Komatsu 107E-1 Series Diesel Engine Shop Manual - PDF DOWNLOAD by www.heydownloads.com

SEN00161-2

ENGINE

107E

-1

SERIES

SEN00163-24

Engine 1SHOP MANUAL

107E-1 Series

00 Index and foreword

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 3

107E-1 Series

SEN00163-24

00 Index and foreword

Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: â&#x20AC;˘ Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: â&#x20AC;˘ File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00161-24

00 Index and foreword Index Foreword and general information

SEN00162-24 SEN00163-24 q SEN00164-06

01 Specification Specification and technical data

SEN00165-16 SEN00166-16

10 Structure, function and maintenance standard Structure, function and maintenance standard

SEN00167-07 SEN00168-07

20 Standard value table Standard service value table

SEN00247-16 SEN00248-16

30 Testing and adjusting Testing and adjusting

SEN00249-09 SEN00250-09

40 Troubleshooting General information on troubleshooting Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 2 Troubleshooting of mechanical system (S-mode)

SEN00251-05 SEN00252-04 SEN00254-04 SEN00255-04 SEN00253-02

50 Disassembly and assembly General information on disassembly and assembly Disassembly and assembly, Part 1 Disassembly and assembly, Part 2

SEN00256-10 SEN00257-06 SEN00258-07 SEN00259-10

90 Repair and replacement of parts Information related to repair and replacement Parts related to cylinder head Parts related to cylinder block

SEN05210-01 SEN05211-01 q SEN05212-00 SEN05213-01 q

107E-1 Series

00 Index and foreword

SEN00163-24

Table of contents

00 Index and foreword Index SEN00163-24 Composition of shop manual ................................................................................................... 2 Table of contents ..................................................................................................................... 3 Foreword and general information SEN00164-06 Safety notice............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code ................................................................................................ 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN00166-16 General.................................................................................................................................... 2 Specifications........................................................................................................................... 3 General view............................................................................................................................ 24 Dimensions table ..................................................................................................................... 64 Engine performance curves..................................................................................................... 65 10 Structure, function and maintenance standard Structure, function and maintenance standard SEN00168-07 Intake system .............................................................................................................................. 3 Exhaust system........................................................................................................................... 4 Lubricating oil system.................................................................................................................. 6 Cooling system............................................................................................................................ 10 Fuel system................................................................................................................................. 11 Fuel supply pump........................................................................................................................ 12 CRI system.................................................................................................................................. 13 Turbocharger............................................................................................................................... 17 Cylinder head .............................................................................................................................. 18 Cylinder block.............................................................................................................................. 20 Crankshaft................................................................................................................................... 22 Piston, piston ring and piston pin ................................................................................................ 24 Connecting rod............................................................................................................................ 26 Vibration damper ......................................................................................................................... 28 Timing gear ................................................................................................................................. 29 Camshaft ..................................................................................................................................... 30 Valve and valve guide ................................................................................................................. 32 Rocker arm, shaft and tappet ...................................................................................................... 34 Flywheel and flywheel housing ................................................................................................... 36 Oil pump...................................................................................................................................... 38 Water pump drive and fan drive .................................................................................................. 39 Water pump................................................................................................................................. 41 Thermostat .................................................................................................................................. 42 Alternator..................................................................................................................................... 43 Starting motor.............................................................................................................................. 48 Sensor......................................................................................................................................... 52 Engine controller ......................................................................................................................... 58 Control system ............................................................................................................................ 61 107E-1 Series

SEN00163-24

00 Index and foreword

20 Standard value table Standard service value table SEN00248-16 Standard value table for testing, adjusting and troubleshooting .............................................. 2 Running-in standard and performance test criteria.................................................................. 22 30 Testing and adjusting Testing and adjusting SEN00250-09 Testing and adjusting tools list..................................................................................................... 2 Sketches of special tools............................................................................................................. 4 Testing boost pressure ................................................................................................................ 5 Adjustment of valve clearance .................................................................................................... 6 Testing compression pressure..................................................................................................... 9 Testing blowby pressure.............................................................................................................. 12 Testing engine oil pressure.......................................................................................................... 13 Handling fuel system parts .......................................................................................................... 14 Releasing remaining pressure in fuel system.............................................................................. 14 Testing fuel pressure ................................................................................................................... 15 Reduced cylinder mode operation............................................................................................... 21 No-injection cranking................................................................................................................... 21 Testing fuel delivery, return and leak amount .............................................................................. 22 Bleeding air from fuel circuit ........................................................................................................ 33 Testing fuel system for leakage ................................................................................................... 34 Handling controller high-voltage circuit ....................................................................................... 35 Replacing the fan belt.................................................................................................................. 35 40 Troubleshooting General information on troubleshooting SEN00252-04 Points on troubleshooting............................................................................................................ 2 Error and failure code table ......................................................................................................... 3 Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 5 Information in troubleshooting table ............................................................................................ 7 Connection table for connector pin numbers............................................................................... 9 T- branch box and T- branch adapter table ................................................................................. 45 Troubleshooting of electrical system (E-mode), Part 1 SEN00254-04 E-1 Code [111/CA111] Abnormality in engine controller.............................................................. 3 E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor....................................... 3 E-3 Code [122/CA122] Charge pressure sensor high error ........................................................ 4 E-4 Code [123/CA123] Charge pressure sensor low error.......................................................... 6 E-5 Code [131/CA131] Throttle sensor power supply high error................................................. 8 E-6 Code [132/CA132] Throttle sensor power supply low error .................................................. 10 E-7 Code [144/CA144] Coolant temperature sensor high error .................................................. 12 E-8 Code [145/CA145] Coolant temperature sensor low error.................................................... 14 E-9 Code [153/CA153] Charge temperature sensor high error................................................... 16 E-10 Code [154/CA154] Charge temperature sensor low error .................................................. 18 E-11 Code [155/CA155] Derating of speed by charge temperature high error ........................... 20 E-12 Code [187/CA187] Sensor power supply 2 low error.......................................................... 22 E-13 Code [221/CA221] Atompspheric pressure sensor high error ............................................ 24 E-14 Code [222/CA222] Atompspheric pressure sensor low error ............................................. 26 E-15 Code [227/CA227] Sensor power supply 2 high error ........................................................ 28 E-16 Code [234/CA234] Engine overspeed ................................................................................ 28 E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply ................................... 29 E-18 Code [271/CA271] Short circuit in IMV/PCV1..................................................................... 30 E-19 Code [272/CA272] Disconnection in IMV/PCV1 ................................................................. 32 E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 ........................................ 34 E-21 Code [323/CA323] Disconnection, short circuit in injector No. 5 ........................................ 36 E-22 Code [324/CA324] Disconnection, short circuit in injector No. 3 ........................................ 38 E-23 Code [325/CA325] Disconnection, short circuit in injector No. 6 ........................................ 40

107E-1 Series

00 Index and foreword

SEN00163-24

E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2 ........................................ 42 E-25 Code [332/CA332] Disconnection, short circuit in injector No. 4 ........................................ 44 E-26 Code [342/CA342] Calibration error in engine controller data ............................................ 46 E-27 Code [351/CA351] Abnormality in injector drive circuit ...................................................... 47 E-28 Code [352/CA352] Sensor power supply 1 low error ......................................................... 48 E-29 Code [386/CA386] Sensor power supply 1 high error ........................................................ 50 E-30 Code [428/CA428] Water-in-fuel sensor high error ............................................................ 52 E-31 Code [429/CA429] Water-in-fuel sensor low error.............................................................. 54 E-32 Code [431/CA431] Abnormality in idle validation switch .................................................... 56 E-33 Code [432/CA432] Abnormality in idle validation processing ............................................. 58 Troubleshooting of electrical system (E-mode), Part 2 SEN00255-04 E-34 Code [435/CA435] Abnormality in engine oil pressure switch............................................ 3 E-35 Code [441/CA441] Abnormally low power supply voltage .................................................. 4 E-36 Code [442/CA442] Abnormally high power supply voltage ................................................ 6 E-37 Code [449/CA449] Common rail pressure high error 2 ...................................................... 7 E-38 Code [451/CA451] Common rail pressure sensor high error ............................................. 8 E-39 Code [452/CA452] Common rail pressure sensor low error ............................................... 10 E-40 Code [488/CA488] Derating of torque by charge temperature high error........................... 12 E-41 Code [553/CA553] Common rail pressure high error 1 ...................................................... 12 E-42 Code [559/CA559] No-pressure feed 1 by supply pump .................................................... 13 E-43 Code [689/CA689] Abnormality in engine Ne speed sensor .............................................. 15 E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase................................ 17 E-45 Code [757/CA757] Loss of all data in engine controller ..................................................... 18 E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor........................................... 19 E-47 Code [1633/CA1633] Abnormality in KOMNET.................................................................. 22 E-48 Code [2185/CA2185] Throttle sensor power supply high error .......................................... 23 E-49 Code [2186/CA2186] Throttle sensor power supply low error............................................ 24 E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump ................................................ 25 E-51 Code [2311/CA2311] Abnormality in IMV solenoid ............................................................. 25 E-52 Code [2555/CA2555] Disconnection in intake air heater relay ........................................... 26 E-53 Code [2556/CA2556] Short circuit in intake air heater relay............................................... 28 E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction .......................... 30 E-55 Code [---/B@BAZK] Engine oil level low ............................................................................ 30 E-56 Code [---/B@BCNS] Engine overheat ................................................................................ 31 E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error ............................. 32 E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error .............................. 34 E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error....................................... 36 E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error........................................ 38 E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) ......................................... 40 E-62 Code [b6] Droop Rate Adjustment Volume High Error ...................................................... 44 E-63 Code [b7] Droop Rate Adjustment Volume Low Error ........................................................ 46 E-64 Code [b8] Low Idle Speed Adjustment Volume High Error ................................................. 48 E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error.................................................. 50 E-66 Code [bc] Rated Speed Median Adjustment Volume High Error ........................................ 52 E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error......................................... 54 E-68 Code [bE] Ramp Time Adjustment Volume High Error....................................................... 56 E-69 Code [bF] Ramp Time Adjustment Volume Low Error........................................................ 58 Troubleshooting of mechanical system (S-mode) SEN00253-02 Troubleshooting of mechanical system (S-mode) ....................................................................... 1 Method of using troubleshooting charts................................................................................... 4 S-1 Starting performance is poor ............................................................................................. 8 S-2 Engine does not start ........................................................................................................ 9 S-3 Engine does not pick up smoothly .................................................................................... 12 S-4 Engine stops during operations ........................................................................................ 13 S-5 Engine does not rotate smoothly ...................................................................................... 14 S-6 Engine lacks output (or lacks power) ................................................................................ 15 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 17 107E-1 Series

SEN00163-24

00 Index and foreword

S-9 Oil becomes contaminated quickly.................................................................................... S-10 Fuel consumption is excessive ....................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. S-12 Oil pressure drops........................................................................................................... S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... S-14 Coolant temperature becomes too high (overheating).................................................... S-15 Abnormal noise is made.................................................................................................. S-16 Vibration is excessive......................................................................................................

18 19 20 21 22 23 24 25

50 Disassembly and assembly General information on disassembly and assembly SEN00257-06 How to read this manual.............................................................................................................. 2 Coating materials list ................................................................................................................... 4 Special tools list........................................................................................................................... 7 Disassembly and assembly, Part 1 SEN00258-07 General disassembly of engine ................................................................................................... 2 Disassembly and assembly, Part 2 SEN00259-10 General assembly of engine........................................................................................................ 2 90 Repair and replacement of parts Information related to repair and replacement SEN05211-01 Special tool table ......................................................................................................................... 2 Parts related to cylinder head SEN05212-00 Repair of cylinder head ............................................................................................................... 2 Check of valve guide ................................................................................................................... 3 Replacement of valve seat insert ................................................................................................ 4 Vacuum test of valve seat insert.................................................................................................. 6 Grinding of valve ......................................................................................................................... 7 Parts related to cylinder block SEN05213-01 Repair of cylinder block ............................................................................................................... 2 Repair of crankshaft .................................................................................................................... 14 Replacement of connecting rod bushing ..................................................................................... 17

107E-1 Series

00 Index and foreword

107E-1 Series

SEN00163-24

KOMATSU 107E-1 Series Diesel engine Form No. SEN00163-24

SEN00164-06

Engine 1SHOP MANUAL

107E-1 Series

00 Index and foreword

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

107E-1 Series

SEN00164-06

00 Index and foreword

Safety notice

(Rev. 2008/08) 1

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

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out 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. 2) Decide a place in the repair workshop to keep 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. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much

107E-1 Series

00 Index and foreword

SEN00164-06

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (â&#x20AC;&#x201C;) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

11)

107E-1 Series

10)

12)

13)

14)

15)

16)

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

SEN00164-06

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use 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. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00 Index and foreword

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. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

107E-1 Series

00 Index and foreword

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN00164-06

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

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 hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

107E-1 Series

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard â&#x20AC;&#x153;Zâ&#x20AC;? twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

SEN00164-06

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)

00 Index and foreword a

Example of O-ring (Fitted to every joint of hoses and tubes)

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.

107E-1 Series

00 Index and foreword

How to read the shop manual q q q

SEN00164-06

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 â&#x20AC;Ś)

Revisions Revised brochures are shown in the shop manual composition table.

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

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Coat

Oil, coolant

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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Explanation of terms for maintenance standard

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

Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size 120

Tolerance –0.022 –0.126

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

Example: Standard size 60

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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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Standard clearance and standard value q 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. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

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Clearance limit 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 “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

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Handling of electric equipment and hydraulic component

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

Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. 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 wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) 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 the connectors is 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 connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

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Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

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

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

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

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 twisted up and down or to the left or right, the housing may break.

