Tools, with advanced part numbers, developed by improving existing tools for other models. Blank: Tools already available for other models that can be used without any modification

A Disassembly and assembly of engine

790-501-2001 795-799-1150

Repair stand

Adapter

t 1

Spring pusher

q 1

795-799-7210 Removal and installation of air intake valve and exhaust valve Removal and installation of piston ring Installation of piston Removal of injector Removal and installation of rear oil seal Removal and installation of front oil seal Angle tightening of bolt Adjustment of valve clearance Adjustment of backlash and end play of gear Removal of inlet connector Removal and installation of supply pump gear Sling for engine assembly Removal and installation of main bearing 107E-2 SERIES

Sketch

Detail of work, remarks

t 1

790T-901-6020 B

New/redesign

Part name

Q'ty

Part number

Necessity

Work item

Symbol

a Tools marked with Q in the sketch column have the sketches. ((See "Sketch of special tool".)

Special for Q KOMATSU repair stand Special for CUMMINS repair stand

795-102-2103 C

795-799-8800

795-100-2800

Piston ring tool

t 1

E F

795-921-1100 795-799-6700

Piston holder Puller

t 1 t 1

795-799-6500

Seal puller

t 1

795-799-6400

Seal puller

t 1

790-331-1120 795-799-2240 Commercially available

Wrench (angle) Angle gauge

q 1 q 1

Feeler gauge

q 1

J K L

Commercially available

Dial gauge stand

q 1

795-799-8150

Remover

q 1

795-799-6130

Support

t 1

795-799-9300

Lifting tool

q 1

795-799-2270

Remover, installer

q 1

f75-175 mm

50-9

50 Disassembly and assembly

Rotating crankshaft Tightening injector wiring harness nut Measuring cylinder head bolt length

50-10

Gear

t 1

W 795-799-7110

Torque wrench

q 1

Gauge

q 1

795-799-1131

795-790-4510

Sketch

New/redesign

Part name

Q'ty

Part number

Necessity

Work item

Symbol

Related information on disassembly and assembly

Detail of work, remarks

107E-2 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Sketch of special tool

(ENG107-3531-066-A-00-A)

Note: Komatsu cannot accept any responsibility for special tool manufactured according to this sketch. B: Adapter

107E-2 SERIES

50-11

50 Disassembly and assembly Disassembly and assembly

Disassembly and assembly

(ENG107-A000-001-K-00-A)

General disassembly of engine

(ENG107-A000-530-K-00-A)

a This disassembly procedure is general disassembly procedure for 107E-2. Since the shapes, quantity, locations, etc. of the parts may be different from the actual machine, check them before starting the work. 1. Preparation Before disassembling the engine, check its parts for cracking, damage, etc. and clean it generally and carefully for accurate inspection of its parts and quick disassembly and assembly. a Before cleaning the engine, carefully seal the openings or remove electric parts and wiring connectors so that water does not enter them. 2. Setting engine assembly 1) Set engine assembly (1) on a rigid and stable stand [1].

[6D107E-2]

3. Starting motor assembly Remove mounting bolts (1), and remove starting motor assembly (2). [4D107E-2]

a The weight depends on the applicable machine model. 4 Engine assembly 460 kg (4D107E-2) 4 Engine assembly 650 kg (6D107E-2) 2) Drain the engine coolant and engine oil. a The quantity of the oil depends on the applicable machine. 6 Engine oil: Approximately 20 l (4D107E-2)

[6D107E-2]

6 Engine oil: Approximately 23 l (6D107E-2) [4D107E-2]

4. Fan 1) Remove fan (3).

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2) Remove fan belt (1). a Set a wrench into A part of tensioner assembly (2) (width across flats: T12.7 mm) and turn it in the opposite direction (R) to the winding-up direction to loosen the fan belt (1). k Be

sure that wrench is set securely to A part of tensioner assembly (2) before turning it. (Since the spring force of the tensioner assembly (2) is strong, the wrench may come off and is very dangerous if it is turned when not attached securely.)

6. Tubes and hoses [4D107E-2] 1) Disconnect tube clamp (1). 2) Disconnect EGR orifice temperature sensor connector (EXHAUST GAS TEMPERATURE) (2). a The sensor is locked with a coming-off prevention stopper. 3) Loosen hose clamp (3), and disconnect hose (4). 4) Remove mounting bolts (5) (4 pieces), and remove EGR piping flange (6).

k After

removing fan belt (1), return tensioner assembly (2) to its original position slowly and carefully.

k Be

careful not to get your fingers caught between the pulley and fan belt (1) during work.

5) Remove mounting bolts (7) (2 pieces) on EGR cooler side and flange clamp bolts (7a) (2 pieces) to remove tube (8). 6) Remove tube (9). a Disconnect the VFT end of tube (9) first, and disconnect the oil cooler end.

5. Alternator Remove mounting bolts (1) and (2), and alternator (3).

7) Remove tube clamp (10). 107E-2 SERIES

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8) Disconnect joint (11). 9) Loosen hose clamp (12) and remove tube (13). 10)Disconnect tube (14), and remove tube (15).

[6D107E-2] 1) Disconnect tube clamp (1). 2) Disconnect EGR orifice temperature sensor connector (EXHAUST GAS TEMPERATURE) (2).

3) 4) 5) 6)

7) Disconnect tube (9) from the KVGT side. 8) Disconnect tube clamp (10). 9) Loosen hose clamp (11) and remove tube (9). 10)Remove tube (12). a KVGT side is tightened together.

a The sensor is locked with a coming-off prevention stopper. Loosen hose clamp (3), and disconnect hose (4). Remove mounting bolts (5) (4 pieces), and remove EGR piping flange (6). Remove mounting bolts (7) at EGR cooler side, and remove tube (8). Remove KVGT return tube (14). 11)Remove tube (13). a KVGT side is tightened together.

7. VFT and KVGT [4D107E-2] 1) Remove mounting bolts (1) (6 pieces), and remove heat insulation covers (2) (2 pieces).

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2) Disconnect harness connector (3). 3) Remove mounting nut (4). 4) For the water-cooled turbocharger, remove the tubes according to the following procedure. 1] Remove joint (5), and remove tubes (6) and (7). 2] Remove joints (8) and (9), and remove tube (10). 5) Sling VFT (11) and remove it. 4 VFT (11): 15 kg

[6D107E-2] 1) Disconnect wiring harness connectors (1), (2), and (3). • Connector (1): KVGT position sensor (SVGT) • Connector (2): KVGT speed sensor (VGT_REV) • Connector (3): Connector box (INTER CONNECT) 2) Disconnect hoses (4) and (5). • Hose (4): KVGT control pressure circuit • Hose (5): KVGT drive hydraulic circuit

3) Sling KVGT (6), and remove it. 4 KVGT: 25 kg

8. Heat insulation plate [6D107E-2] 107E-2 SERIES

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Remove heat insulation plate (1).

9. EGR cooler [4D107E-2] 1) Remove bottom side tube (1) of EGR cooler.

2) Remove mounting bolts (2), and disconnect EGR cooler (3) and exhaust manifold. a When disconnecting, be careful not to drop the gasket. 3) Remove mounting bolts (6) (2 pieces), and remove EGR cooler (5).

4) Remove mounting bolts (7a) and (7b), and remove bracket (8).

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[6D107E-2] 1) Remove the joint bolt, and remove tube (1). 2) Remove bottom side tube (2) of EGR cooler.

3) Remove mounting bolts (3), and disconnect EGR cooler (4) and exhaust manifold. a When disconnecting, be careful not to drop the gasket. 4) Remove EGR cooler (4) and bracket (5).

10.Tensioner assembly Remove mounting bolt tensioner assembly (2).

(1),

and

remove

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11.Oil filter and oil cooler 1) Remove coolant inlet connector (1). 2) Disconnect oil filter hoses (2) and (3), and remove oil filter.

3) Remove mounting bolts (4) (15 pieces), and remove cover (5) and cover gasket (6). 4) Remove oil cooler (7) and cooler gasket (8). [4D107E-2]

[6D107E-2]

12.Exhaust manifold assembly 1) Remove tube (1). 2) Remove exhaust manifold (2). a When disconnecting, be careful not to drop the gasket. [4D107E-2]

[6D107E-2]

13.Installation to engine repair stand 1) Install engine assembly (1) to tool B. Mounting bolts at engine side: M12 x 1.75 2) Sling engine assembly (1), set tool (B) to tool (A), and install engine assembly (1). a The weight depends on the applicable machine model. 4 Engine assembly Approximately 440 kg (4D107E-2)

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4 Engine assembly Approximately 520 kg (4D107E-2)

16.Alternator bracket 1) Remove alternator bracket (1). 2) Remove sling bracket (2). 14.Fan pulley Remove fan pulley (1).

15.Crankshaft pulley and vibration damper [4D107E-2] Remove mounting bolts (1), and remove crankshaft pulley (2).

[6D107E-2] Remove mounting bolts (1), and remove vibration damper (2).

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17.Fan hub Remove mounting bolts (1) (4 pieces), and remove fan hub (2). a The fan hub is tightened together with wiring harness bracket (3).

18.Thermostat 1) Remove mounting bolt (1), and remove coolant outlet connector (2).

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2) Remove thermostat (3).

[6D107E-2] 1) Disconnect tube clamp (1). 2) Disconnect tube clamp (2). 3) Disconnect tube (4) from boost pump (3). 4) Disconnect tube (5). 5) Disconnect clamps (7) and (8) of dipstick pipe (6). 6) Remove mounting bolts (9), and remove bracket (10). 7) Disconnect tubes (11) and (12).

19.Water pump 1) Remove mounting bolt (1), and remove coolant inlet connector (2). 2) Remove mounting bolts (3) (4 pieces), and remove water pump (4).

20.EGR valve [4D107E-2] 1) Disconnect connector (1). 2) Remove mounting bolts (2), and remove EGR valve (3).

107E-2 SERIES

8) Disconnect connector (INNTER-CONNECT) (13). 9) Remove mounting bolts (14), and remove EGR valve (15).

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21.Harness assembly [4D107E-2] 1) Remove mounting bolts (20) (2 pieces), and remove cover (21).

2) Remove mounting nuts (33) (3 pieces) and bolt (22a), and remove bracket (23).

3) Disconnect the connector, clamp, and band, and disconnect wiring harness assembly (1). • Exhaust manifold pressure sensor connector (2) • Common rail pressure sensor connector (3)

• • • • •

Coolant temperature sensor connector (4) Wiring harness clamp (5) Engine pressure switch connector (6) Bkup (cam) speed sensor connector (7) Ne (crankshaft) speed sensor connector (8)

• Wiring harness clamps (9) and (10) • Wiring harness connector (11) • Band (12)

• Wiring harness clamps (13) and (14) • Ambient pressure sensor connector (15) • Charge (boost) pressure and temperature sensor connector (16) • Wiring harness connector (17) • Wiring harness connector (ECM) (18) a Wiring harness connector (ECM) (18) is locked with hexagonal socket head bolt (19) (4 mm).

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[6D107E-2] Disconnect the connector, clamp, and band, and disconnect wiring harness assembly (1). • Exhaust manifold pressure sensor connector (2) • Coolant temperature sensor connector (3) • Wiring harness bracket (4)

• • • •

Wiring harness clamp (5) Engine oil pressure switch connector (6) Bkup (cam) speed sensor connector (7) Ne (crankshaft) speed sensor connector (8)

• • • • •

Band (12) Wiring harness brackets (13) and (14) Wiring harness connectors (15) and (16) Common rail pressure sensor connector (17) Charge (boost) pressure and temperature sensor connector (18)

• Wiring harness connector (20) • Band (21) • Wiring harness clamp (22) a It is tightened together with wiring harness bracket (23). • Wiring harness bracket (23) • Wiring harness connector (ECM) (24) a Wiring harness connector (ECM) (24) is locked with hexagonal socket head bolt (25) (4 mm).

• Wiring harness clamps (9) and (19) • Ambient pressure sensor connector (10) • Wiring harness connector (11)

22.Fuel filter assembly [4D107E-2]

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1) Disconnect fuel filter hoses (2) and (3) from supply pump (1). a The internal parts of the hose fitting may be damaged when the fuel filter hose is disconnected. It is, therefore, prohibited as a rule to reuse the hose. Replace the hose with a new one when reassembling it. a Remove the fuel filter hoses while pushing lock (L) on its both sides. 23.High-pressure pipe and common rail [4D107E-2] 1) Remove fuel spray prevention caps (10) (10 pieces) of fuel high-pressure pipes (5) to (9). 2) Remove fuel high-pressure pipes (5) to (8). 3) Remove tube clamps (11) (2 places), and remove fuel high-pressure pipe (9). 4) Remove spill tube (12). 5) Remove common rail (13).