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

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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

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Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks

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Disconnection

Connection (Example of incomplete setting of (a))

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Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

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Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

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

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

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

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Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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Handling of connectors newly used for engines a

Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

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Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

114 engine

107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing 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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95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)

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Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

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How to read electric wire code a

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

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Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“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

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

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 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

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit

Others

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

AEX

–

R B R D Y G L

–

– –

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

YW GL

– –

Gr Br – –

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Precautions when carrying out operation

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

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal 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. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

07049-02734

22.5

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2. q q q q q q q q q q q q q

a 3.

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Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

107E-1 Series

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Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

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Method of disassembling and connecting push-pull type coupler k k

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

107E-1 Series

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Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

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Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a

The following table applies to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630

kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370

The following table applies to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12 a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Width across flats mm 10 12 14 17

Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)

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Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

Width across flats mm 14 17 22

Tightening torque Nm 59 – 74 98 – 123 235 – 285

kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42

Nominal No. 02 03,04 05,06 10,12 14

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Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal 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

107E-1 Series

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

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Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

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

22 24 27 32 36 41 46 55

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

Target

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}

Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42

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

Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer diameter of pipe (mm)

Width across flats (mm)

8 10 12 15 (16) 22 (20)

19 22 24 (27) 30 (32) 36

Tightening torque Nm {kgm} Range

Target

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

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

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

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts

Thread size mm 6 8 10 12 14

Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

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Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

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Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.

Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4

107E-1 Series

Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

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Conversion table

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.

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

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

Millimeters to inches

(A)

(B)

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

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 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

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

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 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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Millimeters to inches

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

5 0.197 0.591 0.984 1.378 1.772

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

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

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

107E-1 Series

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

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kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 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

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

107E-1 Series

SEN00164-06

00 Index and foreword

Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

107E-1 Series

00 Index and foreword

107E-1 Series

SEN00164-06

KOMATSU 107E-1 Series Diesel engine Form No. SEN00164-06

SEN00166-16

Engine 1SHOP MANUAL

107E-1 Series

01 Specification

Specification and technical data General ........................................................................................................................................................... 2 Specifications .................................................................................................................................................. 3 General view ................................................................................................................................................. 24 Dimensions table .......................................................................................................................................... 64 Engine performance curves .......................................................................................................................... 65

107E-1 Series

SEN00166-16

01 Specification

General

1. Applicable machine Engine

SAA6D107E-1

SAA4D107E-1

Serial No.

Applicable machine PC200-8, PC200LC-8 PC200-8M0, PC200LC-8M0 PC220-8, PC220LC-8 PC220-8M0, PC220LC-8M0, PC240LC-8M0 PC270-8 PC228US-3E0, PC228USLC-3E0 PC228US-8, PC228USLC-8 PC308USLC-3E0

Hydraulic excavator

WA250-6, WA250PZ-6 WA320-6, WA320PZ-6 WA380-6,WA380Z-6

Wheel loader

BR380JG-1E0

Mobile crusher

GD555-5 GD655-5, GD675-5

Motor grader

A6D107E-GD-1

Portable generator

PC160LC-7E0, PC160LC-8 PC200LC-8E0 HB205-1, HB215LC-1 HB205-1M0, HB215LC-1M0

Hydraulic excavator

WA200-6, WA200PZ-6

Wheel loader

D39EX-22, D39PX-22

Bulldozer

107E-1 Series

01 Specification

SEN00166-16

Specifications

1 Engine

SAA6D107E-1

Applicable model

PC200-8, PC200LC-8

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

116 {155}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

624 {63.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

223 {170}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

PC200-8M0, PC200LC-8M0

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,352

Overall width

689

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,413

Rated horsepower

kW{HP}/ min-1{rpm}

109.7 {147.1}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

602 {61.4}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

228 {168}

541

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A, 60A

Starting motor

—

24V, 4.5kW, 5.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

PC220-8, PC220LC-8

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

134 {179}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

710 {72.4}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,160 ± 50{2,160 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

223 {166}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

PC220-8M0, PC220LC-8M0, PC240LC-8M0

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,352

Overall width

689

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,413

Rated horsepower

kW{HP}/ min-1{rpm}

129.3 {173.3}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

690 {70.4}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,160 ± 50{2,160 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

228 {170}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A, 60 A

Starting motor

—

24V, 4.5kW, 5.5 kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

PC270-8

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

149 {200}/2,050{2,050} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

771 {78.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,180 ± 50{2,180 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

223 {166}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

PC228US-3E0, PC228USLC-3E0

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

116 {155}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

624 {63.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

223 {166}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 4.5kW, 5.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

PC228US-8, PC228USLC-8

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

116 {155}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

624 {63.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

223 {166}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A, 60A

Starting motor

—

24V, 4.5kW, 5.5kW

Battery

—

12V, 88Ah × 2, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

PC308USLC-3E0

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

149 {200}/2,050{2,050} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

771 {78.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,180 ± 50{2,180 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

227 {169}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 126Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

WA250-6, WA250PZ-6

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,067

Overall width

819

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,612

Rated horsepower

kW{HP}/ min-1{rpm}

104.1 {140}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

627 {64.0}/1,400{1,400} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,250 ± 50{2,250 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

825 ± 25{825 ± 25}

g/kWh {g/HPh}

227 {169}

590

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 120Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

WA320-6, WA320PZ-6

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,067

Overall width

819

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,612

Rated horsepower

kW{HP}/ min-1{rpm}

127.3 {171}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

672 {68.5}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,250 ± 50{2,250 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

825 ± 25{825 ± 25}

g/kWh {g/HPh}

224 {167}

650

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 92Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

WA380-6, WA380Z-6

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,101

Overall width

882

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,592

Rated horsepower

kW{HP}/ min-1{rpm}

143.4 {192}/2,100{2,100} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

941 {96.0}/1,450{1,450} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,250 ± 50{2,250 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

850 ± 25{850 ± 25}

g/kWh {g/HPh}

234 {174}

570

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 136Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

BR380JG-1E0

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,355

Overall width

790

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,409

Rated horsepower

kW{HP}/ min-1{rpm}

149 {200}/2,050{2,050} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

771 {78.6}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,330 ± 50{2,330 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

227 {169}

553

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 110Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

GD555-5

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,102

Overall width

849

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,592

Rated horsepower

kW{HP}/ min-1{rpm}

146.2 {196}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

880 {89.7}/1,450{1,450} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,200 ± 50{2,200 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

825 ± 25{825 ± 25}

g/kWh {g/HPh}

231 {173}

585

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A (90A (if equipped))

Starting motor

—

24V, 5.5kW

Battery

—

12V, 130Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA6D107E-1

Applicable model

GD655-5, GD675-5

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,102

Overall width

849

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,592

Rated horsepower

kW{HP}/ min-1{rpm}

164.8 {221}/2,100{2,100} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

941 {96.0}/1,450{1,450} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,200 ± 25{2,200 ± 25}

Min. speed with no load (Low idle speed)

min-1{rpm}

825 ± 25{825 ± 25}

g/kWh {g/HPh}

231 {173}

585

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 60A (90A (if equipped))

Starting motor

—

24V, 5.5kW

Battery

—

12V, 130Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA6D107E-1

Applicable model

A6D107E-GD-1

No. of cylinders – Bore × Stroke

6 – 107 × 124

l {cc}

6.69 {6,690}

—

1–5–3–6–2–4

Overall length

1,501

Overall width

764

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,254

50Hz rated horsepower

kW{HP}/ min-1{rpm}

115 {155}/1,500{1,500} (Gross)

60Hz rated horsepower

Nm{kgm}/ min-1{rpm}

139 {186}/1,800{1,800} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

Max. 1,890{Max. 1,890}

Min. speed with no load (Low idle speed)

min-1{rpm}

650 ± 25{650 ± 25}

g/kWh {g/HPh}

221/223 {165/166}

675

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point (50 Hz/60 Hz) Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

25.4 (23.1)

Coolant amount

8.4

Alternator

—

24V, 35A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 100Ah × 2

Turbocharger

—

HOLSET HX35W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA4D107E-1

Applicable model

PC160LC-7E0, PC160LC-8

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

1,104

Overall width

720

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,333

Rated horsepower

kW{HP}/ min-1{rpm}

90.0 {121}/2,200{2,200} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

471 {48.0}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,320 ± 30{2,320 ± 30}

Min. speed with no load (Low idle speed)

min-1{rpm}

1,050 ± 25{1,050 ± 25}

g/kWh {g/HPh}

232 {173}

430

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

18 (16)

Coolant amount

Alternator

—

24V, 60A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 60Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA4D107E-1

Applicable model

PC200LC-8E0

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

1,187

Overall width

726

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,417

Rated horsepower

kW{HP}/ min-1{rpm}

106.6 {143}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

593.9 {60.6}/1,700{1,700} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

700 ± 25{700 ± 25}

g/kWh {g/HPh}

228 {170}

414 (Excluding muffler)

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

18 (16)

Coolant amount

Alternator

—

24V, 35A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 88Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA4D107E-1

Applicable model

HB205-1, HB215LC-1

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

1,187

Overall width

726

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,417

Rated horsepower

kW{HP}/ min-1{rpm}

110.3 {148}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

593.9 {60.6}/1,700{1,700} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

700 ± 25{700 ± 25}

g/kWh {g/HPh}

231 {172}

414 (Excluding muffler)

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

18 (16)

Coolant amount

Alternator

—

24V, 35A,60A

Starting motor

—

24V, 5.5kW

Battery

—

12V, 88Ah × 2,140Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA4D107E-1

Applicable model

HB205-1M0, HB215LC-1M0

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

1,187

Overall width

726

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,421

Rated horsepower

kW{HP}/ min-1{rpm}

110.3 {148}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

593.9 {60.6}/1,700{1,700} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,060 ± 50{2,060 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

700 ± 25{700 ± 25}

g/kWh {g/HPh}

231 {172}

414 (Excluding muffler)

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

18 (16)

Coolant amount

Alternator

—

24V, 35A, 60A

Starting motor

—

24V, 4.5kW, 5.5kW

Battery

—

12V, 88Ah × 2, 140Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

1 Engine

SAA4D107E-1

Applicable model

WA200-6, WA200PZ-6

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

853

Overall width

781

Overall height (excluding exhaust pipe)

—

Overall height (including exhaust pipe)

1,475

Rated horsepower

kW{HP}/ min-1{rpm}

95.2 {128}/2,000{2,000} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

586 {59.8}/1,400{1,400} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,250 ± 50{2,250 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

825 ± 25{825 ± 25}

g/kWh {g/HPh}

228 {170}

465

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

17.5 (15.5)

Coolant amount

Alternator

—

24V, 60A

Starting motor

—

24V, 4.5kW

Battery

—

12V, 88Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

01 Specification

SEN00166-16

1 Engine

SAA4D107E-1

Applicable model

D39EX-22, D39PX-22

No. of cylinders – Bore × Stroke

4 – 107 × 124

l {cc}

4.46 {4,460}

—

1–3–4–2

Overall length

924

Overall width

632

Overall height (excluding exhaust pipe)

1,233

Overall height (including exhaust pipe)

—

Rated horsepower

kW{HP}/ min-1{rpm}

80.0 {107}/2,200{2,200} (Gross)

Max. torque

Nm{kgm}/ min-1{rpm}

476 {48.5}/1,500{1,500} (Gross)

Max. speed with no load (High idle speed)

min-1{rpm}

2,400 ± 50{2,400 ± 50}

Min. speed with no load (Low idle speed)

min-1{rpm}

975 ± 25{975 ± 25}

g/kWh {g/HPh}

234 {172}

455

Total piston displacement

Performance

Dimensions

Firing order

Fuel consumption ratio at rated point Dry weight Fuel injection system Fuel injection system control

—

HPCR Electronic control type

Lubricating oil amount (refill capacity)

15 (13)

Coolant amount

Alternator

—

24V, 35A, 60A (if equipped)

Starting motor

—

24V, 5.5kW

Battery

—

12V, 92Ah × 2

Turbocharger

—

HOLSET HE221W

Air compressor

—

Others

—

107E-1 Series

SEN00166-16

01 Specification

General view

SAA6D107E-1 (Left side view of engine) Machine model: PC200-8, PC200LC-8,PC220-8, PC228US-3E0, PC228US-8, PC228USLC-8, PC270-8, BR380JG-1E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

1 SAA6D107E-1 (Right side view of engine) Machine model: PC200-8, PC200LC-8,PC220-8, PC228US-3E0, PC228US-8, PC228USLC-8, PC270-8, BR380JG-1E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Front view of engine) Machine model: PC200-8, PC200LC-8,PC220-8, PC228US-3E0, PC228US-8, PC228USLC-8, PC270-8, BR380JG-1E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Rear view of engine) Machine model: PC200-8, PC200LC-8,PC220-8, PC228US-3E0, PC228US-8, PC228USLC-8, PC270-8, BR380JG-1E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Left side view of engine) Machine model: PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0, PC240LC-8M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Right side view of engine) Machine model: PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0, PC240LC-8M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Front view of engine) Machine model: PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0, PC240LC-8M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Rear view of engine) Machine model: PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0, PC240LC-8M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Left side view of engine) Machine model: WA380-6, WA380Z-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Right side view of engine) Machine model: WA380-6, WA380Z-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Front view of engine) Machine model: WA380-6, WA380Z-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Rear view of engine) Machine model: WA380-6, WA380Z-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: GD555-5, GD655-5, GD675-5

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: GD555-5, GD655-5, GD675-5

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: GD555-5, GD655-5, GD675-5

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: GD555-5, GD655-5, GD675-5

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Left side view of engine) Machine model: A6D107E-GD-1 (Portable generator)

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Right side view of engine) Machine model: A6D107E-GD-1 (Portable generator)

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Front view of engine) Machine model: A6D107E-GD-1 (Portable generator)

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA6D107E-1 (Rear view of engine) Machine model: A6D107E-GD-1 (Portable generator)

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: PC160LC-7E0, PC160LC-8

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: PC160LC-7E0, PC160LC-8

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: PC160LC-7E0, PC160LC-8

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: PC160LC-7E0, PC160LC-8

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: PC200LC-8E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: PC200LC-8E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: PC200LC-8E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: PC200LC-8E0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: WA200-6,WA200PZ-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: WA200-6,WA200PZ-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: WA200-6,WA200PZ-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: WA200-6,WA200PZ-6

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Left side view of engine) Machine model: D39EX-22, D39PX-22

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Right side view of engine) Machine model: D39EX-22, D39PX-22

The shape may differ according to the machine model.

1. 2.

Crankshaft center Flywheel housing rear surface

107E-1 Series

SEN00166-16

01 Specification

SAA4D107E-1 (Front view of engine) Machine model: D39EX-22, D39PX-22

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Rear view of engine) Machine model: D39EX-22, D39PX-22

The shape may differ according to the machine model.

1. 2.

Crankshaft center Cylinder center

107E-1 Series

SEN00166-16

01 Specification

Dimensions table

1 Unit: mm

Engine

Machine model

Dimension of each part A

PC200-8,PC200LC-8

1,355

1,409

427

790

PC200-8M0, PC200LC-8M0

1,352

1,413

429

689

PC220-8

1,355

1,409

427

790

PC220-8M0, PC220LC-8M0, PC240LC-8M0

1,352

1,413

429

689

PC270-8

1,355

1,409

427

790

PC228US-3E0

1,355

1,409

427

790

PC228US-8, SAA6D107E-1 PC228USLC-8

1,355

1,409

427

790

1,355

1,409

427

790

WA250-6, WA250PZ-6 1,067

1,612

427

819

WA320-6, WA320PZ-6 1,044

1,475

479

817

WA380-6, WA380Z-6

1,101

1,592

407

882

BR380JG-1E0

1,355

1,409

427

790

GD555-5 GD655-5, GD675-5

1,068

1,593

408

849

A6D107E-GD-1 (Portable generator)

1,501

1,254

391

764

PC160LC-7E0, PC160LC-8

1,104

1,333

382

717

PC200LC-8E0

1,187

1,417

433

726

HB205-1, HB215LC-1

1,187

1,417

433

726

HB205-1M0, HB215LC-1M0

1,187

1,421

437

726

WA200-6, WA200PZ-6

853

1,612

427

819

D39EX-22, D39PX-22

885

1,220

295

619

PC308USLC-3E0

SAA4D107E-1

These dimensions are given for reference when the engine is set on a test bench.

107E-1 Series

01 Specification

Engine performance curves

SEN00166-16

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

107E-1 Series

SEN00166-16

SAA6D107E-1 (Machine model: PC200-8M0, PC200LC-8M0)

01 Specification

1 1

Rated horsepower: 109.7 kW {147.1 HP}/2,000 min-1{2,000 rpm}(Gross) Max. torque: 602 Nm {61.4 kgm}/1,500 min-1{1,500 rpm}(Gross)

107E-1 Series

01 Specification

SAA6D107E-1 (Machine model: PC220-8, PC220LC-8)

SEN00166-16

Rated horsepower: 134 kW {179 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 710 Nm {72.4 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Machine model: PC220-8M0, PC220LC-8M0, PC240LC8M0)

Rated horsepower: 129.3 kW {173.3 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 690 Nm {70.4 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

01 Specification

SAA6D107E-1 (Machine model: PC270-8, PC308USLC-3E0)

SEN00166-16

Rated horsepower: 149 kW {200 HP}/2,050 min-1{2,050 rpm} (Gross) Max. torque: 771 Nm {78.6 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

SAA6D107E-1 (Machine model: WA250-6, WA250PZ-6)

01 Specification

Rated horsepower: 104.1 kW {140 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 627 Nm {64.0 kgm}/1,400 min-1{1,400 rpm} (Gross)

107E-1 Series

01 Specification

SAA6D107E-1 (Machine model: WA320-6, WA320PZ-6)

SEN00166-16

Rated horsepower: 127.3 kW {171 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 672 Nm {68.5 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

SAA6D107E-1 (Machine model: WA380-6, WA380Z-6)

01 Specification

Rated horsepower: 143.4 kW {192 HP}/2,100 min-1{2,100 rpm} (Gross) Max. torque: 941 Nm {96.0 kgm}/1,450 min-1{1,450 rpm} (Gross)

107E-1 Series

01 Specification

SAA6D107E-1 (Machine model: BR380JG-1E0)

SEN00166-16

Rated horsepower: 149 kW {200 HP}/2,050 min-1{2,050 rpm} (Gross) Max. torque: 771 Nm {78.6 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

SAA6D107E-1 (Machine model: GD555-5)

01 Specification

Rated horsepower: 146.2 kW {196 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 880 Nm {89.7 kgm}/1,450 min-1{1,450 rpm} (Gross)

107E-1 Series

01 Specification

SAA6D107E-1 (Machine model: GD655-5, GD675-5)

SEN00166-16

Rated horsepower: 164.8 kW {221 HP}/2,100 min-1{2,100 rpm} (Gross) Max. torque: 941 Nm {96.0 kgm}/1,450 min-1{1,450 rpm} (Gross)

107E-1 Series

SEN00166-16

01 Specification

SAA6D107E-1 (Machine model: A6D107E-GD-1 (Portable generator)

60Hz Rated horsepower: 139 kW {186 HP}/1,800 min-1{1,800 rpm} (Gross) 50Hz Rated horsepower: 115 kW {155 HP}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

01 Specification

SAA4D107E-1 (Machine model: PC160LC-7E0, PC160LC-8)

SEN00166-16

Rated horsepower: 90.0 kW {121 HP}/2,200 min-1{2,200 rpm} (Gross) Max. torque: 471 Nm {48.0 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

SAA4D107E-1 (Machine model: PC200LC-8E0)

01 Specification

Rated horsepower: 106.6 kW {143 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 593.9 Nm {60.6 kgm}/1,700 min-1{1,700 rpm} (Gross)

107E-1 Series

01 Specification

SEN00166-16

SAA4D107E-1 (Machine model: HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0 )

Rated horsepower: 110.3 kW {148 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 593.9 Nm {60.6 kgm}/1,700 min-1{1,700 rpm} (Gross)

107E-1 Series

SEN00166-16

SAA4D107E-1 (Machine model: WA200-6, WA200PZ-6)

01 Specification

Rated horsepower: 95.2 kW {128 HP}/2,000 min-1{2,000 rpm} (Gross) Max. torque: 586 Nm {59.8 kgm}/1,400 min-1{1,400 rpm} (Gross)

107E-1 Series

01 Specification

SAA4D107E-1 (Machine model: D39EX-22, D39PX-22)

SEN00166-16

Rated horsepower: 80.0 kW {107 HP}/2,200 min-1{2,200 rpm} (Gross) Max. torque: 476 Nm {48.5 kgm}/1,500 min-1{1,500 rpm} (Gross)

107E-1 Series

SEN00166-16

01 Specification

KOMATSU 107E-1 Series Diesel engine Form No. SEN00166-16

107E-1 Series

SEN00168-07

Engine 1SHOP MANUAL

107E-1 Series

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

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Water pump drive and fan drive .................................................................................................................... 39 Water pump................................................................................................................................................... 41 Thermostat .................................................................................................................................................... 42 Alternator....................................................................................................................................................... 43 Starting motor................................................................................................................................................ 48 Sensor........................................................................................................................................................... 52 Engine controller ........................................................................................................................................... 58 Control system .............................................................................................................................................. 61

107E-1 Series

10 Structure, function and maintenance standard

Intake system

SEN00168-07

General Information

1. 2. 3. 4. 5.

Intake air inlet to turbocharger Turbocharger air to charge air cooler Charge air cooler Intake manifold (integral part of the cylinder head) Intake valve

107E-1 Series

Air is drawn through the air cleaner into the compressor side of the turbocharger. It is then forced through the charge air cooler piping to the charge air cooler, the intake air heater (if applicable), and into the intake manifold. From the intake manifold, air is forced into the cylinders and used for combustion.

SEN00168-07

Exhaust system

10 Structure, function and maintenance standard

General Information

1. 2. 3. 4.

Exhaust valve Exhaust manifold Turbocharger Turbocharger exhaust outlet

The turbocharger uses exhaust gas energy to turn the turbine wheel. The turbine wheel drives the compressor impeller, which provides pressurized air to the engine for combustion. The additional air provided by the turbocharger allows more fuel to be injected to increase the power output from the engine.

The turbine and compressor wheels share a common shaft (referred to as a rotor assembly), which is supported by two rotating bearings in the bearing housing. Passages in the bearing housing direct filtered, pressurized engine oil to the shaft bearings and thrust bearings. The oil is used to lubricate and cool the rotating components. Oil then drains from the bearing housing to the engine sump through the oil drain line.

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Lubricating Oil Consumption and Leaks Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger. The lubricating oil supplied to the turbocharger through the supply line is at engine operating pressure. A return line connected to the bottom of the turbocharger routes the lubricating oil back to the engine lubricating oil pan.

Seal rings are used on each end of the rotor assembly. The primary function of the seals is to prevent exhaust gases and compressed air from entering the turbocharger housing. Lubricating oil leakage from the seals is rare, but it can occur. NOTE: Excessive crankcase pressure will not allow the oil to drain from the turbocharger. This will load the bearing housing and allow lubricating oil to leak past the seal rings and into the engine and exhaust. If turbine seal leakage into the exhaust occurs on engines with a catalyst, check the exhaust restriction during the repair.

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Lubricating oil system

General Information

1. 2. 3. 4. 5. 6. 7.

Gerotor lubricating oil pump From lubricating oil pump Pressure regulating valve closed Pressure regulating valve open To lubricating oil cooler To oil pan Lubricating oil cooler

8. 9. 10. 11. 12. 13. 14.

Filter bypass valve Filter bypass valve closed Filter bypass valve open To lubricating oil filter Full-flow lubricating oil filter From lubricating oil filter Main lubricating oil rifle

Lubrication for the turbocharger 1. 2.

Turbocharger lubricating oil supply Turbocharger lubricating oil drain

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Lubrication for the power components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

From lubricating oil cooler Main lubricating oil rifle To valve train From main lubricating oil rifle To piston-cooling nozzle To camshaft Crankshaft main journal Oil supply to rod bearings Directed piston-cooling nozzle To internal lubrication of air compressor

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Lubrication for the overhead components 1. 2. 3. 4. 5. 6.

Main lubricating oil rifle Rocker lever support Transfer slot Rocker lever shaft Rocker lever bore Rocker lever

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Lubrication for the accessory drive 1. 2.

Oil feed from block Oil supply to accessory drive

NOTE: Oil returns to pan through the gear housing.

107E-1 Series

SEN00168-07

Cooling system

10 Structure, function and maintenance standard

General Information

1. 2. 3. 4. 5.

Coolant inlet Pump impeller Coolant flow past lubricating oil cooler Coolant flow past cylinders Coolant flow from cylinder block to cylinder head 6. Coolant flow between cylinders 7. Coolant flow to thermostat housing 8. Coolant bypass passage 9. Coolant flow back to radiator 10. Bypass open 11. Coolant bypass in cylinder head 12. Coolant flow to water pump inlet

107E-1 Series

10 Structure, function and maintenance standard

Fuel system

SEN00168-07

General Information (Flow Diagram)

1. 2. 3. a 4. 5. 6. 7. 8.

Fuel supply tank Hand primer Prefilter (water/fuel separator) not mounted on engine Clear bowl Gear pump (low pressure fuel pump) Fuel supply pump (high-pressure fuel pump) Fuel main filter Fuel rail (common rail)

a: Injector drain

107E-1 Series

SEN00168-07

Fuel supply pump

10 Structure, function and maintenance standard

Shape may change according to model.

A: Fuel inlet (from prefilter) B: Fuel outlet (to main filter) C: Fuel inlet (from main filter) D: Fuel outlet (to common rail) E: Drain (to fuel tank) 1. 2. 3.

Gear pump (low pressure fuel pump) Fuel supply pump (high pressure fuel pump) Connector of IMA solenoid

Specification q Type: Rotary type with plunger pressure feed q Lubrication method: Fuel lubrication

107E-1 Series

10 Structure, function and maintenance standard

CRI system a

CRI means common rail injection.

Shape may change according to model.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Fuel connector (No. 1) Fuel connector (No. 2) Fuel connector (No. 3) Fuel connector (No. 4) Fuel connector (No. 5) Fuel connector (No. 6) Common rail (fuel rail) Fuel main filter Gear pump (low pressure fuel pump) Fuel supply pump (high pressure fuel pump) Fuel high pressure tube (No. 1) Fuel high pressure tube (No. 2) Fuel high pressure tube (No. 3) Fuel high pressure tube (No. 4) Fuel high pressure tube (No. 5) Fuel high pressure tube (No. 6)

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Injectors and fuel lines - overview General Information q

The fuel system is a high-pressure common rail electronically controlled fuel system. The high-pressure common rail system consists of 4 main components: gear pump (9), fuel supply pump (high-pressure pump) (10), common rail (7), and injectors. The fuel supply pump (high-pressure pump) (10) supplies high-pressure fuel to the common rail (7) independent of engine speed. The high-pressure fuel is then accumulated in the common rail (7). High-pressure fuel is constantly supplied to the injectors by the common rail (7). The engine controller controls the fueling and timing of the engine by actuating the injectors. Prefilter is located off of the engine and has fuel/water separating function. Fuel passed through prefilter flows to the gear pump (9). By gear pump pressure (approximately 0.3 â&#x20AC;&#x201C; 1.3 MPa {3.0 â&#x20AC;&#x201C; 13.3 kg/cm2}), fuel is filtered using an on-engine fuel main filter (8) prior to entering the supply pump (high-pressure fuel pump) (10).