[6D107E-2] Disconnect fuel filter hoses (2) and (3) from supply pump (1). a The internal parts of the hose fitting may be damaged when the fuel filter hose is disconnected. It is, therefore, prohibited as a rule to reuse the hose. Replace the hose with a new one when reassembling it. a Remove the fuel filter hoses while pushing lock (L) on its both sides.

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[6D107E-2] 1) Remove fuel spray prevention caps (8) (14 pieces) of fuel high-pressure pipes (1) to (7). 2) Remove fuel high-pressure pipes (1) to (6). 3) Remove tube clamps (9) (2 places), and remove fuel high-pressure pipe (7). 4) Disconnect tube clamps (10), and remove spill tube (11). 5) Remove mounting bolts and nuts (at 4 places each), and remove common rail (12).

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2) Remove nuts (2) (4 pieces), and remove head cover (3).

24.Intake manifold cover [4D107E-2] 1) Remove mounting bolts (1), and remove tube (2) and intake air heater (3). a Remove intake air heater (3). At this time, remove the plate and gasket together which are between intake air heater (3) and air intake manifold connector (5). 2) Remove air intake manifold connector (4).

3) Remove harness nuts (4) from the injector. a Installed positions of harnesses Color of wiring harness White Black

Cylinder No. 1, 3 2, 4

a Remove injector harness connector (7) from the rocker housing only when required. 4) Remove mounting bolt (5), and remove rocker housing assembly (6).

[6D107E-2] 1) Remove mounting bolts (1) (4 pieces), and remove tube (2) and intake air heater (3). 2) Remove the mounting bolts, and remove intake manifold cover (4) and air intake manifold connector (5).

[6D107E-2] 1) Remove blowby duct (1). 2) Remove nuts (2) (6 pieces), and remove head cover (3).

25.Head cover and rocker housing [4D107E-2] 1) Remove blowby duct (1).

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3) Remove harness nuts (4) from the injector. a Installed positions of harnesses Color of wiring harness White Black

Cylinder No. 1, 3, 5 2, 4, 6

a Remove injector harness connector (7) from the rocker housing only when required. 4) Remove mounting bolt (5), and remove rocker housing assembly (6). 27.Push rod Remove push rod (1).

26.Rocker arm assembly and crosshead 1) Remove mounting bolt (1), and remove rocker arm assembly (2). a Loosen locknut (4), and loosen adjustment screw (5) by 2 or 3 turns so that a force of valve spring is not applied to the rocker arm assembly mounting bolts. 2) Remove crosshead (3).

a Record the locations and shapes of holes "a" and "b". (Install them in the recorded directions when reassembling.)

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28.Injector assembly 1) Remove retaining nut (5), and remove inlet connector (1). a Remove inlet connector by using tool M. 2) Remove mounting bolts (3) of injector (2), and remove holder (4). 3) Remove injector (2).

a Pull up the injector when removing the injector by using tool F. (Do not pry the top of injector to remove.)

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29.Cylinder head assembly 1) Remove mounting bolt (1), and remove cylinder head assembly (2). 4 Cylinder head assembly:

3] Raise the cylinder head assembly, remove valve (6), and remove valve seal (7). a Put marks on valve (6) so that you can find matching cylinder head.

50 kg (4D107E-2) 4 Cylinder head assembly: 75 kg (6D107E-2)

30.Engine controller 1) Remove the mounting bolts (4 pieces), and remove engine controller (2). a Ground (1) is tightened together. 2) Disassemble the cylinder head assembly according to the following procedure. 1] Compress valve spring (3) by using tool C, and remove valve collet (4).

2) Remove engine controller mount bracket (3). [4D107E-2]

2] Remove upper seat (5) and valve spring (3).

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[6D107E-2]

2) Remove the gear from the supply pump according to the following procedure. 1] Fix the gear by using tool N and 1/2 inch spinner handle [1], and loosen nut (3). a Do not remove nut (3) from the shaft.

31.Supply pump 1) Remove nuts (1) (3 pieces), and remove supply pump (2). a Pull supply pump (2) sideways straight when removing it. Otherwise the pump assembly may interfere with the top of boost pump (17).

a Supply pump (2) comes off together with gear. The gear is not worked on its teeth (no missing tooth) to show the mark for 1, 6 TOP adjustment.

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2] Install puller [2] between the flange and gear (4).

3] Install puller [3] on puller [2] and the shaft. 4] Screw in center bolt [4] until the gear is disengaged from the shaft. 5] Remove pullers [2] and [3].

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6] Remove nut (3), lock washer (5) and gear (4) from shaft (6).

3) Remove suction tube (3). 4) Remove plate (4). a Remove hexagonal socket head bolt (A) (1 place) by using hexagonal wrench.

32.Boost pump [6D107E-2] Remove mounting bolts (1) (2 pieces), and remove boost pump (2).

33.Oil pan [4D107E-2] 1) Move the engine repair stand to the position where the oil pan mounting bolts are easily removed. 2) Remove mounting bolts (1) (24 pieces), and remove oil pan (2).

107E-2 SERIES

[6D107E-2] 1) Move the engine repair stand to the position where the oil pan mounting bolts are easily removed. 2) Remove mounting bolts (1) (32 pieces), and remove oil pan (2).

3) Remove suction tube (3). 4) Remove plate (4). a Remove the Torx screw (1 place) by using Torx wrench.

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34.Front cover 1) Remove front oil seal (1) according to the following procedure. 1] Install tool H to the crankshaft. 2] Screw in tapping screw [1] of tool H to the seal carrier section of front oil seal (1). 3] Turn the handle clockwise, and remove front oil seal (1).

36.Flywheel 1) Remove mounting bolts (1), and insert guide bolts [1]. 2) Set slings to flywheel (2), and pull it (2) out. a Be careful not to pull out the guide bolt when removing the flywheel. 3) Sling flywheel (2), and remove it. 4 Flywheel: 35 kg k Since

the faucet joint part of the flywheel is shallow, the flywheel may fall suddenly. Be careful not to get your finger caught.

2) Remove Bkup (cam) speed sensor (2). a If the front cover is removed with Bkup (cam) speed sensor installed, the tip of camshaft may be damaged. 3) Remove mounting bolts (3), and remove front cover (4). 37.Rear oil seal 1) Install tool G to the crankshaft. 2) Screw in tapping screws [1] of tool G to the seal carrier part of rear oil seal (1). 3) Turn the handle clockwise, and remove rear oil seal (1).

35.Oil pump assembly Remove mounting bolts (1), and remove oil pump assembly (2).

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1) Remove camshaft gear (1).

38.Flywheel housing Remove mounting bolts (1), and remove flywheel housing (2).

39.Camshaft

2) Remove thrust plate (2).

3) Remove camshaft (3) while rotating it.

a Rotate the crankshaft to align timing mark (A part) of camshaft gear (1) to the chamfered teeth of crankshaft gear (4). (Above is necessary to prevent interference with the connecting rod when removing the camshaft.)

40.Gear housing Remove mounting bolt (1), and remove gear housing (2). 107E-2 SERIES

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41.Piston and connecting rod assembly 1) Rotate the crankshaft and bring the piston to be removed to the bottom dead center position. 2) Scrub the carbon off the top wall of the cylinder bore by using fine sandpaper. 3) Apply a marking of assembly position to each of connecting rod caps (1) on respective cylinders. a Before removing the piston and connecting rod assembly, measure the side clearance between the connecting rod and crankshaft by using tool K.

6) Push in the piston and connecting rod assembly by using a wooden bar, etc. from the oil pan side, and then remove it from the cylinder head side while supporting piston (6). a Take care not to damage the inner surface of the cylinder with a corner of the connecting rod. a Put the cylinder No. mark on the piston.

7) Remove the remaining piston and connecting rod assemblies according to the same procedure. 4) Remove mounting bolts (2). 5) Tap connecting rod cap (1) with a plastic hammer, and remove connecting rod cap (1) and connecting rod bearing as a unit. a Keep the connecting rod and connecting rod cap so that their mating faces is not damaged. If their mating faces are damaged, replace them.

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a Take care not to damage the sliding surfaces of the pistons, bearings, etc. 8) Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove snap ring (3). 2] Support connecting rod (4) with your hand, pull out piston pin (5) and disconnect piston (6) from the connecting rod. 3] Remove the snap ring on the opposite side.

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4] Remove piston ring (7) by using tool D. a Keep the piston, connecting rod, bearings, piston rings, and piston pin by cylinder.

1) Remove mounting bolt (2) of main cap (1). 2) Insert the bolt into the bolt hole of main cap (1), and remove the main cap while shaking it. a Installation position numbers are stamped on the main cap. No. 1 starts from the front side of the cylinder block. [4D107E-2]

42.Piston cooling nozzle Remove the mounting bolt (1), and remove piston cooling nozzle (2). [6D107E-2]

43.Crankshaft a Before removing the crankshaft, measure its end play (X) by using a dial gauge.

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a Check that the position number (the number is stamped in A part) of the main cap is directed toward the oil cooler.

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3) Remove lower bearing (3) from main cap (1).

[6D107E-2]

a Record the position number on the removed bearing in claw (A) of the bearing. (Do not use the bearing's sliding surface for the record.)

5) Remove upper thrust bearing (5) (1 piece) and upper bearing (6). 4) Sling crankshaft (4) by using a nylon sling, and remove it. a When slinging and removing the crankshaft, do not hit it against the cylinder block and damage the crankshaft.

a Mark the installation position on the main caps, upper bearings, and upper thrust bearings (use the back side for the bearings), and group them on a cap basis. And take care not to damage these parts.

a Keep the crankshaft in a safe place so that its sliding surfaces are not damaged. 4 Crankshaft: 45 kg (4D107E-2) 4 Crankshaft: 60 kg (6D107E-2) [4D107E-2] 44.Tappet Remove tappets (1) and mark the installation position on them. a Tappet must be installed to the original position if it is reused.

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45.Cylinder block Remove cylinder block (1) from tools A and B. 4 Cylinder block: 100 kg (4D107E-2) 4 Cylinder block: 140 kg (6D107E-2)

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General assembly of engine

(ENG107-A000-710-K-00-A)

a This assembly procedure is general assembly procedure for 107E-2. Since the shapes, quantity, locations, etc. of the parts may be different from the actual machine, check them before starting the work. a Parts must be installed to the original position. 1. Preparatory work 1) Install tool B to tool A. 2) Install cylinder block (1) to tools A and B. 4 Cylinder block: 100 kg (4D107E-2) 4 Cylinder block: 140 kg (6D107E-2)

3. Piston cooling nozzle Install piston cooling nozzle (2), and tighten it with bolt (1). 3 Mounting bolt: 15 Âą 2 Nm {1.5 Âą 0.2 kgm}

2. Tappet 1) Apply engine oil to tappet (1). 2 Tappet: Engine oil (EO15W-40)

4. Crankshaft 1) Install upper bearing (6), upper thrust bearing (5) (1 pieces). a Set the protruding part of the bearing to the notch of the cylinder block. a Check that no dirt or dust is sticking to the back side of the bearing before assembling. a Apply engine oil to inside wall of bearing. However, do not apply it to the back side. 2 Inside wall of bearing: Engine oil (EO15W-40)

2) Install tappets (1).

a When reusing the bearing, check the mark placed when it was disassembled, and install it to the original position.

a Tappet must be installed to the original position if it is reused. a Tappet may come off when assembling, do not reverse it more than 90 deg.

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a Check that dowel ring (7) is installed to the main cap.

2) Sling crankshaft (4) by using nylon sling, and install it. a Be careful not to damage the upper thrust bearing when installing. [4D107E-2]

4) Apply engine oil to journal surface of the crankshaft.

4 Crankshaft:

Engine oil (EO15W-40) 5) Check the punching mark No. of main cap (1), and install it. [4D107E-2]

45 kg

2 Journal surface:

a Install it in the order of [1] o [5] from the front side of cylinder block.

[6D107E-2] 4 Crankshaft: 60 kg

[6D107E-2] a Install it in the order of [1] o [7] from the front side of cylinder block.

3) Install the lower main bearing (3) to the main cap while matching its protrusion to the notch.

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a Install it directing the punching mark No. (A part) to oil cooler side. a Push it in by hitting it lightly with a plastic hammer or rubber hammer.

[6D107E-2]

6) Measure the stem lengths (a) of all mounting bolts by using tool X before screwing in main cap mounting bolt (2), and check that the lengths are within the allowable limit. • Allowable limit of bolt length: Less than 120.0 mm a If the bolt is longer than the using limit, do not reuse it but replace it. 3 Main cap mounting bolt

7) Tighten main cap mounting bolts (2) in the order shown in the figure.