(PS) that monitors the fuel pressure provided to the common rail (7) from the fuel supply pump (10). Fuel pressure measured by the common rail pressure sensor (PS) is used by the engine controller to adjust the fuel output of the fuel supply pump (10). The common rail (7) also contains a common rail pressure relief valve (RV). The common rail pressure relief valve (RV) is a safety valve used to bleed off excess pressure if the rail pressure exceeds a preset threshold. Fuel bled off by the common rail pressure relief valve (RV) is returned to the fuel tank through a fuel drain line connected to the common rail (7).

$ (

The fuel that enters the fuel supply pump (10) is pressurized between 25 and 180 MPa [255 to 1,837 kg/cm 2 ] by three radial pumping chambers. The inlet valve to the 3 radial pumping chambers regulates the volume of fuel that is allowed to enter the pumping chambers. By regulating the volume of fuel that is pressurized, the valve maintain the pressure in the common rail (7) at a desired level. Fuel that is not allowed to enter the 3 radial pumping chambers is directed through the Cascade Overflow Valve. The Cascade Overflow Valve directs a certain amount of pressure to the lube channels of the fuel supply (10) pump and then returns the fuel to the fuel tank. The common rail (7) acts as a fuel manifold accumulating and distributing fuel to each of the injector supply lines. Within the common rail (7), there is a common rail pressure sensor

107E-1 Series

10 Structure, function and maintenance standard

High-pressure common rail fuel systems use solenoid-actuated injectors. High-pressure fuel flows into the side of the injector. When the solenoid is activated, an internal needle lifts and fuel is injected. The engine controller (EC) controls the fueling and timing of the engine by actuating the solenoids on each injector (17). An electronic pulse is sent to the solenoids to lift the needle and start the injection event. By electronically controlling each injector (17), there is a more precise and accurate control of fueling quantity and timing. Also, multiple injection events can be achieved by electronically controlling each injector (17).

SEN00168-07

High-pressure fuel is supplied to the injector (17) from the common rail (7) by fuel high pressure tube (11) and a fuel connector (1). The fuel connector (1) pushes against the injector (17) body when the fuel connector nut (18) is tightened. The fuel high pressure tube (11) is then connected to the fuel connector (1). The torque on this fuel connector (1) and the fuel high pressure tube (11) is critical. If the nut (18) is undertightened, the surfaces will not seal and a high-pressure fuel leak will result. If the nut (18) is overtightened, the connector (1) and injector (17) will deform and cause a highpressure fuel leak. This leak will be inside the head and will not be visible. The result will be a fault code, low power, or no-start.

7. Common rail 10. Fuel supply pump 17. Injector EC: Engine controller PS: Common rail pressure sensor The clearances in the nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. This is why it is important to clean around all fuel connections before servicing the fuel system. Also, cap or cover any open fuel connections before a fuel system repair is performed.

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

The fuel connector contains an edge filter that breaks up small contaminants that enter the fuel system. The edge filter uses the pulsating high pressure to break up any particles so that they are small enough to pass through the injector. NOTE: The edge filters are not a substitute for cleaning and covering all fuel system connections during repair. Edge filters are not a substitute for maintaining the recommended engine mounted fuel filter.

All injectors feed into a common return circuit contained within the cylinder head. Any excess fuel is returned to the tank via this drilling in the cylinder head and return line attached to the rear of the cylinder head. A back-pressure valve is located on the back of the cylinder head where the drain line attaches. The fuel drain lines may have either a quick-disconnect fitting or a banjo fitting at ends of the fuel drain lines. Each of the fuel drain lines combine together at the fuel return manifold.

107E-1 Series

10 Structure, function and maintenance standard

Turbocharger

SEN00168-07

Unit: mm No.

Check item

Criteria

Remedy

Radial play (play in radial direction)

0.329 to 0.501

Replace bearing parts

End play (play in axial direction)

0.038 to 0.093

Replace thrust parts

Tightening torque of turbine housing bolt

107E-1 Series

Target (Nm {kgm}) 26 {2.6}

Tighten

SEN00168-07

Cylinder head

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Strain of cylinder head mounting face

Tightening torque for cylinder head mounting bolt (Apply molybdenum disulfide or engine oil to threaded part)

Projection of nozzle

Tightening torque for injector holder mounting bolt

Tightening torque for head cover mounting bolt

107E-1 Series

Criteria

Remedy

End-to-End

Max. 0.305

Side-to-Side

Max. 0.076

Procedure

Correct by grinding or replace

Target (Nm {kgm})

1st stage

90 {9.2}

2nd stage

90 {9.2}

3rd stage

Retighten 90 degrees 2.45 to 3.15

Tighten and retighten

Replace nozzle or gasket

Target (Nm {kgm}) 8 {0.8}

Tighten

24 {2.4}

SEN00168-07

Cylinder block

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Criteria

Remedy

End-to-End

Max. 0.075

Side-to-Side

Max. 0.075

Correct by grinding or replace

Strain of cylinder head mounting face

Diameter of main bearing metal mounting hole

87.982 to 88.008

Inside diameter of main bearing metal

83.041 to 83.109

Thickness of main bearing metal

2.456 to 2.464

Diameter of cam bushing mounting hole

Max.: 59.248

Correct or replace block

Inside diameter of cam bushing

Max.: 54.164

Replace cam bushing

Tightening torque for main cap mounting bolt (Apply engine oil to threads)

Procedure

1st stage

60 {6.1} 80 {8.2}

Retighten 90 degrees

28 {2.8} Procedure

Target (Nm {kgm})

1st stage

50 {5.1}

2nd stage

Rotate 90 degrees clockwise

Inside diameter of cylinder

106.990 to 107.010

Roundness of inside of cylinder

Repair limit: 0.038

Taper of inside of cylinder

Repair limit: 0.076

107E-1 Series

Tighten and retighten

Target (Nm {kgm})

Tightening torque for oil pan mounting bolt Tightening torque for crankshaft pulley mounting bolt

Replace bearing metal

Target (Nm {kgm})

2nd stage 3rd stage

Replace main bearing metal cap

Tighten

Correct by oversize or replace cylinder block

SEN00168-07

Crankshaft

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No. 1

Check item End play (A) Outside diameter of main journal

Criteria

Remedy

0.065 to 0.432

Replace thrust bearing metal or use oversize metal

82.962 to 83.013

Roundness of main journal

Repair limit: 0.050

Taper of main journal

Repair limit: 0.013

Clearance of main journal Outside diameter of crank pin journal

0.04 to 0.12 68.962 to 69.013

Roundness of crank pin journal

Repair limit: 0.050

Clearance of crank pin journal

0.04 to 0.12

Outside diameter of crankshaft gear journal

70.59 to 70.61

Inside diameter of crankshaft gear journal

70.51 to 70.55

107E-1 Series

Use undersize journal or replace Replace main bearing metal Use undersize journal or replace Replace connecting rod bearing metal Use undersize crankshaft or replace

SEN00168-07

10 Structure, function and maintenance standard

Piston, piston ring and piston pin

Unit: mm No. 1

Check item

Criteria

Outside diameter of piston (at right angles to boss)

106.878 to 106.892 Top ring

Clearance at piston ring end gap

Replace piston

0.33 to 0.43

2nd ring

0.55 to 0.85

Oil ring

0.25 to 0.50

2nd ring

0.040 to 0.110

Oil ring

0.040 to 0.085

Clearance of piston ring

Outside diameter of piston pin

39.997 to 40.003

Inside diameter of piston pin bore

40.006 to 40.012

Remedy

Replace piston ring or piston

Peplace piston or piston pin

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

107E-1 Series

SEN00168-07

Connecting rod

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Criteria

Remedy

40.019 to 40.042

Replace bushing (spare part is semi-finished part)

Inside diameter of connecting rod bushing (when bushing is installed)

Inside diameter of connecting rod bearing

69.05 to 69.10

Thickness of connecting rod bearing

1.955 to 1.968

Inside diameter of connecting rod bearing mounting hole

72.99 to 73.01

Tightening torque for connecting rod cap mounting bolt (Coat thread of bolt nut with engine oil)

Procedure

Side clearance of connecting rod

107E-1 Series

Replace connecting rod bearing Replace connecting rod

Target (Nm {kgm})

1st stage

30 {3.1}

2nd stage

60 {6.1}

3rd stage

Rotate 60 degrees clockwise 0.10 to 0.33

Tighten and retighten

Replace connecting rod

SEN00168-07

10 Structure, function and maintenance standard

Vibration damper

Unit: mm No.

Check item

Tightening torque of vibration damper

Criteria Procedure

Target (Nm {kgm})

1st stage

50 {5.1}

2nd stage

Retighten 90 degrees

Remedy Tighten and retighten

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Timing gear

Unit: mm No.

â&#x20AC;&#x201C;

Check item

Criteria A

0.170 to 0.300

Backlash of camshaft gear

0.076 to 0.280

Backlash of oil pump idler gear

0.170 to 0.300

Backlash of fuel injection pump gear

0.022 to 0.146

Backlash of each gear

107E-1 Series

Remedy

Backlash of oil pump gear

Replace

SEN00168-07

10 Structure, function and maintenance standard

Camshaft

Unit: mm No.

Check item

End play

Outside diameter of camshaft bearing journal

Height of cam

Thickness of camshaft thrust plate

Tightening torque of camshaft thrust plate mounting bolt

Tightening torque of camshaft gear mounting bolt

Criteria 0.100 to 0.360 53.095 to 54.045 Intake Exhaust

Remedy Replace thrust plate Correct or replace

47.175 to 47.855 45.632 to 46.312

Replace

9.40 to 9.60 Target (Nm {kgm}) 24 {2.4}

Tighten

36 {3.7}

107E-1 Series

10 Structure, function and maintenance standard

107E-1 Series

SEN00168-07

Valve and valve guide

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Criteria 0.584 to 1.092

Exhaust

0.965 to 1.473

Sunk depth (A) of valve

Thickness (B) of valve head

Angle of valve seat

Outside diameter of valve stem

Diameter of valve guide bore

7.027 to 7.077

Clearance between valve guide and valve stem

0.017 to 0.117

Depth of valve insert bore (standard insert)

107E-1 Series

Remedy

Intake

Min. 0.79 Valve

Angle

Intake

30 degrees

Exhaust

45 degrees

Replace valve or valve seat Replace

Repair limit Judge condition of contact surface with vacuum test 6.96 to 7.01

34.847 to 34.863

Correct or replace valve, valve seat

Replace Replace valve or valve guide Replace

SEN00168-07

Rocker arm, shaft and tappet

10 Structure, function and maintenance standard

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Criteria

Remedy

Outside diameter of rocker arm shaft

Min. 21.965

Replace rocker arm shaft

Inner diameter of rocker arm shaft hole

Max. 22.027

Replace rocker arm

Clearance between rocker arm shaft and rocker arm

Max. 0.062

Replace rocker arm or shaft

Tightening torque of locknut for rocker arm adjustment screw

Target (Nm {kgm}) 24 {2.4} Valve

Valve clearance (cold)

Tighten

Repair limit

Intake

0.25

Exhaust

0.51

Adjust

Outside diameter of tappet

15.936 to 15.977

Replace tappet

Inside diameter of tappet hole

16.000 to 16.055

Replace cylinder block

Clearance between tappet and tappet hole

0.023 to 0.119

Replace tappet or cylinder block

Tightening torque of rocker arm mounting bolt

107E-1 Series

Target (Nm {kgm}) 36 {3.7}

Tighten

SEN00168-07

10 Structure, function and maintenance standard

Flywheel and flywheel housing 1

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Unit: mm No.

Check item

Criteria

Face runout of flywheel housing

Repair limit: 0.20 <All engine except for generator> 0.28 <A6D107E-GD-1 (Protable generator)>

Radial runout of flywheel housing

Repair limit: 0.20 <All engine except for generator> 0.50 <A6D107E-GD-1 (Protable generator)>

Tightening torque of flywheel housing mounting bolt

Remedy Reassemble, correct

Target (Nm {kgm}) M10: 49 {5.0}

Tighten

M12: 85 {8.7}

5 6

Face runout of flywheel

Flywheel

Repair limit

For clutch

0.013 / Ă¸25.4

For torque converter

Diameter (actual measurement) Ă&#x2014; 0.0005

Radial runout of flywheel

Repair limit: 0.13

Tightening torque of flywheel mounting bolt(Coat bolt thread with engine oil)

Target (Nm {kgm})

107E-1 Series

137 {14.0}

Reassemble, correct

Tigthen and retighten

SEN00168-07

10 Structure, function and maintenance standard

Oil pump

Unit: mm No.

Check item

Criteria

Clearance of rotor in axial direction

Max. 0.127

Clearance between outer rotor and inner rotor

Max. 0.178

Tightening torque of oil pump mounting bolt

Procedure

Target (Nm {kgm})

1st stage

8 {0.8}

2nd stage

24 {2.4}

Remedy Replace oil pump

Tigthen and retighten

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Water pump drive and fan drive

a The shape is subject to machine models. A: To radiator 1. Poly V-belt

5. Alternator

B: From radiator

6. Fan pulley

2. Crankshaft pulley 3. Tension pulley

a, b, c, d, e: Outside diameter of pulley

107E-1 Series

4. Water pump

SEN00168-07

10 Structure, function and maintenance standard

Outside diameter of pulley Unit: mm Engine

SAA6D107E-1

SAA4D107E-1

Applicable machines

a (Water pump)

b (Alternator)

c (Tension)

d (Crank)

e (Fan)

PC200-8

174

200

PC200-8M0 PC200LC-8M0 PC220-8 PC220-8M0 PC220LC-8M0 PC240LC-8M0

174

183

PC270-8

174

169

PC228US-3E0 PC228USLC-3E0

174

182

PC228US-8 PC228USLC-8

174

182

WA320-6

174

158

WA380-6

174

129

WA380Z-6

174

BR380JG-1E0

174

158

A6D107E-GD-1 (Portable generator)

174

158

PC160LC-7E0 PC160LC-8

174

169

PC200-8E0

174

189

HB205-1 HB215LC-1

174

182

HB205-1M0 HB215LC-1M0

174

190

WA200-6

174

158

D39EX-22 D39PX-22

174

ďź?

*1: Air conditioner compressor *2: Idler pulley (for machine without air conditioner)

107E-1 Series

10 Structure, function and maintenance standard

Water pump

SEN00168-07

The shape is subject to machine models.

1. Impeller 2. Water seal 3. Pump body 4. Pulley 5. Drive shaft

Specification Type: centrifugal type, poly V-belt drive

107E-1 Series

SEN00168-07

Thermostat

10 Structure, function and maintenance standard

The shape is subject to machine models.

1. Thermostat A: To radiator

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Alternator

Alternator with built-in regulator (open type, 35 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

107E-1 Series

4B. Regulator 4C. Terminal L load 4D. Starting switch 4E. Battery

SEN00168-07

10 Structure, function and maintenance standard

Pulley Engine

Applicable machines

PC200-8 PC200-8M0 PC200LC-8M0 PC220-8 PC220LC-8 PC220-8M0 PC220LC-8M0 PC240LC-8M0 SAA6D107E-1 PC270-8 PC228US-3E0 PC228USLC-3E0 PC228US-8 PC228USLC-8 BR380JG-1E0 A6D107E-GD-1 (Portable generator)

Type

Specification

Open type, manufactured by DENSO

24 V, 35 A

Number of ribs

Outside diameter (mm)

Weight (kg)

Poly V-ribbed with 8 ribs

77.5

5.4

PC200-8E0 HB205-1 HB215LC-1 SAA4D107E-1 HB205-1M0 HB215LC-1M0 D39EX-22 D39PX-22

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Alternator with built-in regulator (open type, 60 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.Initial energizing resistance 6C.Regulator Pulley

Engine

Applicable machines

SAA6D107E-1 WA380Z-6

107E-1 Series

Type

Specification

Open type, manufactured by Nikko Electric Industry Co.

24 V, 60 A

Number of ribs

Outside diameter (mm)

Weight (kg)

Poly V-ribbed with 8 ribs

11.0

SEN00168-07

10 Structure, function and maintenance standard

Alternator with built-in regulator (open type, 60 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

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Pulley Engine

Applicable machines

PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 PC240LC-8M0 PC228US-8 PC228USLC-8 PC308USLC-3E0 SAA6D107E-1 WA250-6 WA250PZ-6 WA320-6 WA320PZ-6 WA380-6 WA380Z-6 GD655-5 GD675-5

Type

Specification

Open type, manufactured by DENSO

24 V, 60 A

Number of ribs

Outside diameter (mm)

Weight (kg)

Poly V-ribbed with 8 ribs

77.5

6.3

PC160LC-7E0 PC160LC-8 HB205-1 HB215LC-1 HB205-1M0 SAA4D107E-1 HB215LC-1M0 WA200-6 WA200PZ-6 D39EX-22 D39PX-22

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Starting motor

For 4.5 kW

a The shape is subject to machine models. 1. Pinion gear 2. Magnetic switch 3. Starting motor assembly 4. Jump start prohibition 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-1 Series

10 Structure, function and maintenance standard

Engine

Applicable machines

PC200-8 PC200LC-8 PC200-8M0 PC200LC-8M0 PC220-8 PC220LC-8 PC220-8M0 PC220LC-8M0 PC240LC-8M0 PC270-8 SAA6D107E-1 PC228US-3E0 PC228USLC-3E0 PC228US-8 PC228USLC-8 WA250-6 WA250PZ-6 WA320-6 WA320PZ-6 A6D107E-GD-1 (Portable generator)

SAA4D107E-1

SEN00168-07

Type

Specification

Number of pinion teeth

Weight (kg)

Drip proof, oil proof type, manufactured by DENSO

24 V, 4.5 kW

8.4

HB205-1M0 HB215LC-1M0 WA200-6 WA200PZ-6

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

For 5.5 kW

The shape is subject to machine models.

1. Pinion gear 2. Magnetic switch 3. Starting motor assembly 4. Jump start prohibition warning plate 5. Jump start prevention cover 6. 50 (terminal C) 7. 30 (terminal B)

8. Internal electrical circuit diagram 8 A.Relay 8B.Starting switch 8C.Battery 8D.30 (terminal B) 8E.50 (terminal C)

107E-1 Series

10 Structure, function and maintenance standard

Engine

Applicable machines

PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 PC240LC-8M0 PC228US-3E0 PC228USLC-3E0 SAA6D107E-1 PC228US-8 PC228USLC-8 PC308USLC-3E0 WA380-6 WA380Z-6 BR380JG-1E0 GD655-5 GD675-5

SEN00168-07

Type

Specification

Number of pinion teeth

Weight (kg)

Drip proof, oil proof type, manufactured by DENSO

24 V, 5.5 kW

10.5

PC160LC-7E0 PC160LC-8 PC200-8E0 PC200LC-8E0 HB205-1 SAA4D107E-1 HB215LC-1 HB205-1M0 HB215LC-1M0 D39EX-22 D39PX-22

107E-1 Series

SEN00168-07

Sensor

10 Structure, function and maintenance standard

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

107E-1 Series

10 Structure, function and maintenance standard

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

SEN00168-07

Coolant temperature sensor

q q

Connector label: COOLANT TEMP The coolant temperature sensor detects the coolant temperature.

Temperature characteristics of resistance

When the temperature increases, the resistance of the thermistor (TH) decreases.

The thermistor signal (Sig) is connected to the resistor (R) inside the engine controller. The engine controller detects the thermistor voltage (VTH) by applying a voltage of 5 V to the resistor (R) and thermistor (TH) in series. The engine controller calculates the temperature from the thermistor voltage (VTH). If the circuit is open because of a disconnection of the temperature sensor connector (CN) etc., no current flows and thus the voltage does not decrease through the resistor (R) in th e eng in e c o ntr ol le r. As a re s ult , V T H becomes 5 V and the failure code "**** Temp Sensor High Error" is displayed on the machine monitor to notify the abnormality. If short circuit occurs between (A) and (B) or the thermistor signal (Sig) has a ground fault, the failure code "**** Temp Sensor Low Error" is displayed to notify the abnormality.

107E-1 Series

0°C

Resistance

30 to 37 kz

25°C

Resistance

9.3 to 10.7 kz

50°C

Resistance

3.2 to 3.8 kz

80°C

Resistance

1.0 to 1.3 kz

95°C

Resistance

700 to 800 kz

SEN00168-07

10 Structure, function and maintenance standard

Charge (Boost) temperature and pressure sensor

Charge (Boost) temperature and pressure sensor Connector label: BOOST PRESS & IMT a Integrated with the charge (boost) temperature sensor (See the figure at left). - The charge pressure sensor detects the intake air (boost) pressure.

Connector label: BOOST PRESS & IMT a Integrated with the charge (boost) pressure sensor. q The charge temperature sensor detects the intake air (boost) temperature. q

Temperature characteristics of resistance -40°C

Resistance

41 to 48 kz

-20°C

Resistance

14 to 16 kz

0°C

Resistance

5.4 to 6.1 kz

30°C

Resistance

1.6 to 1.8 kz

60°C

Resistance

560 to 600 z

90°C

Resistance

230 to 250 z

130°C

Resistance

80 to 90 z

Pressure sensor The pressure sensor inputs power of 5 V and outputs pressure signals as voltage. The output (pressure - voltage) characteristics depend on each sensor. a The 5 V power supply and GND for the sensor are used partly in common when viewed from the engine controller. a Since semiconductors are used in the sensor, it is impossible to use the resistance to judge if the sensor itself is defective.

Ambient pressure sensor

Connector label: AMB. AIR PRESSURE a The engine controller detects the altitude from the ambient pressure and calculates the oxygen concentration.

107E-1 Series

10 Structure, function and maintenance standard

Common rail pressure sensor

SEN00168-07

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

Connector label: FUEL RAIL PRESS q The common rail pressure sensor is installed in the common rail and detects the fuel pressure. a

a a

Similarly to the temperature sensor, the sensor output voltage is connected to 5 V po we r i ns i d e t he e ng i ne c on tr ol l er. Accordingly, if the circuit is open (if the connector is disconnected), SIG voltage of the common rail pressure sensor becomes 5 V and the failure code "Common Rail Press Sensor High Error" is displayed. When the common rail pressure sensor needs to be replaced, the whole common rail must be replaced. A characteristics graph cannot be obtained.

107E-1 Series

SEN00168-07

Speed sensor

10 Structure, function and maintenance standard

1) q

There are 2 speed sensors; One is the Bkup speed sensor (CAM sensor) and the other is the NE speed sensor (crankshaft sensor). Both of them receive power of 5 V and output the speed signals as pulse voltages of 0 to 5 V. There are the hall element and the waveform shaping circuit in each speed sensor. If the magnetic line of force changes, the output of the hall element sensor changes linearly and it is converted into pulse of 0 to 5 V by the waveform shaping circuit. a The speed sensor functions only when combined with a rotary mating part. a Since semiconductors (not coils) are used in the speed sensor, it is impossible to use the resistance to judge if the sensor itself is defective. a The engine controller can detect the TOP of the No. 1 cylinder by the two speed sensors of the Bkup speed sensor (CAM sensor) and NE speed sensor (crankshaft sensor).

2) q

Bkup speed sensor (CAM sensor) Connector label: CAM SENSOR The Bkup speed sensor (CAM sensor) detects groove (B) of the camshaft ring.

NE speed sensor (Crankshaft sensor) Connector label: CRANK SENSOR The NE speed sensor (Crankshaft sensor) detects a hole (WS) of the wheel that is installed inside the crankshaft damper. There is paint mark (M1) on the damper which is aligned with a hole (WS) of the wheel.

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Engine oil level sensor

1) Connector

This sensor is installed to the oil pan.

2) Bracket

Float (3) moves up and down according to the change of the engine oil level, and it turns switch (4) ON and OFF.

This sensor is installed to the bottom of the prefilter.

If water is accumulated at the bottom of the prefilter, the resistance between elect rodes (2) changes. Sensor (3) detects this change of the resistance.

3) Float 4) Switch

Water-in-fuel sensor

1) Connector 2) Electrode 3) Sensor 4) O-ring

107E-1 Series

SEN00168-07

Engine controller

10 Structure, function and maintenance standard

Features Mounting of engine controller on engine q Since the engine controller is mounted on the engine, the operator can service it easily in the field. q Vibrations are damped by the vibration-proof rubber. Unified specifications of engine controller q Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is employed. (Employment in 107, 114, 125, 140, 170 and 12V 140 engines) 3

Lock screws (L1) and (L2) (at wiring harness side) of connector ECM (DRC26-60) and machine wiring harness connector (DRC2650): 3Âą1 Nm (Use 4 mm hexagonal wrench) a If lock screws (L1) and (L2) (at wiring harness side) are tightened excessively, the female screws will be broken and the engine controller will have to be replaced. Take care.

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

Input/Output signal q The following is the list of the symbols used for signal classification in the input/output signal table. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication Connector ECM (DRC26-60P) 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

Signal name NC (*) IMA power supply Ambient pressure sensor NC (*) NC (*) CAN (-) NC (*) CAN (+) NC (*) NC (*) NC (*) NC (*) NC (*) Water-in-fuel sensor Coolant temperature sensor Sensor power supply (5 V) Engine oil pressure switch NC (*) NC (*) NC (*) NC (*) NC (*) Intake air temperature sensor NC (*) Common rail pressure sensor Camshaft speed sensor (+) Crankshaft speed sensor (+) NC (*) NC (*) NC (*)

Signal classification – D B – – E – E – – – – – B B A,D B – – – – – B – B B B – – –

Pin No. 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 NC (*) IMA return Sensor power supply (5 V) NC (*) NC (*) NC (*) Sensor power supply (5 V) GND NC (*) NC (*) NC (*) NC (*) NC (*) Boost pressure sensor Injector #1 (+) Injector #5 (+) Sensor GND Crankshaft speed sensor (-) NC (*) NC (*) Injector #2 (–) Injector #3 (–) Injector #1 (–) Injector #2 (+) Injector #3 (+) Injector #4 (+) Injector #6 (+) Injector #4 (–) Injector #6 (–) Injector #5 (–)

Signal classification – C A,D – – – A,D C – – – – – B D D C C – – C C C D D D D C C C

*: Never connect any cable to NC, or malfunctions or failures will occur.

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

Connector for machine wiring harness (DRC26-50P) a Connector lable changes according to model Signal Pin No. Signal name classification 1 Idle validation 2 B 2 NC (*) – 3 NC (*) – 4 NC (*) – 5 NC (*) – 6 NC (*) – 7 NC (*) – 8 NC (*) – 9 Fuel control dial (+) B 10 NC (*) – 11 Idle validation 1 B 12 NC (*) – 13 NC (*) – 14 NC (*) –

Signal category

Pin No.