• When the bolt is reused: 1] 60 ± 5 Nm {6.1 ± 0.5 kgm} 2] 80 ± 5 Nm {8.2 ± 0.5 kgm} 3] 90 ± 5 deg. (angle tightening tool J is used) • When the bolt is new: 1] 120 ± 10 Nm {12.2 ± 1.02 kgm} 2] Loosen it by 360 deg. 3] 60 ± 5 Nm {6.1 ± 0.5 kgm} 4] 85 ± 5 Nm {8.7 ± 0.5 kgm} 5] 120 ± 5 deg. (angle tightening tool J is used)

a Apply engine oil to the threaded part and the seat surface of the bolt. 2 Main cap mounting bolt: Engine oil (EO15W-40) [4D107E-2]

• When tool J is not used

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Put the mark on the main cap and bolt with paint, and retighten the bolt. When the bolt is reused: 90 ± 5 deg. When the bolt is new: 120 ± 5 deg.

8) After tightening the bolt, rotate the crankshaft to check for smooth rotation. 9) Measure the end play of crankshaft by using dial gauge.

3) Install second ring (10) directing the punching mark "TOP" near the abutment joint upward. 4) Install top ring (11) directing the punching mark "dot" near the abutment joint upward. 5) Install each ring directing the abutment joint to the direction other than the direction of thrust and opposite direction of thrust, and axial direction of piston.

a End play X: 0.24 ± 0.175 mm

5. Piston and connecting rod assembly 1) Install piston ring (7) to the piston by using tool D.

6) Apply engine oil to piston ring and piston skirt. 2 Piston ring: Engine oil (EO15W-40) 2 Piston skirt: Engine oil (EO15W-40) 7) Assembling of piston and connecting rod a Connecting rod (4) must face to the direction shown in the figure when directing "FRONT" mark on the head of piston (6) upward.

2) Installation of oil ring Fit oil ring (9) so that its abutment joint is 180 deg. away from the end of expander (8)

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a Do not damage mating surfaces of connecting rod and connecting rod cap by hitting when disassembling. When the connecting rod is damaged, replace it. a Ensure that foreign material is not attached to the back side of the bearing. a Install the bearing to connecting rod and connecting rod cap while matching its protrusion to the notches.

1] Apply engine oil to piston pin hole and piston pin. 2 Piston pin hole: Engine oil (EO15W-40) 2 Piston pin: Engine oil (EO15W-40)

10)Set the crankshaft of the cylinder to be installed at the bottom dead center, and apply engine oil to inner surface of cylinder. 2 Inner surface of cylinder: Engine oil (EO15W-40) 11)Insert piston and connecting rod assembly directing "FRONT" mark of piston (6) to the front of cylinder block. a Check the directions of the abutment joint of the piston rings again. 2] Insert connecting rod (4) into piston (6), and insert piston pin (5). 3] Attach snap rings (3) on both sides. 8)

9) Install the bearing to connecting rod and connecting rod cap.

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a Be careful not to damage the cylinder wall when inserting the connecting rod. a Be careful not to hit the cooling nozzle when installing it.

a Compress the piston rings by using tool E, and push in the piston head with a wood bar, etc.

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12)Tighten bolt (1) according to the following procedure, and install connecting rod cap (2).

[6D107E-2]

a Apply engine oil to the threaded part of the bolt and the inner surface of connecting rod bearing. 2 Connecting rod threaded part: Engine oil (EO15W-40) 2 Inside wall of connecting rod bearing: Engine oil (EO15W-40)

• When tool J is not used Put the mark on the cap and bolt with paint, and retighten the bolt 60 ± 5 deg.

a Perform angle tightening by using tool J. 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 deg. (angle tightening tool J is used) [4D107E-2]

13)Check that crankshaft rotates smoothly without any abnormality after installing piston and connecting rod assembly. 14)Measure the side clearance between connecting rod and crankshaft by using tool K. a Side clearance: 0.10 to 0.33 mm

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3 Mounting bolt • M12 (no mark) 77 ± 7 Nm {7.9 ± 0.7 kgm} • M10 (T T mark: l = 30, Q mark: l = 50): 47 ±5 Nm {4.8 ± 0.5 kgm} • M8 (E E mark): 24 ± 4 Nm {2.5 ± 0.4 kgm}

6. Gear housing 1) Apply the liquid gasket to the mounting surface (A part) of gear housing (2). a Apply a continuous bead of liquid gasket f 1 to 2mm in diameter. 2 Gear housing: Liquid gasket (LG-7) a If liquid gasket applied too much around the oil groove (B part) of blowby, it may block the groove. Do not apply the liquid gasket too much. 2) Check that dowel rings of the gear housing are securely inserted into the dowel holes (C) (2 places) of upper and lower cylinder blocks. a If tightening the bolt with dowel rings not properly inserted, it may damage the dowel rings. 3) Push the gear housing for mating surface with the cylinder block to be entirely attached.

7. Camshaft a Rotate the crankshaft so that No.1 cylinder comes to top dead center (TDC). 1) Apply engine oil to camshaft bore, camshaft journal, and lobe face. Push the camshaft (3) lightly, and install it rotating. a Install camshaft taking care not to damage the cam bushing. 2 Camshaft sliding surface: Engine oil (EO15W-40)

a Do not apply any torque to the mounting bolt before it is not entirely attached.

2) Install thrust plate (2). 3 Mounting bolt: 4) Tighten the mounting bolts in the order shown in the figure.

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24 ± 4 Nm {2.4 ± 0.4 kgm}

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1) Apply liquid gasket to the mounting flange surface of the flywheel housing (2) and around the mounting bolt holes. a Apply a continuous bead of liquid gasket f 1 to 2mm in diameter. 2 Flywheel housing: Liquid gasket (LG-7) 2) Install flywheel housing (2) with mounting bolt (1).

3) Install it aligning timing mark A part of camshaft gear (1) and chamfered teeth (1 place) of crankshaft gear (4). 3 Mounting bolt: 36 ± 4 Nm {3.7 ± 0.4 kgm}

3) Tighten mounting bolts (1) in the order shown in the figure. a When installing, be careful that there are 5 types of mounting bolts. 3 Mounting bolt • M12 (e e mark: l = 80, t mark: l = 110): 4) Measure the end play and backlash of camshaft by using dial gauge. a The amount of end play is determined by thickness of thrust plate and groove of camshaft. • End play: 0.23 ± 0.13 mm • Backlash: 0.178 ± 0.102 mm

85 ± 10 Nm {8.7 ± 1.0 kgm} • M10 (Q Q mark: l = 40, T mark: l = 80, E mark: l = 110): 49 ± 5 Nm {5.0 ± 0.5 kgm}

4) After installing the flywheel housing, measure the radial runout and facial runout by using tool L. • Measurement of radial runout 8. Flywheel housing

a Radial runout: Max. 0.20 mm 1] Set tool L to the end surface of crankshaft.

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2] Apply the probe of the dial gauge perpendicularly to the spigot joint part of the flywheel housing. 3] Set the dial gauge pointer to zero, rotate the crankshaft by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points.

a Do not remove pilot [1] attached to rear oil seal (1) until it is inserted into the crankshaft. a Before installing the rear oil seal, degrease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leakage.

a After the crankshaft is rotated by 1 turn, check that the dial gauge indicates the same value as it of the starting rotation.

1) Install pilot [1] to crankshaft (2), and insert rear oil seal (1) into flywheel housing (3). 2) Push in rear oil seal (1) further, and remove pilot [1].

â&#x20AC;˘ Measurement of facial runout a Facial runout: Max. 0.20 mm 1] Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end face of the flywheel housing. a When measuring, move the crankshaft to either front or rear end to eliminate error caused by the end play. 2] Set the dial gauge pointer to zero, rotate the crankshaft by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points.

3) Install rear oil seal (1) to the proper depth in flywheel housing (3) by using tool G. a When inserting rear oil seal (1), be careful that there are no bend etc. on it. a Protrusion of rear seal (1) from flywheel housing (3) X: Max. 0.38 mm

9. Rear oil seal

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a Tighten the bolts while preventing rotation of the flywheel by using plate [2].

10.Flywheel 1) Install guide bolt [1], and flywheel (2). 2 Flywheel mounting bolt: Engine oil (EO15W-40)

3) After installing flywheel (2), measure the radial runout and facial runout by using tool L. • Measurement of radial runout

4 Flywheel: 35 kg 2) Tighten mounting bolts (1) in the order shown in the figure. 3 Mounting bolt: 137 ± 7 Nm {14.0 ± 0.7 kgm}

a Radial runout: Max. 0.13 mm 1] Set tool L to the flywheel housing. 2] Set the probe of the dial gauge perpendicularly to the spigot joint part (a) or outside perimeter of the flywheel. 3] Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points. a When the flywheel rotated 1 turn, check that the dial gauge indicates the same value as it of the starting rotation. • Measurement of facial runout a Facial runout: Max. 0.20 mm 1] Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end face (b) near the outside perimeter of the flywheel.

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a When measuring, move the crankshaft to either front or rear end to eliminate error caused by the end play. 2] Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points.

2) Tighten the mounting bolts in the order shown in the figure. 3 Mounting bolt

11.Oil pump assembly a Fill the space in the oil pump rotor and idler shaft bore with engine oil, and rotate it by 2 turns.

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) Measuring backlash Lock either gear, and measure backlash (C) between the pump and idler gear. a Backlash (C): 0.2 ± 0.05 mm

2 Space in oil pump rotor Engine oil (EO15W-40) 2 Idler shaft bore Engine oil (EO15W-40)

12.Front cover 1) Apply the liquid gasket to the mounting surface (A part) of front cover (4). a Apply a continuous bead of liquid gasket 1 to 2mm in diameter. 1) Install oil pump assembly (2) with mounting bolt (1).

a When applying the liquid gasket, be careful that it does not enter the oil circuit (B part). 2 Front cover: Liquid gasket (LG-7)

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a When installing the front oil seal, do not apply either oil or grease to crankshaft and seal lip. Wipe off oil or grease thoroughly from the crankshaft.

a The deflection of front oil seal (1) from front cover (4) must meet the following criteria. • Protrusion (x): Max. 0.38 mm • Facial runout (TIR) (y): Max. 0.25 mm

2) Tighten mounting bolts (3) in the order shown in the figure. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 3) Install Bkup (cam) speed sensor (2). 3 Mounting bolt: 8 ± 2 Nm {0.8 ± 0.2 kgm} 13.Oil pan 1) Install plate (4). a Tighten hexagonal socket head bolt (A) (1 place) by using hexagonal wrench. 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 2) Install suction tube (3). 3 Flange mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} [4D107E-2] 4) Install front oil seal (1) by using tool H. a Before installing the front oil seal, check that the end corner and the lip sliding surface of the crankshaft are free from a flaw, burr, fin, and rust.

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[6D107E-2]

3) Remove the liquid gasket protruding from the place between the cylinder block and the gear housing and between the cylinder block and the front cover (4 places on t part) by using a scraper. a When removing and installing only the oil pan, remove the used liquid gasket filled in borders (4 places on t part) by using a scraper. 4) Apply liquid gasket to the place between the cylinder block and the gear housing and between the cylinder block and the front cover (4 places on t part).

[6D107E-2]

5) Install gasket (5) to the mounting face. a Do not apply oil when installing the gasket. a When installing, direct its silicone bead (B) toward the oil pan side. a Apply liquid gasket to the clinch part (4 places on e part) on both sides of the gasket. 2 Gasket (e e parts on both sides): Liquid gasket (LG-7) [4D107E-2]

2 Oil pan t part: Liquid gasket (LG-7) â&#x20AC;˘ Continuous bead of liquid gasket: 3 mm [4D107E-2]

[6D107E-2]

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6) Install oil pan (2) and plates (6) (2 pieces) with mounting bolts (1).

14.Crankshaft pulley vibration damper [4D107E-2] 1) Install crankshaft pulley (4) while aligning its dowel hole with dowel pin (b) of the crankshaft. 2) Tighten mounting bolts (5) according to the following procedure. 3 Mounting bolt (5):

7) Tighten mounting bolts (1) in the order shown in the figure. a Take care since 6 mounting bolts (Q part) of plate (6) have different lengths.

1] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2] Loosen the bolts 180 deg. 3] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4] Tighten the bolts diagonally by 90 deg. ± 5 deg. (Use angle tightening tool J)

3 Oil pan mounting bolt: 28 ± 2 Nm {2.9 ± 0.2 kgm} [4D107E-2]

• When not using angle tightening tool J Put marks on crankshaft pulley (4) and mounting bolt (5) with paint, and retighten the bolt by 90 deg. ± 5 deg. [6D107E-2]

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[6D107E-2] 1) Install vibration damper (2) while aligning its dowel hole to dowel pin (a) of the crankshaft. 2) Tighten mounting bolts (1) according to the following procedure. 3 Mounting bolt 1] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2] Loosen bolts by 180 deg. 3] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4] Tighten the bolts by 90 ± 5 deg. by using angle tightening tool J)

15.Engine controller 1) Install engine controller mounting bracket (3) with mounting bolts (4). a Do not install a stud bolt (A) (1 place) to a wrong place. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

2) Install engine controller (2) and ground (1) with mounting bolts (5). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

• When not using angle tightening tool J Put the mark on the vibration damper and mounting bolts with paint, and retighten the bolt to 90 ± 5 deg.

16.Cylinder head assembly 1) Assemble the cylinder head according to the following procedure:

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1] Install valve seal (7). 2] Apply engine oil to the valve stem and the inside of the valve guide, and install valve (6). 2 Valve stem and valve guide: Engine oil (EO15W-40)

3] Raise the cylinder head, and install valve spring (3) and upper seat (5).

mounting bolts, and check that the lengths are within the allowable limit. â&#x20AC;˘ Allowable limit of bolt length: Less than 132.1 mm a If a bolt is longer than the allowable limit, do not reuse it but replace it.

3) Check that the cylinder head mounting face and inside of the cylinders are free from dirt and foreign matter, and set cylinder head gasket (8). a Check that the holes of the gasket is fitted to those of the cylinder head. [4D107E-2]

4] Compress valve spring (3) and remove valve collet (4) by using tool C.

[6D107E-2]

a Check that the valve collet is fitted securely to the groove of the valve stem by hitting the valve stem part lightly with a plastic hammer. 2) Before tightening cylinder head mounting bolt, measure the stem lengths (a) of all 107E-2 SERIES

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4) Install cylinder head assembly (2) to the cylinder block. 4 Cylinder head assembly: 50 kg (4D107E-2)

3 Mounting bolt: 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 3] 90 ± 5 deg. (Perform angle tightening by using tool J.)

4 Cylinder head assembly: 75 kg (6D107E-2) 5) Tighten the mounting bolt (1) at least 2 to 3 turns first by fingers. a Apply engine oil to threaded part of mounting bolt and bolt head seat surface. 2 Threaded part and seat surface of head of mounting bolt: Engine oil (EO15W-40)

• When not using angle tightening tool J Put the mark on cylinder head and bolt with paint, and retighten the bolt to 90 ± 5 deg.

6) Tighten mounting bolts (1) in the order according to the following procedure. [4D107E-2] 3 Mounting bolt: 1] 2] 3] 4]

70 ± 6 Nm {7.1 ± 0.6 kg} Loosen it by 360 ± 5 deg. 105 ± 3 Nm {10.7 ± 0.3 kgm} 90 ± 5 deg. (Perform angle tightening by using tool J.) A: Exhaust side, B: Air intake side

17.Injector assembly a When replacing the injector with a new one, replace the inlet connector with a new one, as well. a Check that the injector sleeve is free of scratches and dirt. 1) Attach the gasket (6) and O-ring (7) to the injector (2). 2) Apply engine oil to O-ring (7) and the cylinder head side of injector (2). 2 O-ring and head side of injector:

[6D107E-2]

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Engine oil (EO15W-40) 3) Direct fuel inlet hole of injector (2) toward intake manifold side, and install it to cylinder head. 4) Install holder (4) and tighten mounting bolts (3) by 3 to 4 threads.

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a Check inlet connector on the following points. If any abnormality is found, replace it. 1] When there are burrs or wear on frontend part (a) or rear-end part (b) of inlet connector. 2] When there is foreign matter on edge filter at rear-end part (c) of inlet connector. 3] When there are cracks or deterioration on the O-ring of the inlet connector upper (d) part.

5) Apply engine oil to the O-ring and the head side of inlet connector (1). 2 O-ring and the head side of inlet connector: Engine oil (EO15W-40) 6) Insert inlet connector (1) to injector (2), and tighten retaining nut (5) lightly. a After tightening each of them lightly, tighten it to the specified torque. If tightening torque is insufficient or too much, it will cause fuel leakage inside the engine. a Install the inlet connector so that the positioning ball of inlet connector (7) comes to the guide groove on the head side. 3 Retaining nut (5) (tightening lightly): 15 ± 5 Nm {1.53 ± 0.51 kgm} 7) Tighten mounting bolts (3) alternately. 3 Holder mounting bolt:

4] When there is wear or uneven seat contact on seat surface (e) at front-end of inlet connector. a If high-pressure fuel leaks through the inlet connector, seat surface has fine streaks or cracks.

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8 ± 0.8 Nm {0.82 ± 0.08 kgm} 8) Tighten retaining nut (5) of inlet connector (1). 3 Retaining nut (5) (tightening to the specified torque): 50 ± 5 Nm {5.1 ± 0.5 kgm}

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18.Push rod 1) Pour engine oil to push rod socket part 2 Push rod socket part: Engine oil (EO15W-40) 2) Install push rods (1).

a Shape of hole of (a) and (b) parts of crosshead is not identical. When reusing them, use them with the same intake or exhaust valve, and also install them in the same direction.

a Check that push rod is fitted to tappet.

19.Rocker arm assembly and crosshead 1) Install crosshead (3). 2) Install rocker arm assembly (2), and tighten it with mounting bolts (1).

20.Adjusting valve clearance Adjust the valve clearance according to the following procedure. 1) Remove plug (1) under the starting motor and install tool V.

a Check that the spherical part of the adjustment screw is fitted properly in the socket of the push rod, and tighten the mounting bolt. 3 Mounting bolt: 36 Âą 5 Nm {3.7 Âą 0.5 kgm}

2) Rotate the crankshaft forward with tool V, and align the yellow paint part (line) of vibration damper (6) with the position of engine oil pan mounting bolt (7) as a straight line. a Yellow paint is painted on the tip of bolt (7).

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a When the crankshaft is set as above, the piston in the No. 1 or No. 6 cylinder is not set to the compression top dead center (TDC). (76 to 88 deg. before top dead center)

[6D107E-2]

3) Adjust the valve clearance according to the following procedure. a If you can move the rocker arm of air intake valves (IN) with the hand by the valve clearance amount, check the valves with Q mark in the valve arrangement drawing. a If you can move the rocker arm of exhaust valves (EX) with the hand by the valve clearance amount, check the valves marked with q in the valve arrangement drawing. a Valve arrangement drawing [4D107E-2]

1] Loosen lock nut (4) with adjustment screw (5) fixed. 2] Insert tool K (feeler gauge) into the clearance between rocker arm (2) and crosshead (3). 3] Adjust the valve clearance by using adjustment screw (5). a Turn the adjustment screw (5), and adjust it with feeler gauge inserted so that the feeler gauge can move lightly. a Adjust the valve clearance to be within the following target value. Intake valve Exhaust valve

0.25 ± 0.05 mm 0.51 ± 0.05 mm

4] Tighten lock nut (4) with adjustment screw (5) fixed. 3 Lock nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a Tighten lock nut (4), and check the valve clearance again.

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Color of wiring harness White Black [6D107E-2]

Cylinder No.

Color of wiring harness White Black

Cylinder No.

1, 3 2, 4

1, 3, 5 2, 4, 6

3 Mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} 4) In the same way as step 2), rotate the crankshaft forward with tool V, and align the yellow paint part (line) of vibration damper (6) with the position of engine oil pan mounting bolt (7) as a straight line. 5) Adjust the clearances of the other valves according to steps 3). a If the valves marked with Q in the valve arrangement drawing were adjusted in the previous step, adjust the rest valves marked with q. If valves marked with q are adjusted, adjust the valves marked with Q. 6) After adjustment of valve clearance is performed, remove tool V, and install plug (1). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

a Check that wiring harness does not interfere with rocker arm. a If the injector wiring harness connector (7) is removed, apply liquid gasket to Oring part (8) and flange surface (9) of connector when installing. a Apply a continuous bead of liquid gasket 3 mm in diameter to the O-ring part until O-ring groove is completely hidden. a When O-ring is damaged, replace it as the wiring harness assembly. 2 O-ring part (8) and flange surface (9) of connector: Liquid gasket (LG-7) 3 Connector flange mounting bolt (10): 10 ± 2 Nm {1 ± 0.2 kgm}

21.Rocker housing and head cover 1) Install rocker housing assembly (6) with mounting bolt (5). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 2) Install nut (4) of harness. a Installed positions of harnesses [4D107E-2]

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3) Install gasket, and install head cover (3) with mounting nut (2). 3 Mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install blowby duct (1). 3 Mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm} [4D107E-2]

23.Supply pump 1) Install supply pump gear (4) according to the following procedure. a Before installation, clean dusts and foreign substances on the mating surfaces of shaft (6) and gear (4), and keep the mating surfaces dry. 1] Install gear (4) to shaft (6). 2] Install lock washer (5) and nut (3), and finger-tighten the nut lightly.

[6D107E-2] 3] Fix the gear by using tool N and 1/2 spinner handle [1], and tighten nut (3). 3 Supply pump gear mounting nut: 105 ± 5 Nm {10.7 ± 0.51 kgm}

22.Boost pump [6D107E-2] Install gasket, and install boost pump (2) with mounting nut (1). 3 Mounting bolt: 77 ± 12 Nm {7.9 ± 1.2 kgm} 107E-2 SERIES

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2) Install supply pump (2) with mounting nuts (1) (3 pieces).

24.Intake manifold cover 1) Install gasket (1). a If grease is applied too much to O-ring (7), it will ooze out. Do not apply grease too much. (Apply it only to O-ring groove area of A part.)

a Direct the part number tag toward rear side when installing the gasket. [4D107E-2]

a When replacing supply pump stud bolt (8), apply Loctite to stud bolt (8). 3 Stud bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm}

[6D107E-2]

a Since it is difficult to install the cylinder block side nuts when installing supply pump assembly mounting nuts (1), be sure to use a new socket for their installation. 3 Supply pump assembly mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

2) Install intake manifold cover (2). 3 Intake manifold cover mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [4D107E-2]

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[6D107E-2]

25.Common rail pressure sensor and pressure limiter 1) Replace common rail pressure sensor (2) according to the following procedure. a Do not remove the common rail pressure sensor (2) from common rail (1) for a purpose other than replacement. a Be sure to replace the common rail pressure sensor removed from the common rail with a new one. 1] Before removing the common rail pressure sensor, clean the area around it, and remove dirt, etc. throughly. 2] Remove the common rail pressure sensor. 3] Check the common rail pressure sensor connector for crack, breakage, damage of the seal, foreign matter on the pin and corrosion, bend and breakage of the pin. 4] Install a new common rail pressure sensor.

[6D107E-2]

2) Replace pressure limiter (3) according to the following procedure. 1] Before removing pressure limiter, remove dirt and dusts on and around it. 2] Remove pressure limiter. 3] Do not use the pressure limiter if leakage is beyond the specified value. 4] Check that there is no damage on highpressure fuel sealing surfaces (A) on the pressure limiter and common rail. 5] Install pressure limiter. a Be careful not to tighten excessively since it can cause leakage. 2 Threaded part of pressure limiter: Gear oil (#90) 3 Pressure limiter: 100 Âą 4 Nm {10.2 Âą 0.4 kgm}

2 Threaded part of common rail pressure sensor: Gear oil (#90) 3 Common rail pressure sensor: 70 Âą 5 Nm {7.1 Âą 0.5 kgm} [4D107E-2] 107E-2 SERIES

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2 Threaded part of common rail mounting bolt: Liquid gasket (LG-7) 3 Mounting bolt and sleeve nut (lightly tightening):

26.High-pressure pipe and common rail k Do

not bend the fuel high-pressure pipe to correct before installing.

k Be

sure to use the genuine fuel highpressure pipe clamp and strictly observe the specified tightening torque.

k Install

each fuel high-pressure pipe and wiring harness at least 10mm apart from each other.

a A fuel high-pressure pipe must be replaced if dents such as slits (b) or spots (c) are visually recognizable in taper seal part (a) (in 2 mm area from tip part) of its connection, or if level difference in part (d) (2mm from tip part) due to fatigue is large enough to catch your fingers because such fuel high-pressure pipe can induce fuel leakage.