Signal name

26 27 28 29 30 31 32 33 34 35 36 37 38 39

NC (*) NC (*) NC (*) IVS P (-) NC (*) NC (*) OEM sensor (-) DIS_SEL0 (GND) NC (*) NC (*) NC (*) NC (*) NC (*) Starting switch ACC signal Electrical intake air heater relay drive NC (*) Electrical intake air heater relay return NC (*) NC (*) NC (*) CAN (+) CAN (-) NC (*) Engine controller power cutoff relay NC (*)

NC (*)

–

NC (*)

–

NC (*)

–

18 19 20 21 22 23 24 25

NC (*) NC (*) NC (*) OEM sensor supply (+5V) Fuel control dial (5 V) Fuel control dial (–) NC (*) NC (*)

– – – A,D A,D C – –

43 44 45 46 47 48 49 50

– – – C – – C C – – – – – A,B D – C – – – E E – D –

*: Never connect any cable to NC, or malfunctions or failures will occur. Connector for power supply (DTP-4P) a Connector lable changes according to model Pin No. 1 2 3 4

Signal name GND GND Continuous power supply (24 V) Continuous power supply (24 V)

Signal classification C C A,B A,B

107E-1 Series

10 Structure, function and maintenance standard

Control system

SEN00168-07

The CRI* system checks the condition of the engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors. The engine controller of the CRI system controls the fuel injection rate, fuel injection timing, fuel injection pressure, etc. totally to operate the engine under the best condition. The CRI system has a diagnosis function which engine controller checks the main component parts and notifies the operator of detected failures. In addition, the CRI system has a failsafe function which stops the engine when a certain parts fail and a backup function which continues the operation by changing the control method in such a case. *: CRI means common rail injection.

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

1.Fuel injection rate control function q

The fuel injection rate control function is employed instead of the function of the conventional governor. It controls the fuel injection for each injector according to the signals of engine speed and accelerator angle so that the fuel injection rate will be most proper.

107E-1 Series

10 Structure, function and maintenance standard

SEN00168-07

2.Fuel injection timing control function q

The fuel injection timing control function is employed instead of the function of the conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

3.Fuel injection pressure control function (Common rail fuel pressure control function) q

The fuel injection pressure control function (common rail fuel pressure control function) is a function of measuring the fuel pressure with the common rail fuel pressure sensor and feeding it back to the engine controller to control the delivery of the fuel supply pump. This function performs pressure feedback control so that the fuel injection pressure will be the same as the optimum value (command value) set according to the engine speed and fuel injection rate.

107E-1 Series

10 Structure, function and maintenance standard

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

*: Label of power supply connector (DTP-4) and machine wiring harness connector (DRC26-50) changes according to model. a Power supply wiring harness and pin name of machine wiring harness connector (DRC26-50) are an example of PC200-8 a Engine wiring harness is common to all model.

107E-1 Series

10 Structure, function and maintenance standard

107E-1 Series

SEN00168-07

SEN00168-07 a

Exclusive for generator

10 Structure, function and maintenance standard a

SEN00168-07

Exclusive for generator

107E-1 Series

SEN00168-07

10 Structure, function and maintenance standard

KOMATSU 107E-1 Series Diesel engine Form No. SEN00168-07

107E-1 Series

SEN00248-16

Engine 1SHOP MANUAL

107E-1 Series

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

107E-1 Series

SEN00248-16

20 Standard value table

Air intake and exhaust system

Performance

Category

Standard value table for testing, adjusting and troubleshooting Engine

SAA6D107E-1

Applicable machine

PC200-8, PC200LC-8

Item Engine speed

Body Lubrication system Cooling system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,740

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

20 Standard value table

SEN00248-16

Air intake and exhaust system

Performance

Category

1 Engine

SAA6D107E-1

Applicable machine

PC200-8M0, PC200LC-8M0

Item Engine speed

Body Lubrication system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

1,050 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,920

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC220-8, PC220LC-8

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,160 ± 50

Min. speed with no load

rpm

1,050 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,920

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC220-8M0, PC220LC-8M0, PC240LC-8M0

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,180 ± 50

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,920

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC270-8

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,180 ± 50

Min. speed with no load

rpm

1,050 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,100}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

2,112

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC228US-3E0, PC228USLC-3E0

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

2,100

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC228US-8, PC228USLC-8

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

1,050 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,920

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

PC308USLC-3E0

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,180 ± 50

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,100}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

2,255

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

WA250-6, WA250PZ-6

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,250 ± 50

Min. speed with no load

rpm

825 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 120 {Min. 900}

93 {700}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

WA320-6, WA320PZ-6

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,250 ± 50

Min. speed with no load

rpm

825 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

WA380-6, WA380Z-6

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,250 ± 50

Min. speed with no load

rpm

850 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

BR380JG-1E0

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,330 ± 50

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,100}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

2,255

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

GD555-5

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,200 ± 50

Min. speed with no load

rpm

825 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,100}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

GD655-5, GD675-5

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,200 ± 25

Min. speed with no load

rpm

825 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 160 {Min. 1,200}

133 {1,000}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA6D107E-1

Applicable machine

A6D107E-GD-1 (Portable generator) Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

Max. 1,890

Min. speed with no load

rpm

650 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,102}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 650

700

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

At rated horsepower

kPa {mmH2O}

Max. 1.18 {Max. 120}

1.96 {200}

At rated horsepower (At 60 Hz) (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Item Engine speed

Exhaust gas color

Body

Valve clearance

Compression pressure

Cooling system

Lubrication system

Blowby pressure

Oil pressure

Measurement conditions

Oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

49 {0.5}

Fan speed

At rated engine speed (At 60 Hz)

rpm

1,980

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA4D107E-1

Applicable machine

PC160LC-7E0, PC160LC-8

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,320 ± 30

Min. speed with no load

rpm

1,050 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 133 {Min. 1,000}

107 {800}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 680

730

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

2,266

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA4D107E-1

Applicable machine

PC200LC-8E0

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

700 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 133 {Min. 1,000}

107 {800}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 700

750

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

1,895

Auto-tensioner

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA4D107E-1

Applicable machine

HB205-1, HB215LC-1 HB205-1M0, HB215LC-1M0

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,060 ± 50

Min. speed with no load

rpm

700 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 133 {Min. 1,000}

107 {800}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 700

750

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.381

Exhaust valve

0.51

0.381 to 0.762

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

Air intake and exhaust system

Performance

Category

SEN00248-16

20 Standard value table

Engine

SAA4D107E-1

Applicable machine

WA200-6, WA200PZ-6

Item Engine speed

Body Lubrication system Cooling system

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,250 ± 50

Min. speed with no load

rpm

825 ± 25

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 147 {Min. 1,100}

120 {900}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 700

750

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.382

Exhaust valve

0.51

0.381 to 0.763

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Unit

Measurement conditions

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

107E-1 Series

Air intake and exhaust system

Performance

Category

20 Standard value table

Engine

SAA4D107E-1

Applicable machine

D39EX-22, D39PX-22

Item Engine speed

Body Lubrication system

Unit

Standard value for new machine

Repair limit

Max. speed with no load

rpm

2,400 ± 50

Min. speed with no load

rpm

975 ± 25

Measurement conditions

Necessary starting speed

At 0°C

rpm

—

At –20°C

rpm

—

Intake resistance

At all speed

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.45 {760}

Intake pressure (Aftercooler inlet)

At rated horsepower

kPa {mmHg}

Min. 140 {Min. 1,050}

113 {850}

Exhaust pressure (Turbine inlet press.)

At rated horsepower

kPa {mmHg}

—

Exhaust temperature (Turbine outlet temp.)

At all speed (at 20°C)

°C

Max. 700

750

At rated horsepower

Opacity %

Max. 12

Quick acceleration (Low idle o high idle)

Opacity %

Max. 25

Intake valve

0.25

0.152 to 0.382

Exhaust valve

0.51

0.381 to 0.763

Oil temperature: 40 to 60°C Compression pressure Engine speed: 250 to 280 rpm

MPa {kg/cm2}

Min. 2.41 {Min. 24.6}

1.69 {17.2}

Blowby pressure

At rated horsepower

kPa {mmH2O}

Max. 0.98 {Max. 100}

1.96 {200}

At rated horsepower (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

At low idle (Oil temperature: Min. 80°C) SAE15W-40

MPa {kg/cm2}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Exhaust gas color

Valve clearance

Cooling system

SEN00248-16

Oil pressure

Oil temperature

At all speed (Oil in oil pan)

°C

80 to 110

120

Oil consumption ratio

At continuous rated horsepower (Ratio to fuel consumption)

Max. 0.15

0.3

Radiator pressure valve

Opening pressure (Differential pressure)

kPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

Fan and alternator belt Deflects when pushed with a tension finger force of 98 N {10 kg}

107E-1 Series

Hydraulically driven on machine side Auto-tensioner

Auto-tensioner

SEN00248-16

20 Standard value table

Running-in standard and performance test criteria

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC200-8, PC200LC-8 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

771 {78.6}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

116 {155}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC200-8, PC200LC-8

Test item

Rated horsepower

Max. torque 624+19.6/–39.2 Nm/ 1,500 ± 100 rpm {63.6+2/–4 kgm/ 1,500 ± 100 rpm}

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

116 ± 5.81 kW/ 2,000 rpm {155 ± 8 HP/ 2,000 rpm}

Engine speed

rpm

2,000

1,500 ± 100

2,060 ± 50

1,050 ± 25

Dynamometer load

N {kg}

771 {78.6}

871 {88.8}

—

Output (Gross)

kW {HP}

116 {155}

—

Torque (Gross)

Nm {kgm}

—

624 {63.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

2,060 ± 50 rpm 1,050 ± 25 rpm

This table shows the standard values using the JIS correction factor. The output and torque values in the table are the standard values with the fan removed, so they are different from the specification values. This table shows the standard values when an air cleaner and a muffler are installed, and no load is applied to the alternator. The dynamometer load shows the value for an arm length of 716 mm. Use ASTM D975 diesel oil as the fuel. Use SAE15W-40 as the lubricating oil.

107E-1 Series

20 Standard value table

SEN00248-16

1 Running-in standard Engine

SAA6D107E-1

Applicable machine

PC200-8M0, PC200LC-8M0 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

732 {74.6}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

109.7 {147.1}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC200-8M0, PC200LC-8M0

Test item

Rated horsepower

Max. torque 602 ± 30 Nm/ 1,500 rpm {61.4 ± 3.1 kgm/ 1,500 rpm}

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

109.7 ± 5.5 kW/ 2,000 rpm {147.1 ± 7.4 HP/ 2,000 rpm}

Engine speed

rpm

2,000

1,500

2,060 ± 50

1,050 ± 25

Dynamometer load

N {kg}

732 {74.6}

841 {85.8}

—

Output (Gross)

kW {HP}

109.7 {147.1}

—

Torque (Gross)

Nm {kgm}

—

602 {61.4}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to110

80 to 110

Lubricating oil pressure

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}

Exhaust temperature (Turbine outlet temperature)

°C

Max. 550

Max. 590

—

a a a a a a

2,060 ± 50 rpm 1,050 ± 25 rpm

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC220-8, PC220LC-8 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

892 {91}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

134 {179}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC220-8, PC220LC-8

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,000

1,500 ± 100

2,160 ± 50

1,050 ± 25

Dynamometer load

N {kg}

892 {91}

991 {101.0}

—

Output (Gross)

kW {HP}

134 {179}

—

Torque (Gross)

Nm {kgm}

—

710 {72.4}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

134±6.69 kW/2,000 rpm 710±34.3 Nm/1,500±100 rpm 2,160 ± 50 rpm 1,050 ± 25 rpm {179±9 HP/2,000 rpm} {72.4±3.5 kgm/1,500±100 rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC220-8M0, PC220LC-8M0, PC240LC-8M0 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

863 {88}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

129.3 {173.3}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC220-8M0, PC220LC-8M0,PC240LC-8M0

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,000

1,500 ± 100

2,160 ± 50

1,050 ± 25

Dynamometer load

N {kg}

863 {88}

964 {98.3}

—

Output (Gross)

kW {HP}

129.3 {173.3}

—

Torque (Gross)

Nm {kgm}

—

690 {70.4}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature (Turbine outlet temperature)

°C

Max. 550

Max. 590

—

a a a a a a

129.6±6.4 kW/2,000 rpm 690±34.3 Nm/1,500±100 rpm 2,160 ± 50 rpm 1,050 ± 25 rpm {173.3 ± 8.6 HP/2,000 rpm} {70.4±3.5 kgm/1,500±100 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC270-8 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,050

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

971 {99}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

149 {200}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC270-8

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,050

1,500 ± 100

2,180 ± 50

1,050 ± 25

Dynamometer load

N {kg}

971 {99}

1,077 {109.8}

—

Output (Gross)

kW {HP}

149 {200}

—

Torque (Gross)

Nm {kgm}

—

771 {78.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to110

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

149±7.43 kW/2,050 rpm 771±38.2 Nm/1,500±100 rpm 2,180 ± 50 rpm 1,050 ± 25 rpm {200±10 HP/2,050 rpm} {78.6±3.9 kgm/1,500±100 rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC228US-3E0, PC228USLC-3E0 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

771 {78.6}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

116 {155}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC228US-3E0, PC228USLC-3E0

Test item

Rated horsepower

Max. torque 624+19.6/–39.2 Nm/ 1,500 ± 100 rpm {63.6+2/–4 kgm/ 1,500 ± 100 rpm}

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

116 ± 5.81 kW/ 2,000 rpm {155 ± 8 HP/ 2,000 rpm}

Engine speed

rpm

2,000

1,500 ± 100

2,060 ± 50

1,050 ± 25

Dynamometer load

N {kg}

771 {78.6}

871 {88.8}

—

Output (Gross)

kW {HP}

116 {155}

—

Torque (Gross)