0.2 to 0.8 Nm {0.02 to 0.08 kgm} 2) Tighten fuel high-pressure pipes (1) to (4) according to the following procedure. 1] Fuel high-pressure pipe ((1): connector side) o ((2): connector side) o ((1): common rail side) o ((2): common rail side) 2] Fuel high-pressure pipe ((3): connector side) o ((4): connector side) o ((3): common rail side) o ((4): common rail side) 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3) Lightly tighten fuel high-pressure pipe (5) and tube clamp (7). 4) Tighten fuel high-pressure pipe (5) in the order of supply pump side o common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 5) Tighten common rail (8). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 6) Fasten tube clamp (7) to the specified torque. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 7) Install fuel spray prevention cap (6). k Direct

the slits of fuel spray prevention cap outward or downward When installing it.

[4D107E-2] 1) Lightly tighten common rail (8) and fuel highpressure pipes (1) to (4). a Apply liquid gasket to threaded part of bolts (2 pieces) on the engine side when installing the common rail.

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7) Install fuel spray prevention cap (8). k Direct

the slits of fuel spray prevention cap outward or downward When installing it.

[6D107E-2] 1) Lightly tighten common rail (10) and fuel high-pressure pipes (1) to (6). a Apply liquid gasket to threaded part of bolts (2 pieces) on the engine side when installing the common rail. 2 Threaded part of common rail mounting bolt: Liquid gasket (LG-7) 3 Mounting bolt and sleeve nut (lightly tightening): 0.2 to 0.8 Nm {0.02 to 0.08 kgm} 2) Tighten fuel high-pressure pipes (1) to (6) according to the following procedure.

27.Fan hub Install fan hub (2) with mounting bolts (1). a Leave a bolt untightened, and perform the tightening of it after installing the wiring harness bracket. 3 Mounting bolt: 32 ± 5 Nm {3.3 ± 0.5 kgm}

1] Fuel high-pressure pipe ((1): Connector side) o ((2): Connector side) o ((3): Connector side) o ((1): Common rail side) o ((2): Common rail side) o ((3): Common rail side) 2] Fuel high-pressure pipe ((4): Connector side) o ((5): Connector side) o ((6): Connector side) o ((4): Common rail side) o ((5): Common rail side) o ((6): Common rail side) 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3) Lightly tighten fuel high-pressure pipe (7) and tube clamp (9). 4) Tighten fuel high-pressure pipe (7) in the order of supply pump side o common rail side.

28.Water pump Install seal ring, and install water pump (1) according to the following procedure. 3 Mounting bolt (2) 1st time: 8 ± 1 Nm {0.8 ± 0.1 kgm} 2nd time: 30 ± 4 Nm {3.1 ± 0.4 kgm}

3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 5) Tighten common rail (10). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 6) Fasten tube clamp (9) to the specified torque. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 107E-2 SERIES

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29.Thermostat 1) Install thermostat (3).

2) Install EGR valve (2) with mounting bolts (3) (4 pieces). 3 Mounting bolt (3): 24 ± 4 Nm {2.45 ± 0.41 kgm}

2) Install coolant outlet connector (2) with mounting bolts (1). 3 Mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}

[6D107E-2] 1) Install gasket (1). a Direct the part number tag toward rear side when installing the gasket.

30.EGR valve and tubes [4D107E-2] 1) Install gasket (1).

2) Install intake manifold connector (2) with mounting bolts (3). 3 Intake manifold connector mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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• Top (EGR valve side) 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} • Mid position and bottom (engine side) 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 9) Install tube (11). 3 Sleeve nut: 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 10)Fasten tube clamp (12). 3) Install gasket, and install EGR valve (4) with mounting nut (5).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3 Intake manifold connector mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}

11)Install spill tube (15).

4) If there is any items removed from the cylinder block side, tighten them with the following torques. • If oil drain connector (13) has been removed and ring seal has been replaced.

3 Joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 12)Fasten tube clamp (16). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3 Mounting bolt: 77 ± 12 Nm {7.9 ± 1.2 kgm} • If tube bracket (14) is removed. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Install tube (6). 3 Sleeve nut: 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 6) Fasten tube clamp (7). 3 Stud bolt: 77 ± 12 Nm {7.9 ± 1.2 kgm} 7) Fasten tube clamp (8). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 8) Install bracket (9) to EGR valve (4) with mounting bolts (10) (4 pieces). 107E-2 SERIES

31.Harness assembly [4D107E-2] Install the connector, clamp, and band, and install wiring harness assembly (1). a Install the sensor, lock it with stopper to prevent falling off, and check that the connector is securely connected.

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• Exhaust manifold pressure sensor connector (2) • Common rail pressure sensor (3)

• • • •

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} Ambient pressure sensor connector (15) Charge (boost) pressure and temperature sensor connector (16) Wiring harness connector (17) Wiring harness connector (ECM) (18) a Wiring harness connector (ECM) (18) is locked with hexagonal socket head bolt (19) (4mm). 3 Mounting bolt (19): 3 ± 1 Nm {0.31 ± 0.1 kgm}

• Coolant temperature sensor connector (4) • Wiring harness clamp (5) 3 Mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm} • Engine oil pressure switch connector (6) • Bkup (cam) speed sensor connector (7) • Ne (crankshaft) speed sensor connector (8)

[6D107E-2] Install the connector, clamp, and band, and install wiring harness assembly (1). a Install the sensor, lock it with stopper to prevent falling off, and check that the connector is securely connected. • Coolant temperature sensor connector (3) • Wiring harness bracket (4) 3 Mounting bolt: • Wiring harness clamps (9) and (10) 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} • Wiring harness connector (11) • Band (12)

24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Fan hub mounting bolt: 32 ± 5 Nm {3.3 ± 0.5 kgm} • Wiring harness clamp (5) 3 Mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}

• Wiring harness clamps (13) and (14)

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• Engine oil pressure switch connector (6) • Bkup (cam) speed sensor connector (7) • Ne (crankshaft) speed sensor connector (8)

• Wiring harness connector (20) • Band (21) • Wiring harness clamp (22) a It is tightened together with wiring harness bracket (23). • Wiring harness bracket (23) 3 Mounting nut: 10 ± 2 Nm {1.0 ± 0.2 kgm} • Wiring harness connector (ECM) (24) a Fix wiring harness connector (ECM) (24) with hexagonal socket head bolt (25) (4 mm). 3 Hexagonal socket head bolt (25): 3 ± 1 Nm {0.31 ± 0.1 kgm}

• Wiring harness clamps (9) and (19) 3 Mounting bolt (9): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Mounting bolt (19): 43 ± 6 Nm {4.4 ± 0.6 kgm} • Ambient pressure sensor connector (10) • Wiring harness connector (11)

• Bracket (26) a Secure the clearance Min. 4 mm between the head cover and nipple for exhaust manifold pressure. 3 Mounting bolt:

• • • • •

Band (12) Wiring harness brackets (13) and (14) Wiring harness connectors (15) and (16) Common rail pressure sensor connector (17) Charge (boost) pressure and temperature sensor connector (18)

107E-2 SERIES

24 ± 4 Nm {2.45 ± 0.41 kgm} • Exhaust manifold pressure sensor connector (2) • Wiring harness connector box (INTER CONNECT) (27)

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50 Disassembly and assembly Disassembly and assembly

32.Tube, intake air heater, and dipstick pipe [4D107E-2] 1) Install gasket, and install tube (1) and intake air heater (2). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} a Install the gasket plate between intake air heater (2) and intake manifold connector (6) from the direction of intake manifold connector (6). 2) Install dipstick pipe (3) together with bracket (4) and (5). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

33.Alternator bracket 1) Install sling bracket (2). 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 2) Install alternator bracket (1). a Install tube, and install alternator. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

[6D107E-2] a Install the gasket plate between intake air heater (2) and intake manifold connector (6) from the direction of intake manifold connector (6).

34.Fan pulley Install fan pulley (1). 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}

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2) Tighten the mounting bolts in the order shown in the figure. a When installing, be careful that there are 3 types of mounting bolts. (No mark: 6 pieces, e mark: 4 pieces, t mark: 5 pieces) (No mark: 7 pieces, e mark: 4 pieces, t mark: 4 pieces) [6D107E-2] 3 Mounting bolt:

35.Removal from engine repair stand

1] 15 ± 4 Nm {1.5 ± 0.4 kgm} 2] 27 ± 4 Nm {2.8 ± 0.4 kgm} [4D107E-2]

1) Set tool P to engine assembly (1), and disconnect it from tool A. 4 Engine assembly Approximately. 440 kg (4D107E-2) 4 Engine assembly Approximately 520 kg (4D107E-2) (The weight depends on the applicable machine model.) 2) Remove tool B from engine assembly (1). [6D107E-2]

36.Oil cooler 1) Install cooler gasket (8), oil cooler (7), cover gasket (6), and cover (5).

37.Coolant inlet connector and tensioner assembly. 1) Install seal ring, and coolant inlet connector (1). 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 2) Install tensioner assembly (2). a Check that belt mounting parts of tensioner pulley and alternator pulley are parallel by visual check or using a ruler. 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}

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1) Install heat insulation plate (1). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 2) Install bracket (2). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3) Lightly tighten EGR cooler (3) to bracket (2). a Tighten exhaust manifold lightly, and tighten it to the specified torque. 4) Install tube (4) to EGR cooler (3). 38.EGR cooler, and heat insulation plate. [4D107E-2] 1) Install bracket (8) with mounting bolts (7a) and (7b).

3 Mounting bolt: 9.5 ± 2 Nm {0.97 ± 0.2 kgm} 3 Hose clamp: 5 ± 1 Nm {0.5 ± 0.1 kgm}

3 Mounting bolt (7a): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Mounting bolt (7b): 43 ± 6 Nm {4.38 ± 0.61 kgm}

39.Exhaust manifold assembly 1) Install a gasket, and lightly tighten exhaust manifold (1) to cylinder head and EGR cooler (3) with mounting bolts (4) and (5). 2) Lightly tighten EGR cooler (1) to bracket (5). a Tighten exhaust manifold lightly, and tighten it to the specified torque. 3) Install tube (3) to EGR cooler (1). 3 Hose clamp: 5 ± 1 Nm {0.5 ± 0.1 kgm}

a Adjust the cylinder head, exhaust manifold, and EGR cooler by loosening and tightening the mounting bolts so that there is no phase shift or play in them. 2) Tighten exhaust manifold mounting bolts (4) to the specified torque in the order shown in the figure. 3 Mounting bolt: 1] Tighten bolts in the order of [1] to [12] as shown in the figure to 53 ± 5 Nm {5.4 ± 0.5 kgm}. 2] Retighten bolts [1] to [4] shown in the figure to 53 ± 5 Nm {5.4 ± 0.5 kgm}. 3) Tighten mounting bolt (5) to the specified torque.

[6D107E-2]

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3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 4) Tighten EGR cooler (3) to bracket with the specified torque.

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50 Disassembly and assembly Disassembly and assembly

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [4D107E-2]

5) Install tube (6). 3 Sleeve nut (sensor bracket side): 24.5 ± 9.8 Nm {2.5 ± 1.0 kgm} 3 Sleeve nut (exhaust manifold side): 18 ± 3 Nm {1.8 ± 0.3 kgm} [4D107E-2]

[6D107E-2]

40.EGR cooler piping [4D107E-2] 1) Install tube (2). 3 Hose clamp (2): 5 ± 1Nm {0.5 ± 0.1 kgm} 2) Install tube clamps (5). 3 Mounting bolt (5): 24 ± 4 Nm {24 ± 4 kgm}

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a Install the sensor, lock it with stopper to prevent falling off, and check that the connector is securely connected.

3) Install tube (1). 3 Joint bolt: 12 ± 2Nm {1.2 ± 0.2 kgm}

[6D107E-2] 1) Install tube (1). 3 Joint bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm} 3 Sleeve nut: 15 ± 1 Nm {1.5 ± 0.1 kgm}

4) Install gasket and install tube (6) to EGR cooler side. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Install bracket (12). 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 6) Install tube clamp (7) of tube (6) to bracket. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 7) Connect tube (6) and EGR piping flange (8) with hose (9), and fasten it with hose clamp (10). 3 Hose clamp: 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm} 8) Install gasket, and install EGR piping flange (8).

2) Install tube (2). 3 Hose clamp (3): 5 ± 1 Nm {0.5 ± 0.1 kgm} 3 Tube mounting joint (4): 9.5 ± 2 Nm {0.96 ± 0.2 kgm} 3) Install tube clamps (5). 3 Mounting nut: 9.5 ± 2 Nm {0.96 ± 0.2 kgm}

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 9) Install EGR orifice temperature sensor connector (EXHAUST GAS TEMPERATURE) (11).

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4) Install gasket and install tube (6) to EGR cooler side. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Install tube clamp (7) of tube (6) to bracket. 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 6) Connect tube (6) and EGR piping flange (8) with hose (9), and fasten it with hose clamp (10). 3 Hose clamp: 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm} 7) Install gasket, and install EGR piping flange (8).

41.VFT and KVGT [4D107E-2] 1) Install gasket, and install VFT (11). 4 VFT: 15 kg 3 Mounting nut (4): 43 ± 6 Nm {4.4 ± 0.6 kgm} a Tighten the mounting nuts in diagonal order. 2) Install harness connector (3).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 8) Install EGR orifice temperature sensor connector (EXHAUST GAS TEMPERATURE) (11). a Install the sensor, lock it with stopper to prevent falling off, and check that the connector is securely connected. 3) Install tube (12). 3 Mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm} 4) Install tube (13). 3 Mounting bolt (VFT side): 9.8 to 12.7 Nm {1.0 to 1.3 kgm} 3 Tube (13) (oil cooler side): 35 ± 5 Nm {1.0 ± 1.3 kgm}

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6) Install heat insulation cover (2) with mounting bolts (1) (6 pieces). 3 Mounting bolt: 8.8 to 10.8 Nm {0.9 to 1.1 kgm}

5) For the water-cooled turbocharger, install the tubes according to the following procedure. 1] Tighten tube (10) with joints (8) and (9). 3 Joint (8): 12 ± 2 Nm {1.2 ± 0.2 kgm} 3 Joint (9): 65 ± 6 Nm {6.63 ± 0.61 kgm} 2] Tighten tubes (6) and (7) with joints (5) and (5a). 3 Joint (5): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Joint (5a): 12 ± 2 Nm {1.2 ± 0.2 kgm}

[6D107E-2] 1) Install gasket, and install KVGT (1). 4 KVGT: 25 kg 3 Mounting nut: 43 ± 6 Nm {4.4 ± 0.6 kgm} a Tighten the mounting nuts in diagonal order. 2) Install a gasket, and install KVGT return tube (2). 3 Hose clamp: 5 ± 1 Nm {0.5 ± 0.1 kgm} 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3) Install tube (3). a KVGT side is tightened together. 3 Sleeve nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install tube (4). a KVGT side is tightened together.

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3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Install tube (5). a KVGT side is tightened together. a Install the eye joint which is tightened with tube (5) so that its mounting angle becomes 15 deg. ± 5 deg. 3 Sleeve nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

42.Alternator Install alternator (3) with mounting bolts (1) and (2). 3 Mounting bolt (1): 43 ± 6 Nm {4.4 ± 0.6 kgm} 3 Mounting bolt (2): 24 ± 4 Nm {2.45 ± 0.41 kgm}

43.Fan 1) Install fan belt (1). 6) Install hoses (7) and (8) to EGR valve. • Hose (7): KVGT control pressure circuit 3 Sleeve nut: 25 ± 1.5 Nm {2.6 ± 0.15 kgm} • Hose (8): KVGT drive hydraulic circuit 3 Sleeve nut: 15 ± 1 Nm {1.5 ± 0.1 kgm} 7) Install connectors (9) and (10). • Connector (9): KVGT position sensor (SVGT) • Connector (10): KVGT speed sensor (VGT_REV)

a Insert a wrench in A part (width across flatsT12.7 mm) of the tensioner assembly (2), and install the fan belt (1) as rotating it in the counter-direction (R) to the winding-up direction. k Be

sure that wrench is set securely to A part of tensioner assembly (2) before turning it. (Since the spring force of tensioner assembly (2) is strong, the wrench may come off and is very dangerous if it is turned when it is not attached securely.)

k After

installing fan belt (1), slowly and carefully restore tensioner assembly (2).

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k Be

careful not to get your fingers caught between the pulley and fan belt (1) during work.

[4D107E-2]

[6D107E-2]

45.Oil filter Install oil filter hose (1) and (2).

2) Install fan (3).

44.Starting motor assembly Install gasket, and install starting assembly (2) with mounting bolt (1).

3 Sleeve nut: 177 to 245 Nm {17.7 to 24.5 kgm} [4D107E-2]

[6D107E-2]

3 Mounting bolt: 43 Âą 6 Nm {4.4 Âą 0.6 kgm} [4D107E-2]

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46.Fuel filter assembly Install fuel filter hoses (2) and (3) to supply pump (1). a The internal parts of the hose fitting may be damaged when the fuel filter hose is disconnected. It is, therefore, prohibited as a rule to reuse the hose. Replace the hose with a new one when reassembling it. a Insert the fuel filter hose straight as pushing lock (L) without twisting or shaking it. a If it is difficult to insert it, do not push it in forcibly but pull it out once. Then, check concave and convex part for damage and dirt.

47.Dipstick pipe and tube [4D107E-2] 1) Apply adhesive to the guide when removing and installing dipstick pipe (1) and tube (2), and drive them in.

107E-2 SERIES

[6D107E-2] 1) Apply adhesive to the guide when removing and installing dipstick pipe (1) and tube (2), and drive them in. 2 Installing position of dipstick pipe and tube. Adhesive (LT-4) 2) When removing and installing hose (3) and check valve (4) of tube (2), or replacing them, set the gray part of check valve (4) so that it comes to the left. 3 Hose clamp: 3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}

48.Tightening torque of sensor When removing and installing the sensor, or replacing it, tighten it to the following torque. Sensor name Coolant temperature sensor Engine oil pressure switch Ne (crankshaft) speed sensor Ambient pressure sensor Charge (boost) pressure and temperature sensor

Tightening torque 20 ± 3 Nm {2.04 ± 0.31 kgm} 8 ± 2 Nm {0.82 ± 0.2 kgm} 8 ± 2 Nm {0.82 ± 0.2 kgm} 8 ± 2 Nm {0.82 ± 0.2 kgm} 8 ± 2 Nm {0.82 ± 0.2 kgm}

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Sensor name Exhaust manifold pressure sensor EGR orifice temperature sensor

Tightening torque 20 ± 3 Nm {2.04 ± 0.31 kgm} 20 ± 3 Nm {2.04 ± 0.31 kgm}

49.Check for fuel leakage a When removing and installing fuel supply pump (1), common rail (2), and fuel highpressure piping, check for fuel leakage by the following method after assembling the engine. [4D107E-2]

a If any fuel leakage is detected, repair it, and perform the checks from step 2) again. 4) Start the engine, and keep it running at low idle. 5) Check the fuel piping and devices for fuel leakage. a Check the fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it, and perform the checks from step 2) again. 6) Start the engine, and keep it running at high idle. 7) Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed.

[6D107E-2]

a If any fuel leakage is detected, repair it, and perform the checks from step 2) again. 8) Start the engine and keep it running at high idle, and apply a load to the engine. a When checking the engine for leakage as it is installed on the machine, stall the torque converter or relieve the hydraulic pump. 9) Check the fuel piping and devices for fuel leakage. a Check the fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it, and perform the checks from step 2) again.

a Clean the engine and the parts around it and degrease them in advance so that you can check easily for fuel leakage.

a If no fuel leakage is detected, check is complete.

1) Spray color checker (developer) to the joints of supply pump, common rail, and fuel highpressure pipe. 2) Start the engine, keep its speed at 1,000 rpm or below, and stop it when its speed is stabilized. 3) Check the fuel piping and devices for fuel leakage. a Check the fuel high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed.

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Removal and installation procedure of supply pump unit alone

(ENG107-AD70-924-

K-00-A)

Removal

(ENG107-AD70-520-K-00-A)

1. Disconnect fuel filter hoses (9) and (10) from supply pump (2). [*1] a Pull out hose to the direction (a) while pressing lock (L) on both sides.

3) Remove fuel spray prevention cap (12). 4) Disconnect tube clamp (13). 5) Remove fuel high-pressure pipe (16). 4. Remove spill tube (15). [*3]

2. Disconnect harness connector (11). [4D107E-2] 3. Install the high-pressure fuel pipe (16) according to the following procedure. [*2] 1) Remove mounting bolt (20), and remove cover (19).

2) Remove mounting nuts (18) (3 pieces) and bolt (18a) to remove bracket (17).

[6D107E-2] 5. Install the high-pressure fuel pipe (16) according to the following procedure. [*2] 1) Remove fuel spray prevention cap (12). 2) Disconnect tube clamp (13). 3) Remove fuel high-pressure pipe (16). 6. Remove spill tube (15) according to the following procedures. [*3] 1) Disconnect tube clamp (14). 2) Remove spill tube (15).

a Bracket (17) and cover (19) are installed so that fuel will not spout over the high temperature parts of the engine and catch fire when it leaks by any chance.

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7. Remove nuts (1) (3 pieces) , and remove supply pump (2). [*4]

2) Install puller [2] between the flange and gear (4).

a Pull supply pump (2) sideways straight when removing it. Otherwise the pump assembly may interfere with the top of boost pump (17).

3) Install puller [3] on puller [2] and the shaft. 4) Screw in center bolt [4] until the gear is disengaged from the shaft. 5) Remove pullers [2] and [3]. a Supply pump (2) comes off together with gear. The gear is not worked on its teeth (no missing tooth) to show the mark for 1, 6 TOP adjustment.

6) Remove nut (3), lock washer (5) and gear (4) from shaft (6).

8. Remove the gear from the supply pump (2) according to the following procedure. [*5] 1) Fix the gear by using tool N and 1/2 inch spinner handle [1], and loosen nut (3). a Do not remove nut (3) from the shaft.

Installation

(ENG107-AD70-720-K-00-A)

Perform installation in the reverse order to removal. [*1] When installing a connector of quick coupling type, observe the following points.

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a The internal parts of the fitting of the hose or tube may be damaged when it is once disconnected. Do not reuse them. For installation, replace it with a new one. a Ensure that mud or dirt is not sticking to the hose joint portions in advance. a Push the connector and insert it straight (in the direction (b)) without prying or shaking it. If it is difficult to insert it, do not push it in forcibly but pull it out once. Then, check concave and convex part for damage and dirt. [*3] 3 Spill tube (15) mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Tube clamp (14) mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [*4] Install supply pump (2). a If grease is applied too much to O-ring (7), it will ooze out. Do not apply grease too much. (Apply it only to O-ring groove area of A part.) [*2] Procedure for installing high-pressure pipe (16)

a When replacing supply pump stud bolt (8), apply Loctite to stud bolt (8).

1. Tighten sleeve nut by hand. (both sides) 2. Tighten the sleeve nuts in the order of the supply pump side o the common rail side.

3 Stud bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm}

3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3. Install tube clamps (13) (2 pieces). 3 Clamp mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4. Install fuel spray prevention cap (12). a Direct slits of fuel spray prevention caps outward and downward. a The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the engine and catch fire when it leaks by any chance. 5. Install bracket (17) and cover (19). 3 Mounting nut (18): 13 ± 1 Nm {1.35 ± 0.15 kgm} 3 Mounting bolt (18a): 67 ± 7 Nm {6.75 ± 0.75 kgm} 3 Mounting bolt (20): 31 ± 3 Nm {3.15 ± 0.35 kgm}

107E-2 SERIES

a Since it is difficult to install the cylinder block side nuts when installing supply pump mounting nuts (1), be sure to use a new socket for the installation. a If an old socket is used, the nut may fall off or be damaged due to excess clearance between the socket and mounting nut (33). 3 Supply pump mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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[*5] Procedure for installing gear (4) a Before installation, clean dusts and foreign substances on the mating surfaces of shaft (6) and gear (4), and keep the mating surfaces dry. 1. Install gear (4) to shaft (6). 2. Install lock washer (3) and nut (5), and fingertighten the nut lightly.

3. Fix the gear by using tool N and 1/2 spinner handle [1], and tighten nut (3). 3 Supply pump gear mounting nut: 105 Âą 5 Nm {10.7 Âą 0.51 kgm}

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Engine front oil seal replacement procedure Removal

(ENG107-A350-924-K-00-A)

(ENG107-A350-520-K-00-A)

1. Remove fan (3).

4. Remove mounting bolts (5) (6 pieces), and remove vibration damper (4). 2. Remove fan belt (1). a Set a wrench into A part of tensioner assembly (2) (width across flats: T12.7mm) and turn it in the opposite direction (R) to the winding-up direction to loosen the fan belt (1). k Be

k After

removing fan belt (1), return tensioner assembly (2) to its original position slowly and carefully.

k Be

careful not to get your fingers caught between the pulley and fan belt (1) during work.