Nm {kgm}

—

624 {63.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to110

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

2,060 ± 50 rpm 1,050 ± 25 rpm

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC228US-8, PC228USLC-8 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

771 {78.6}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

116 {155}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC228US-8, PC228USLC-8

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

116 ± 5.81 kW/ 2,000 rpm {155 ± 8 HP/ 2,000 rpm}

623.7 ± 31.2 Nm/ 1,500 ±100 rpm {63.6 ± 3.2 kgm/ 1,500 ± 100 rpm}

Engine speed

rpm

2,000

1,500 ± 100

2,060 ± 50

1,050 ± 25

Dynamometer load

N {kg}

771 {78.6}

871 {88.8}

—

Output (Gross)

kW {HP}

116 {155}

—

Torque (Gross)

Nm {kgm}

—

624 {63.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

2,060 ± 50 rpm 1,050 ± 25 rpm

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

PC308USLC-3E0 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,050

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

971 {99}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

149 {200}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

PC308USLC-3E0

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,050

1,500 ± 100

2,180 ± 50

1,050 ± 25

Dynamometer load

N {kg}

971 {99}

1,077 {109.8}

—

Output (Gross)

kW {HP}

149 {200}

—

Torque (Gross)

Nm {kgm}

—

771 {78.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

149±7.43 kW/2,050 rpm 771±38.2 Nm/1,500±100 rpm 2,180 ± 50 rpm 1,050 ± 25 rpm {200±10 HP/2,050 rpm} {78.6±3.9 kgm/1,500±100 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

WA250-6, WA250PZ-6 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

694 {71}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

104.1 {140}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

WA250-6, WA250PZ-6

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,000

1,400 ± 100

2,250 ± 50

825 ± 25

Dynamometer load

N {kg}

694 {71}

875 {89.4}

—

Output (Gross)

kW {HP}

104.1 {140}

—

Torque (Gross)

Nm {kgm}

—

627 {64.0}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

kPa {kg/cm2}

Min. 261.8 {Min. 2.67}

Min. 193.2 {Min. 1.97}

Min. 294 {Min. 3.0}

Min. 98 {Min. 1.0}

Exhaust temperature

°C

Max. 650

—

a a a a a a

104.1 ± 5.2 kW/2,000 rpm 627 ± 31 Nm/1,400 ± 100 rpm 2,250 ± 50 rpm 825 ± 25 rpm {140 ± 7.1 HP/2,000 rpm} {64 ± 3.2 kgm/1,400 ± 100rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

WA320-6, WA320PZ-6 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,100

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

853 {87}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

127.3 {171}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

WA320-6, WA320PZ-6

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

127.3 ± 6.4kW/2,000 rpm {171 ± 8.6 HP/2,000 rpm}

672 ± 34 Nm/1,500 rpm {68.5 ± 3.5 kgm/1,500 rpm}

Engine speed

rpm

2,000

1,500

2,250 ± 50

825 ± 25

Dynamometer load

N {kg}

853 {87}

938 {95.7}

—

Output (Gross)

kW {HP}

127.3 {171}

—

Torque (Gross)

Nm {kgm}

—

672 {68.5}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

kPa {kg/cm2}

Min. 261.8 {Min. 2.67}

Min. 193.2 {Min. 1.97}

Min. 294 {Min. 3.0}

Min. 98 {Min. 1.0}

Exhaust temperature

°C

Max. 650

—

a a a a a a

2,250 ± 50 rpm 825 ± 25 rpm

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

WA380-6, WA380Z-6 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,100

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

911 {93}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

143.4 {192}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

WA380-6, WA380Z-6

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,100

1,450 ± 100

2,250 ± 50

850 ± 25

Dynamometer load

N {kg}

911 {93}

1,315 {134.1}

—

Output (Gross)

kW {HP}

143.4 {192}

—

Torque (Gross)

Nm {kgm}

—

941 {96.0}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

kPa {kg/cm2}

Min. 294 {Min. 3.0}

Min. 193.2 {Min. 1.97}

Min. 294 {Min. 3.0}

Min. 98 {Min. 1.0}

Exhaust temperature

°C

Max. 700

—

a a a a a a

143.4 ± 7.21kW/2,100rpm 941 ± 47 Nm/1,450 ± 100 rpm 2,250 ± 50 rpm 850 ± 25 rpm {192 ± 9.7 HP/2,100 rpm} {96.0± 4.8kgm/1,450 ± 100rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

BR380JG-1E0 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,050

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

971 {99}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

149 {200}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

BR380JG-1E0

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,050

1,500 ± 100

2,330 ± 50

1,050 ± 25

Dynamometer load

N {kg}

971 {99}

1,077 {109.8}

—

Output (Gross)

kW {HP}

149 {200}

—

Torque (Gross)

Nm {kgm}

—

771 {78.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

—

a a a a a a

149±7.43 kW/2,050 rpm 771±38.2 Nm/1,500±100 rpm 2,330 ± 50 rpm 1,050 ± 25 rpm {200±10 HP/2,050 rpm} {78.6±3.9 kgm/1,500±100 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

GD555-5 Procedure

Item 1

Running time

min

Engine speed

rpm

825

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

973 {99.2}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

146.2 {196}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

GD555-5

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,000

1,450

2,200 ± 50

825 ± 25

Dynamometer load

N {kg}

973 {99.2}

1,229 {125.3}

—

Output (Gross)

kW {HP}

146.2 {196}

—

Torque (Gross)

Nm {kgm}

—

880 {89.7}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

82 to 95

Lubricating oil temperature

°C

80 to 120

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

Max. 690

—

a a a a a a

146.2 ± 7.3 kW/2,000 rpm 880 ± 44 Nm/1,450 rpm 2,200 ± 50 rpm 825 ± 25 rpm {176 ± 9.8 HP/2,000 rpm} {89.7 ± 4.5 kgm/1,450 rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA6D107E-1

Applicable machine

GD655-5, GD675-5 Procedure

Item

a a

Running time

min

Engine speed

rpm

825

1,000

1,200

1,600

2,100

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

1,047 {106.7}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

53 {71}

164.8 {221}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

GD655-5, GD675-5

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,100

1,450

2,200 ± 25

825 ± 25

Dynamometer load

N {kg}

1,047 {106.7}

1,314 {134}

—

Output (Gross)

kW {HP}

164.8 {221}

—

Torque (Gross)

Nm {kgm}

—

941 {96.0}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

82 to 95

Lubricating oil temperature

°C

80 to 120

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

Max. 690

—

a a a a a a

164.8 ± 8.2 kW/2,100 rpm 941 ± 47 Nm/1,450 rpm 2,200 ± 25 rpm 825 ± 25 rpm {221±11.1HP/2,100rpm} {96.0 ± 4.8 kgm/1,450 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA6D107E-1

Applicable machine

A6D107E-GD-1 (Portable generator) Procedure

Item 1

Running time

min

Engine speed

rpm

650

1,000

1,200

1,500

1,800

Dynamometer load

N {kg}

0 {0}

98 {10}

245 {25}

440 {45}

1,030 {105}

Output

kW {HP}

0 {0}

7.4 {10}

22 {29.5}

50 {68}

139 {189}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA6D107E-1

Applicable machine

A6D107E-GD-1 (Portable generator)

Test item

50 Hz Rated horsepower

60 Hz Rated horsepower

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

115 ± 5.81 kW/1,500 rpm {155 ± 7.8 HP/1,500 rpm}

139 ± 6.99 kW/1,800 rpm {186 ± 9.4 HP/1,800 rpm}

Engine speed

rpm

1,500

1,800

Max. 1,890

650 ± 25

Dynamometer load

N {kg}

1,027 {104.7}

1,030 {105}

—

Output (Gross)

kW {HP}

115 {155}

139 {186}

—

Torque (Gross)

Nm {kgm}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 110

Lubricating oil pressure

kPa {kg/cm2}

Min. 193.2 {Min. 1.97}

Min. 261.8 {Min. 2.67}

Min. 98 {Min. 1.0}

Exhaust temperature

°C

Max. 650

—

a a a a a a

Max.1,890 rpm 650 ± 25 rpm

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA4D107E-1

Applicable machine

PC160LC-7E0, PC160LC-8 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,050

Dynamometer load

N {kg}

0 {0}

98 {10}

147 {15}

245 {25}

545 {55.6}

Output

kW {HP}

0 {0}

7.4 {10}

13.2 {18}

29.4 {39}

90 {121}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA4D107E-1

Applicable machine

PC160LC-7E0, PC160LC-8

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,200

1,500

2,320 ± 30

1,050 ± 25

Dynamometer load

N {kg}

545 {55.6}

657 {67.0}

—

Output (Gross)

kW {HP}

90 {121}

—

Torque (Gross)

Nm {kgm}

—

471 {48.0}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 120

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

Max. 680

—

a a a a a a

90.0 ± 4.5 kW/2,200 rpm 471 ± 23.5 Nm/1,500 rpm 2,320 ± 30 rpm 1,050 ± 25 rpm {121 ± 6 HP/2,200 rpm} {48.0 ± 2.4 kgm/1,500 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA4D107E-1

Applicable machine

PC200LC-8E0 Procedure

Item 1

Running time

min

Engine speed

rpm

700

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

147 {15}

245 {25}

711 {72.5}

Output

kW {HP}

0 {0}

7.4 {10}

13.2 {18}

29.4 {39}

106.6 {143}

Max. speed with no load

Min. speed with no load

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA4D107E-1

Applicable machine

PC200LC-8E0

Test item

Rated horsepower

Max. torque

Specification value (Gross)

—

Engine speed

rpm

2,000

1,700

2,060 ± 50

700 ± 25

Dynamometer load

N {kg}

711 {72.5}

829 {84.6}

—

Output (Gross)

kW {HP}

106.6 {143}

—

Torque (Gross)

Nm {kgm}

—

593.9 {60.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

82 to 95

Lubricating oil temperature

°C

80 to 120

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 700

Max. 750

—

a a a a a a

106.6 ± 5.4 kW/2,200 rpm 593.9 ± 29 Nm/1,700 rpm 2,060 ± 50 rpm 700 ± 25 rpm {143 ± 7.0 HP/2,000 rpm} {60.6 ± 3.0 kgm/1,700 rpm}

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA4D107E-1

Applicable machine

HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0 Procedure

Item

a a

Running time

min

Engine speed

rpm

700

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

147 {15}

245 {25}

735 {75.0}

Output

kW {HP}

0 {0}

7.4 {10}

13.2 {18}

29.4 {39}

110.3 {148}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA4D107E-1 HB205-1, HB215LC-1, HB205-1M0, HB215LC-1M0

Applicable machine Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,000

1,700

2,060 ± 50

700 ± 25

Dynamometer load

N {kg}

735 {75.0}

829 {84.6}

—

Output (Gross)

kW {HP}

110.3 {148}

—

Torque (Gross)

Nm {kgm}

—

593.9 {60.6}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

82 to 95

Lubricating oil temperature

°C

80 to 120

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 700

Max. 750

—

a a a a a a

110.3 ± 5.5 kW/2,200 rpm 593.9 ± 29 Nm/1,700 rpm 2,060 ± 50 rpm 700 ± 25 rpm {148 ± 7.0 HP/2,000 rpm} {60.6 ± 3.0 kgm/1,700 rpm}

107E-1 Series

SEN00248-16

20 Standard value table

Running-in standard Engine

SAA4D107E-1

Applicable machine

WA200-6, WA200PZ-6 Procedure

Item 1

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,000

Dynamometer load

N {kg}

0 {0}

98 {10}

147 {15}

245 {25}

635 {64.8}

Output

kW {HP}

0 {0}

7.4 {10}

13.2 {18}

29.4 {39}

95.2 {128}

a a

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA4D107E-1

Applicable machine

WA200-6, WA200PZ-6

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

95.2 ± 4.78 kW/2,000 rpm {128 ± 6.4 HP/2,000 rpm}

586 ± 29 Nm/1,400 rpm {59.8 ± 3.0 kgm/1,400 rpm}

Engine speed

rpm

2,000

1,400

2,250 ± 50

825 ± 25

Dynamometer load

N {kg}

635 {64.8}

819 {83.5}

—

Output (Gross)

kW {HP}

95.2 {129.5}

—

Torque (Gross)

Nm {kgm}

—

586 {59.8}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 120

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

Max. 700

—

a a a a a a

2,250 ± 50 rpm 825 ± 25 rpm

107E-1 Series

20 Standard value table

SEN00248-16

Running-in standard Engine

SAA4D107E-1

Applicable machine

D39EX-22, D39PX-22 Procedure

Item

a a

Running time

min

Engine speed

rpm

1,050

1,000

1,200

1,600

2,200

Dynamometer load

N {kg}

0 {0}

98 {10}

147 {15}

245 {25}

484 {49.4}

Output

kW {HP}

0 {0}

7.4 {10}

13.2 {18}

29.4 {39}

80 {107}

The table gives the standard values for machines without fan. The loads for the dynamometer are at an arm’s length of 716 mm.