3. Remove mounting bolts (5) (6 pieces), and remove crankshaft pulley (4).

107E-2 SERIES

5. Remove engine front oil seal (6) according to the following procedure. 1) Install tool H to the crankshaft. 2) Screw in tapping screw [1] of tool H to the seal carrier section of engine front oil seal (6). 3) Turn the handle clockwise, and remove engine front oil seal (6).

a Be careful not to damage the crankshaft when removing the oil seal.

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2. Crankshaft pulley and vibration damper [4D107E-2] 1) Install crankshaft pulley (4) while aligning its dowel hole with dowel pin (b) of the crankshaft. 2) Tighten mounting bolts (5) according to the following procedure. 3 1]

Installation

(ENG107-A350-720-K-00-A)

1. Install engine front oil seal (6) by using tool H. a Before installing the engine front oil seal, check that the end corner and the lip sliding surface of the crankshaft are free from a flaw, burr, fin, and rust.

2] 3] 4]

Mounting bolt (5): Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. Loosen the bolts 180 deg. Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. Tighten the bolts by 90 deg. ± 5 deg. (Use angle tightening tool J)

a When installing the engine front oil seal, do not apply oil or grease to the crankshaft and seal lip. Also, thoroughly wipe off oil or grease from the crankshaft.

• When an angle tightening tool J is not used Put marks on crankshaft pulley (4) and mounting bolts (5) in paint, and retighten the bolts by 90 deg. ± 5 deg.

a Measure the protrusion and facial runout of engine front oil seal (6) from cover (7). a Protrusion x: Max. 0.38 mm a Facial runout y: Max. 0.25 mm

[6D107E-2] 1) Install vibration damper (4) while aligning its dowel hole to dowel pin B of the crankshaft. 2) Tightening procedure for vibration damper mounting bolts (5) 3 Vibration damper mounting bolt:

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1] Tighten the bolts diagonally to 55 ± 5 Nm {5.61 ± 0.51 kgm}. 2] Loosen bolts by 180 deg. 3] Tighten the bolts diagonally to 55 ± 5 Nm {5.61 ± 0.51 kgm}. 4] Retighten them 90 ± 5 deg. in a diagonal order.

k After

installing fan belt (1), slowly and carefully restore tensioner assembly (2).

k Be

careful not to get your fingers caught between the pulley and fan belt (1) during work.

a Perform angle tightening by using tool J.

4. Install fan (3).

• When an angle tightening tool is not used Put marks on the vibration damper and bolts with a felt-tip pen and retighten the bolts to 90 ± 5 deg.

3. Install fan belt (1). a Insert a wrench in A part (width across flatsT12.7mm) of the tensioner assembly (2), and install the fan belt (1) as rotating it in the counter-direction (R) to the winding-up direction. k Be

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50 Disassembly and assembly Disassembly and assembly

Engine rear oil seal replacement procedure Removal

(ENG107-A510-924-K-00-A)

(ENG107-A510-520-K-00-A)

1. Remove mounting bolts (1), and insert guide bolt [1]. 2. Set slings to flywheel assembly (2), and pull it (2) out. a Be careful not to pull out the guide bolt when removing the flywheel. 3. Sling flywheel assembly (2), and remove it. 4 Flywheel assembly: 35 kg

Installation

(ENG107-A510-720-K-00-A)

a Do not remove pilot [3] attached to engine rear oil seal (3) until it is inserted into the crankshaft. a Before installing the engine rear oil seal, degrease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leakage.

4. Remove engine rear oil seal (3) according to the following procedure. 1) Install tool G to the crankshaft. 2) Screw in tapping screws [2] of tool G to the seal carrier part of engine rear oil seal (3). 3) Turn the handle clockwise, and remove engine rear oil seal (3). 1. Install pilot [3] to crankshaft (4), and insert engine rear oil seal (3) into flywheel housing (5). 2. Push in engine rear oil seal (3) further, and then remove pilot [3].

a Be careful not to damage the crankshaft when removing it.

3. Install rear oil seal (3) to the proper depth in flywheel housing (5) by using tool G.

50-82

107E-2 SERIES

50 Disassembly and assembly Disassembly and assembly

a When inserting rear oil seal (3), be careful that there are no bend etc. on it. a Measure the protrusion of rear oil seal (3) from flywheel housing (5). X: Max. 0.38 mm

a Tighten the bolts while preventing rotation of the flywheel (2) by using plate [4].

4. Install guide bolt [1], and flywheel (2). 2 Flywheel mounting bolt: Engine oil (EO15W-40) 4 Flywheel: 35 kg 5. Tighten mounting bolts (1) in the order shown in the figure. 3 Mounting bolt: 137 ± 7 Nm {14.0 ± 0.71 kgm}

6. After installing flywheel (2), measure the radial runout and facial runout by using tool L. • Measurement of radial runout a Radial runout: Max. 0.13 mm 1) Set tool L to the flywheel housing. 2) Set the probe of the dial gauge perpendicularly to the spigot joint part (a) or outside perimeter of the flywheel. 3) Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points.

107E-2 SERIES

50-83

50 Disassembly and assembly Disassembly and assembly

a When the flywheel is rotated by 1 turn, check that the dial gauge indicates the same value as it of the starting rotation. â&#x20AC;˘ Measurement of facial runout a Facial runout: Max. 0.20 mm 1) Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicularly to the end face (b) near the outside perimeter of the flywheel. a When measuring, move the crankshaft to either front or rear end to eliminate error caused by the end play. 2) Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values the pointer of dial gauge points.

50-84

107E-2 SERIES

SHOP MANUAL

ENGINE 107E-2 SERIES Model

Serial Number

107E-2 SERIES

60 Maintenance standard 6 60 Maintenance standard

107E-2 SERIES

60-1

60 Maintenance standard Table of contents

Table of contents

(ALL-0310-002-A-00-A)

60 Maintenance standard................................................................................................................... 60-1 Table of contents ........................................................................................................................ 60-2 Intake and exhaust system parts .................................................................................................. 60-3 VFT (4D107)........................................................................................................................ 60-3 KVGT(6D107)...................................................................................................................... 60-4 Engine main body parts............................................................................................................... 60-5 Cylinder head ...................................................................................................................... 60-5 Cylinder block ...................................................................................................................... 60-7 Crankshaft........................................................................................................................... 60-9 Piston ............................................................................................................................... 60-11 Connecting rod .................................................................................................................. 60-12 Vibration damper (6D107)................................................................................................... 60-14 Timing gear ....................................................................................................................... 60-15 Camshaft .......................................................................................................................... 60-16 Valve and valve guide......................................................................................................... 60-18 Rocker arm........................................................................................................................ 60-20 Tappet............................................................................................................................... 60-21 Flywheel............................................................................................................................ 60-22 Lubrication system.................................................................................................................... 60-24 Oil pump ........................................................................................................................... 60-24

60-2

107E-2 SERIES

60 Maintenance standard VFT (4D107)

Intake and exhaust system parts VFT (4D107)

(ENG107-A900-001-K-00-A)

(ENG107-AA10-034-K-01-A)

a This section corresponds to 4-cylinder engine. a VFT: Abbreviation for Variable Flow Turbocharger

No.

Item

Radial play (play in radial direction)

End play (play in axial direction)

Wear of onnector pin (Backlash check)

107E-2 SERIES

Unit: mm Remedy

Criteria When compressor wheel and turbine wheel are pushed lightly with fingers toward housing, neither of them must touch housing. Repair limit Standard 0.02 to 0.07 0.103 (reference value) [Checking procedures] Check wear (backlash) in the following procedure. 1. Manually rotate the connector pin in the flow control valve closing direction of EACT (electric actuator) until it Replace turbocharger cannot be rotated. 2. Push the flow control valve lever to the flow control valve assembly closing direction when the connector pin is unable to rotate. [Judgment] â&#x20AC;˘ If there is no backlash, the flow control valve stuck to the valve seat within the EACT rotation range. It means there is no abnormality in the flow control valve. â&#x20AC;˘ If backlash occurs, it means the flow control valve is not completely closed within the EACT rotation range. The flow control valve may exceed the wear limit.

60-3

60 Maintenance standard KVGT(6D107)

KVGT(6D107)

(ENG107-AA10-034-K-00-A)

a This section corresponds to 6-cylinder engine. KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

No.

Item

Radial play (Play in radial 1 direction) End play (play in axial 2 direction)

Check of KVGT opration 3 (Check of nozzle ring operation)

60-4

Criteria Use light finger pressure to push the compressor wheel towards the side of the compressor housing. Repeat the procedure for the turbine wheel and housing. Either wheel shall not contact the housing. 0.025 to 0.127 If values of KDOC inlet temperature: approximately 250 Â°C or below and KVGT solenoid current: approximately 1000 mA remain unchanged after performing regeneration for service, KVGT is defective. (Since the time required for manual stationary regeneration depends on the accumulated soot level, see failure code CA2639 )

Unit: mm Remedy

Replace KVGT as an assembly (including hydraulic actuator, KVGT position sensor)

107E-2 SERIES

60 Maintenance standard Cylinder head

Engine main body parts Cylinder head

107E-2 SERIES

(ENG107-R402-001-K-00-A)

(ENG107-A100-034-K-00-A)

60-5

60 Maintenance standard Cylinder head

No.

Item

Distortion of mounting 1 surface to cylinder block Tightening torque for cylinder head mounting bolt 2 (apply engine oil to threads and seat surface)

Criteria End-to-End

Max.: 0.305

Side-to-Side

Max.: 0.076

Procedure 1st stage 2nd stage 3rd stage 4th stage

Target (Nm {kgm}) 70 ±6 {7.1 ± 0.6 } Loosen by 360 ± 5 5 deg. 105 ±3 {10.7 ± 0.3 } Retighten by 90 ± 5 deg.

3 Protrusion of injector nozzle

1.63 to 1.98

Tightening torque for injector 4 holder mounting bolt Tightening torque for head 5 cover mounting bolt

Target (Nm {kgm}) 8 {0.8}

Unit: mm Remedy Repair by grinding or replace cylinder head Tighten and retighten Replace nozzle or gasket Tighten

24 {2.4}

* : However, see "Disassembly and assembly" for the assembly procedure.

60-6

107E-2 SERIES

60 Maintenance standard Cylinder block

Cylinder block

107E-2 SERIES

(ENG107-A300-034-K-00-A)

60-7

60 Maintenance standard Cylinder block

No.

Item

Distortion of mounting 1 surface to cylinder head

Criteria End-to-End

Max. 0.075

Side-to-Side

Max. 0.051

Inside diameter of main 2 bearing metal mounting hole Inside diameter of main 3 bearing metal Thickness of main bearing 4 metal Inside diameter of cam 5 bushing mounting hole

87.983 to 88.019 83.041 to 83.109

Replace metal 2.456 to 2.464 Max. 59.248

Inside diameter of camshaft 6 bore (without bushing) Tightening torque for main cap mounting bolt (apply 7 engine oil to threads) Service limit for stem length of main cap bolt Tightening torque for oil pan 8 mounting bolt Tightening torque for 9 crankshaft pulley mounting bolt Cylinder bore 10

60-8

Roundness of cylinder bore

Unit: mm Remedy Repair by grinding or replace cylinder block Replace main cap

Max. 54.164 Procedure 1st stage 2nd stage 3rd stage

Target (Nm {kgm}) 60 {6.1} 80 {8.2} Retighten by 90 deg. Max. 120

Target (Nm {kgm}) 28 {2.8} Target (Nm {kgm}) Procedure 1st stage 50 {5.1} 2nd stage Retighten by 90 deg. 106.990 to 107.030 Repair limit: 0.038

Correct or replace block Correct block and insert camshaft bushing Tighten and retighten Replace main cap bolt Tighten Tighten and retighten Repair by using oversize parts or replace cylinder block

107E-2 SERIES

60 Maintenance standard Crankshaft

Crankshaft

107E-2 SERIES

(ENG107-A530-034-K-00-A)

60-9

60 Maintenance standard Crankshaft

No.

Item

1 End play (A) Outside diameter of main journal Roundness of main journal 2 Taper of main journal Clearance of main journal Outside diameter of crankpin journal Roundness of crankpin 3 journal Clearance of crankpin journal Outside diameter of front 4 crankshaft gear journal Inside diameter of front 5 crankshaft gear journal

60-10

Criteria 0.065 to 0.432

Unit: mm Remedy Replace thrust bearing or repair with oversize parts

Repair limit : 0.050 Repair limit : 0.013

Repair with undersize parts or replace journal

0.04 to 0.12

Replace main bearing

82.962 to 83.013

68.962 to 69.013 Repair limit : 0.050 0.04 to 0.12 70.59 to 70.61 70.51 to 70.55

Repair with undersize parts or replace journal Replace connecting rod bearing Repair with undersize parts or replace journal

107E-2 SERIES

60 Maintenance standard Piston

Piston

(ENG107-A580-034-K-00-A)

No.

Item Outside diameter of piston 1 skirt (at right angles to boss) 2 Closed gap of piston ring 3 Clearance of piston ring Outside diameter of piston 4 pin Inside diameter of piston pin 5 hole

107E-2 SERIES

Unit: mm Remedy

Criteria 106.878 to 106.892 Top ring Second ring Oil ring Second ring Oil ring

0.30 to 0.46 0.52 to 0.88 0.22 to 0.58 0.040 to 0.110 0.040 to 0.085

39.997 to 40.003 40.006 to 40.012

Replace piston

Replace piston ring or piston

Replace piston or piston pin

60-11

60 Maintenance standard Connecting rod

Connecting rod

60-12

(ENG107-A590-034-K-00-A)

107E-2 SERIES

60 Maintenance standard Connecting rod

No.

Item

Criteria

Inside diameter of 1 connecting rod bushing (bushing installed) Inside diameter of 2 connecting rod bearing Thickness of connecting rod 3 bearing Inside diameter of 4 connecting rod bearing hole Tightening torque of connecting rod cap mounting bolt 5 (apply engine oil to bolt threads and seat surface of nut) Side clearance of 6 connecting rod

107E-2 SERIES

40.019 to 40.042

69.05 to 69.10

1st stage 2nd stage 3rd stage

Unit: mm Remedy Replace bushing (semi- finished part supplied as replacement part)

1.955 to 1.968

Replace connecting rod bearing

72.99 to 73.01

Replace connecting rod

30 ± 3 Nm {3.06 ± 0.1 kgm} 60 ± 5 Nm {6.12 ± 0.51 Tighten and kgm} retighten Retighten by 60 ± 5 deg. 0.10 to 0.33

Replace connecting rod

60-13

60 Maintenance standard Vibration damper (6D107)

Vibration damper (6D107)

(ENG107-A5E0-034-K-00-A)

a This section corresponds to 6-cylinder engine.

No.

Item

Tightening torque of 1 vibration damper

60-14

Unit: mm Remedy

Criteria Procedure

Target (Nm {kgm})

1st stage 2nd stages

50 {5.1} Retighten by 90 deg.

Tighten and retighten

107E-2 SERIES

60 Maintenance standard Timing gear

Timing gear

No.

â&#x20AC;&#x2022;

(ENG107-A5A0-034-K-00-A)

Item Backlash of each gear

A B C D

107E-2 SERIES

Criteria Backlash of oil pump gear Backlash of camshaft gear Backlash of idler gear Backlash of fuel supply pump gear

Unit: mm Remedy 0.170 to 0.300 0.076 to 0.280 0.150 to 0.250

Replace

0.022 to 0.146

60-15

60 Maintenance standard Camshaft

Camshaft

60-16

(ENG107-A5G0-034-K-00-A)

107E-2 SERIES

60 Maintenance standard Camshaft

No.

Item

Criteria

1 End play Outside diameter of 2 camshaft bearing journal 3 Height of camshaft Thickness of camshaft thrust 4 plate Tightening torque of 5 camshaft thrust place mounting bolt Tightening torque of 6 camshaft gear mounting bolt

107E-2 SERIES

0.23 ± 0.13 53.095 to 54.045 Intake side Exhaust side

47.175 to 47.855 45.632 to 46.312

Unit: mm Remedy Replace thrust plate Correct or replace Replace

9.4 to 9.60 24 ± 4 Nm {2.45 ± 0.41 kgm} Tighten 36 ± 4 Nm {3.67 ± 0.41 kgm}

60-17

60 Maintenance standard Valve and valve guide

Valve and valve guide

60-18

(ENG107-A700-034-K-00-A)

107E-2 SERIES

60 Maintenance standard Valve and valve guide

No.

Item

Depression of valve in 1 cylinder head (A)

Intake side Exhaust side

2 Thickness of valve rim (B) 3 Valve seat angle

Valve Intake side Exhaust side

Outside diameter of valve stem 5 Diameter of valve guide bore Inside diameter of valve 6 insert bore (standard insert)

107E-2 SERIES

Criteria 0.584 to 1.092 0.965 to 1.473 Min. 0.79 Angle 30 deg. 45 deg. 6.96 to 7.01 7.027 to 7.077 34.847 to 34.863

Repair limit Judge contact surface condition by vacuum test.

Unit: mm Remedy Correct or replace valve or valve seat Replace valve Correct or replace valve or valve seat Replace cylinder head Replace

60-19

60 Maintenance standard Rocker arm

Rocker arm

(ENG107-A770-034-K-00-A)

No.

Item Outside diameter of rocker 1 arm shaft Diameter of rocker arm shaft 2 hole 3

Criteria Min. 21.965 Max. 22.027

Clearance between rocker arm shaft and rocker arm

Max. 0.062

Tightening torque for locknut 4 of rocker arm adjustment screw 5 Valve clearance (when cold) Tightening torque of rocker 6 arm mounting bolt

60-20

Target (Nm {kgm}) 24 {2.4} Valve Intake side Exhaust side

Repair limit adjustment value 0.152 to 0.381 0.25 Âą 0.05 0.381 to 0.762 0.51 Âą 0.05 Target (Nm {kgm}) 36 {3.7}

Unit: mm Remedy Replace rocker arm shaft Replace rocker arm Replace rocker arm or rocker arm shaft Tighten

Adjust Tighten

107E-2 SERIES

60 Maintenance standard Tappet

Tappet

(ENG107-A730-034-K-00-A)

No. Item 1 Outside diameter of tappet Inside diameter of tappet 2 hole Clearance between tappet 3 and tappet hole

107E-2 SERIES

Criteria 15.936 to 15.977 16.000 to 16.055 0.023 to 0.119

Unit: mm Remedy Replace tappet Replace cylinder block Replace tappet or cylinder block

60-21

60 Maintenance standard Flywheel

Flywheel

60-22

(ENG107-A560-034-K-00-A)

107E-2 SERIES

60 Maintenance standard Flywheel

No.

Item Radial runout of flywheel 1 housing

Criteria Repair limit: 0.20

Facial runout of flywheel 2 housing

Tightening torque for 3 flywheel housing mounting bolt 4 Facial runout of flywheel 5 Radial runout of flywheel Tightening torque for flywheel mounting bolt 6 (apply engine oil to threads and seat surface)

107E-2 SERIES

Unit: mm Remedy

Repair limit: 0.20

Correct by reassembling

49 ± 5 Nm {5 ± 0.51 kgm} 85 ± 10 Nm {8.67 ± 1.38 Tighten M12 kgm} Repair limit Correct by Diameter (actual measurement) x 0.0005 reassembling Repair limit: 0.13 M10

137 ± 7 Nm {14 ± 0.71 kgm}

Tighten

60-23

60 Maintenance standard Oil pump

Lubrication system Oil pump

No.

(ENG107-AB00-001-K-00-A)

(ENG107-AB50-034-K-00-A)

Item

Criteria

Axial clearance of rotor

Unit: mm Remedy

Max. 0.127 Replace oil pump

60-24

Clearance between outer rotor and inner rotor Tightening torque for oil pump mounting bolt

Max. 0.178 1st time 2nd time

8 ± 1 Nm {0.82 ± 0.1 kgm} (Tightening order: A) 24 ± 4 Nm {2.45 ± 0.41 kgm} (Tightening order: B)

Tighten

107E-2 SERIES

INDEX

INDEX A

Aftercooler ................................................... 10-29 Air cleaner..........................................10-14â&#x20AC;&#x201C;10-15 Air cleaner (4D107)....................................... 10-14 Air cleaner (6D107)....................................... 10-15 Alternator ................................................... 10-109 Applicable machines ....................................... 01-9

Flywheel ............................................ 10-73, 60-22 Front cover................................................... 10-69 Fuel cooler ................................................... 10-96 Fuel system circuit diagram ........................... 10-91 Fuel system parts layout drawing ................... 10-88

B Boost oil pump (6D107)................................. 10-82

C Camshaft ..................................................... 60-16 Coating materials list....................................... 50-5 Components layout drawing (4D107)................ 10-4 Components layout drawing (6D107)................ 10-6 Connecting rod ............................................. 60-12 Conversion table .......................................... 00-50 Cooling system circuit diagram (4D107)........ 10-100 Cooling system circuit diagram (6D107)........ 10-101 Cooling system parts layout drawing .............. 10-99 Crankshaft ..................................................... 60-9 Cylinder block.......................................10-61, 60-7 Cylinder head .......................................10-59, 60-5

D Drive pulley ................................................ 10-102

E EGR cooler .................................................. 10-42 EGR system circuit diagram .......................... 10-36 EGR system circuit diagram (4D107).............. 10-34 EGR system circuit diagram (6D107).............. 10-36 EGR system piping drawing................. 10-30, 10-32 EGR system piping drawing (4D107) .............. 10-30 EGR system piping drawing (6D107) .............. 10-32 EGR valve ......................................... 10-38, 10-40 EGR valve (4D107)....................................... 10-38 EGR valve (6D107)....................................... 10-40 Engine controller............................. 10-126, 10-132 Engine controller (4D107)............................ 10-126 Engine controller (6D107)............................ 10-132 Engine front oil seal replacement procedure.... 50-79 Engine performance curve............................. 01-43 Engine rear oil seal replacement procedure .... 50-82 Engine wiring harness (4D107) .................... 10-122 Engine wiring harness (6D107) .................... 10-124 Exhaust gas regulation.................................... 01-3 Explanation of terms for maintenance standard ...0014 107E-2 SERIES

G General assembly of engine .......................... 50-34 General disassembly of engine ...................... 50-12 General view ................................................ 01-18

H Handling equipment of fuel system devices..... 00-16 Handling of electrical equipment .................... 00-23 Handling of hydraulic equipment .................... 00-18 Handling of intake system parts ..................... 00-17 How to read electric wire code ....................... 00-31 How to read the shop manual ........................ 00-12 How to read this manual .................................. 50-3

I Important safety notice .................................... 00-5 Intake air heater.......................................... 10-121 Intake and exhaust system circuit diagram (4D107)...................................................... 10-10 Intake and exhaust system circuit diagram (6D107)...................................................... 10-12 Intake and exhaust system layout drawing (4D107)........................................................ 10-8 Intake and exhaust system layout drawing (6D107)........................................................ 10-9

K KCCV layout drawing .......................... 10-43, 10-46 KCCV ventilator............................................ 10-48 KDOC muffler............................................... 10-52 KDOC muffler (4D107) .................................. 10-52 KDPF .......................................................... 10-54 KDPF (6D107).............................................. 10-54 KVGT .......................................................... 10-21 KVGT (6D107) .....................................10-21, 60-4

L Layout of KCCV (4D107) ............................... 10-43 Layout of KCCV (6D107) ............................... 10-46 List of abbreviation........................................ 00-45 Lubrication system circuit diagram (4D107)..... 10-79 Lubrication system circuit diagram (6D107)..... 10-80

INDEX

Lubrication system parts layout drawing (4D107)...................................................... 10-75 Lubrication system parts layout drawing (6D107)...................................................... 10-77

Vibration damper (6D107) ................... 10-67, 60-14

W Water pump ............................................... 10-107

M Main filter ..................................................... 10-98 Main moving parts ........................................ 10-63 Method of disconnecting and connecting of push-pull type coupler ................................. 00-20

O Oil cooler ..................................................... 10-84 Oil filter ........................................................ 10-83 Oil pan ......................................................... 10-87 Oil pump ............................................ 10-81, 60-24

P Piston .......................................................... 60-11 Pre-filter ....................................................... 10-97 Precautions when performing operation.......... 00-34

R Regulator valve ............................................ 10-85 Removal and installation procedure of supply pump unit alone .......................................... 50-75 Rocker arm .................................................. 60-20 Running-in standard and performance test standard..................................................... 20-27

S Safety valve ................................................. 10-86 Sensor....................................................... 10-138 Sketch of special tool .................................... 50-11 Special tool list ............................................... 50-9 Specifications .......................................01-9â&#x20AC;&#x201C;01-10 Standard tightening torque table .................... 00-39 Standard value table for engine........................ 20-3 Starting motor............................................. 10-117 Supply pump ................................................ 10-95

T Tappet ......................................................... 60-21 Thermostat................................................. 10-108 Timing gear ........................................ 10-68, 60-15

V Valve and valve guide ................................... 60-18 Valve system ................................................ 10-70 VFT ............................................................. 10-17 VFT (4D107) ........................................10-17, 60-3

107E-2 SERIES

107E-2 SERIES ENGINE Form No. SEN05623-06