Performance test criteria Engine

SAA4D107E-1

Applicable machine

D39EX-22, D39PX-22

Test item

Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

Specification value (Gross)

—

Engine speed

rpm

2,200

1,500

2,400 ± 50

975 ± 25

Dynamometer load

N {kg}

484 {49.4}

664 {67.7}

—

Output (Gross)

kW {HP}

80.0 {107}

—

Torque (Gross)

Nm {kgm}

—

476 {48.5}

—

Fuel consumption

sec/ 300cc

—

Coolant temperature

°C

75 to 94

Lubricating oil temperature

°C

80 to 120

80 to 110

Lubricating oil pressure

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}

Exhaust temperature

°C

Max. 650

Max. 700

—

a a a a a a

800 ± 4.0 kW/2,200 rpm 476 ± 23.5 Nm/1,500 rpm 2,400 ± 50 rpm 975 ± 25 rpm {108.7 ± 5.3 HP/2,200 rpm} {48.5 ± 2.4 kgm/1,500 rpm}

107E-1 Series

SEN00248-16

KOMATSU 107E-1 Series Diesel engine Form No. SEN00248-16

SEN00250-09

Engine 1SHOP MANUAL

107E-1 Series

30 Testing and adjusting

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

SEN00250-09

30 Testing and adjusting

Testing and adjusting tools list Testing and adjusting item

Symbol

Testing boost pressure Adjusting valve clearance

Testing compression pressure

Testing blowby pressure

Testing oil pressure

Remarks

799-201-2202 Boost gauge kit

–101 – 200 kPa {–760 – 1,500 mmHg} I-coupler type (if necessary)

795-799-1131 Gear

Commercially Clearance gauge available

795-799-6700 Puller

795-502-1590 Gauge assembly

795-790-4410 Adapter

6754-11-3130 Gasket

799-201-1504 Blowby checker

795-790-3300 Blowby tool

799-101-5002 Hydraulic tester

F 2 3

790-301-1230 Nipple

799-101-5160 Nipple

799-401-2320 Gauge

Pressure gauge: 1.0 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

G 2

0 – 5 kPa {0 – 500 mmH2O} Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

6732-81-3170 Adapter

10 × 1.0 mm o Rc1/8

795-790-4430 Adapter

10 × 1.0 mm o Rc1/8

6215-81-9710 O-ring

799-401-2320 Gauge

Pressure gauge: 1.0 MPa {10 kg/cm2}

795-790-5110 Screw

799-201-2202 Boost gauge kit

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

795-790-4430 Adapter

10 × 1.0 mm o Rc1/8

6215-81-9710 O-ring

799-201-2202 Boost gauge kit

G 2 5 6

795-790-5110 Screw

799-401-2320 Gauge

795-790-4700 Tester kit

6754-71-5340 Connector

6754-71-5350 Washer

Commercially Measuring cylinder available

Commercially Stopwatch available

Commercially Hose available

Inside diameter: ø14 mm

Commercially Hose available

Inside diameter: ø8 mm

Testing fuel delivery, return and leak amount

Q'ty

799-401-2220 Hose

Testing fuel pressure (*)

Part name

Testing fuel pressure

Part No.

Pressure gauge: 1.0 MPa {10 kg/cm2}

*: Devices shown with this mark are for testing and adjustment for HB205-1M0 and HB215LC-1M0 .

107E-1 Series

30 Testing and adjusting

Testing and adjusting item

SEN00250-09

Symbol 1 2

Testing fuel delivery, return and leak amount (*)

Part No.

Part name

795-790-4700 Tester kit

Q'ty 1

6754-71-5340 Connector

6754-71-5350 Washer

6164-81-5790 Joint

6745-71-1130 Seal washer

07206-30812 Joint bolt

Commercially Stopwatch available

Commercially Measuring cylinder available

Commercially Hose available

H 5

Remarks

Measuring voltage and resistance

—

Commercially Circuit tester available

Removal and installation of booster pressure and temperature sensors

—

795-799-6210 Hexlobe (TORX) wrench

3.26 mm Hexlobe (TORX) wrench (KTC Q4T15 or equivalent)

Removal and installation of engine oil pressure sensor

—

Commercially Deep socket available

27 mm deep socket

21 mm deep socket (MITOLOY 4ML-21 or equivalent) Applicable engine serial No. : 26500006 - 26530192

795T-981-1010 Socket

19 mm deep socket (MITOLOY 4ML-19 or equivalent) Applicable engine serial No. : 26530193 and up

799-601-7400 T-adapter assembly

AMP040 Connector

799-601-7500 T-adapter assembly

AMP070 Connector

799-601-9000 T-adapter assembly

DT, HD30 Connector

799-601-9300 T-adapter assembly

DRC26-40 (5 pins)

799-601-7360 Adapter

Relay (5 pins)

799-601-7310 T-adapter

SWP (12 poles)

799-601-7070 T-adapter

SWP (14 poles)

799-601-4100 T-adapter assembly

Connected with engine

799-799-5530 T-adapter

Engine coolant temperature

799-601-4230 T-adapter

Boost temperature/pressure sensor

799-601-4130 T-adapter

Ne sensor, CAM sensor

799-601-4160 T-adapter

Hydraulic pressure sensor

799-601-4211 T-adapter

Controller (50 poles)

Removal and installation of engine cool— ant temperature sensor —

Diagnosis sensor and harness

—

Commercially Socket available

799-601-4220 T-adapter

Controller (60 poles)

799-601-4140 T-adapter

Atmosperic pressure sensor

799-601-4340 T-adapter

Pump actuator

799-601-4260 T-adapter

Controller (4 poles)

799-601-4190 T-adapter

Common rail pressure sensor

*: Devices shown with this mark are for testing and adjustment for HB205-1M0 and HB215LC-1M0 .

107E-1 Series

SEN00250-09

Sketches of special tools

30 Testing and adjusting

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Socket

107E-1 Series

30 Testing and adjusting

SEN00250-09

Testing boost pressure a

Testing tools for boost pressure

Symbol A

Part No.

Part name

799-201-2202

Boost gauge kit

799-401-2220

Hose

1 2.

Install nipple [1] of boost gauge kit A and connect it to gauge [2]. <4D107E-1> (Aftercooler inlet side)

Be careful not to touch any hot part when removing or installing the testing tools. The test point is subject to machine models.

1. Remove boost pressure pickup plug (1). <4D107E-1>

<6D107E-1> (Aftercooler outlet side)

<6D107E-1>

107E-1 Series

Run the engine at the rated output and test the boost pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the measuring tools and return the removed parts.

SEN00250-09

30 Testing and adjusting

Adjustment of valve clearance a

Valve clearance adjusting tools

Symbol C

Part No.

Part name

795-799-1131

Gear

Commercially available

Clearance gauge

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC2208M0, PC220LC-8M0 and PC240LC-8M0 only> 1. Remove three connectors (4) and two bands (5) from wiring harness (3) and separate wiring harness (3) from the head cover. 2. Remove five head cover mounting bolts (6). a After loosening the bolts, remove mud and foreign matter sticking around the head cover by blowing air against them, while holding the head cover. 3. Remove head cover (7). a When removing the head cover, take care not to hit it against a part around it.

1 5.

Remove gasket (4a). a Take care so that foreign matter does not enter the engine. a If gasket (4a) is cracked, deteriorated, or worn, replace it with a new one.

<other than WA380Z-6, PC200-8M0, PC200LC8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0> 1. Remove cylinder head cover (1). <The following photo shows 6D107E-1>

Loosen injector terminal nuts (8) to remove the terminals (12 pieces) from the injectors. <The following procedures are common to all the machine models> 2. Remove plug (2) from the starting motor top and install tool C1. <The following photo shows PC200-8>

107E-1 Series

30 Testing and adjusting

SEN00250-09

<4D107E-1>

<6D107E-1> 3.

Rotate the crankshaft forward with tool C1 and set wide slit (b) on the disc having the revolution sensor slits at the rear of the crankshaft pulley to projection top (a) of the front cover. a Seeing from the air intake manifold side, set projection top (a) into wide slit (b). <The following photo shows 4D107E-1>

1) 2)

q q

After this positioning, each cylinder is not set to the top dead center. Take care. (Each cylinder is set 76 – 88° before the top dead center.) 4D107E-1: No. 1 cylinder or No. 4 cylinder 6D107E-1: No. 1 cylinder or No. 6 cylinder

Insert clearance gauge C2 in the clearance between rocker arm (3) and crosshead (4). Loosen locknut (5) and adjust the valve clearance with adjustment screw (6). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the clearance gauge lightly. While fixing adjustment screw (6), tighten locknut (5). 3 Locknut: 20 – 28 Nm {2.04 – 2.86 kgm} a After tightening the locknut, check the valve clearance again.

Adjust the valve clearance according to the following procedure. a If you cannot move the rocker arms of the exhaust valves (on the EX side) with the hand, adjust the valves marked with Q in the valve arrangement drawing. a If you can move the rocker arms of the exhaust valves (EX) with the hand by the valve clearance, adjust the valves marked with q in the valve arrangement drawing.

107E-1 Series

SEN00250-09

Rotate the crankshaft forward by 1 turn with tool C1 and set wide slit (b) to projection top (a) according to step 3.

Adjust the other valve clearances according to step 4. a If the valves marked with Q in the valve arrangement drawing were adjusted in step 4, adjust the valves marked with q.

After finishing adjustment, remove the adjusting tools and return the removed parts. k Remove tool C1 without fail. 3 Cylinder head cover mounting nut: 20 – 28 Nm {2.04 – 2.86 kgm} 3 Injector harness nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}

30 Testing and adjusting

107E-1 Series

30 Testing and adjusting

SEN00250-09

Testing compression pressure a

Testing tools for compression pressure

Symbol

a a 1.

Part No.

1 4.

Loosen injector terminal nut (4) and remove the terminal from the injector.

Move the cylinder to be tested to the compression top dead center. a See “Adjusting valve clearance”.

Remove rocker arm assembly (5).

Remove retainer (6) and disconnect fuel inlet connector (7).

Remove holder (8).

Remove injector (9). a Remove the injector using puller D1 and the impact of slide hammer. a Do not unclench the upper part of the injector.

Part name

795-799-6700

Puller

795-502-1590

Gauge assembly

795-790-4410

Adapter

6754-11-3130

Gasket

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

Disconnect fuel high-pressure tube (3).

107E-1 Series

SEN00250-09

30 Testing and adjusting

15. Disconnect all the injector wiring harness connectors. k If the connectors are not disconnected, the engine will start during measurement and that is dangerous. Accordingly, be sure to disconnect them. k If the crankshaft is rotated without turning on the controller, the common rail is damaged. Accordingly, be sure to check that the controller is turned ON. k Cover the disconnected connectors with a vinyl sheet etc. to prevent electric leakage and grounding fault. 10. Install gasket D4 to the tip of adapter D3 and connect it to the injector mount. 11. Fix adapter D3 with the injector holder. a Tighten the holder mounting bolts alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 12. Connect gauge assembly D2 to adaptor D3. a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily. 13. Install rocker arm assembly (5). 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm}

16. Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. 17. After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Mate protrusion (a) of the injector with notch (b) of the holder, and set the injector to the cylinder head. a Set the injector with the above mating position toward the fuel inlet connector insertion side.

14. Adjust valve clearance. a See “Adjusting valve clearance”.

2) 3)

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

107E-1 Series

30 Testing and adjusting

Tighten retainer (6) of the fuel inlet connector. 3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}

Tighten the sleeve nut of the fuel highpressure tube (3) in order of the head side and common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}

SEN00250-09

18. After installing the rocker arm assembly, adjust the valve clearance. For details, see “Adjusting valve clearance”. 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm} 19. Tighten the injector terminal nut with the following torque. 3 Terminal nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm} Check that the injector wiring harness does not interfere with the rocker arm. 20. Tighten the head cover mounting nuts to the following torque. 3 Head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

107E-1 Series

SEN00250-09

30 Testing and adjusting

Testing blowby pressure a

Testing tool for blowby pressure

Symbol E

Part No.

Part name

799-201-1504

Blowby checker

795-790-3300

Blowby tool

a a

The test point is subject to machine models. The photo below shows 6D107E-1 as an example.

Install adaptor [1] of blowby checker E1 to the tip of blowby hose (1).

Connect hose [2], and then connect it to adaptor [1] and gauge [3].

Run the engine at the rated output and test the blowby pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the measuring tools and return the removed parts.

107E-1 Series

30 Testing and adjusting

SEN00250-09

Testing engine oil pressure a

Testing tools for engine oil pressure

Symbol

Part No.

1 <4D107E-1 (PC160LC-7) as an example>

Part name

799-101-5002

Hydraulic tester

790-301-1230

Nipple

799-101-5160

Nipple

799-401-2320

Gauge

The test point is subject to machine models.

1. Remove oil pressure pickup plug (1). <4D107E-1 (PC160LC-7) as an example>

Install the nipples to the plug mount in order of F2 and F3, and connect it to gauge F4. <6D107E-1 (WA380-6) as an example>

<6D107E-1 (WA380-6) as an example>

Run the engine at the rated output and low idle and test the oil pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

After finishing testing, remove the measuring tools and return the removed parts.

Install nipple [1] of hydraulic tester F1 and connect it to gauge F4. (4D107E-1)

107E-1 Series

SEN00250-09

30 Testing and adjusting

Handling fuel system parts 1 a

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than before. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.

Releasing remaining pressure in fuel system 1 a

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the remaining pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the remaining pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is remaining pressure.)

107E-1 Series

30 Testing and adjusting

SEN00250-09

Testing fuel pressure a

Testing tools for fuel pressure

Symbol

a a a

Part No.

Hydraulic tester

790-261-1204

Digital hydraulic tester

6732-81-3170

Adapter (10 Ă&#x2014; 1.0 mm o Rc1/8)

795-790-4430

Adapter (10 Ă&#x2014; 1.0 mm o Rc1/8)

6215-81-9710

O-ring

799-401-2320

Gauge

795-790-5110

Screw

799-201-2202

Boost gauge kit

<6D107E-1 (PC200-8) as an example>

Part name

799-101-5002

See PAGE 18 for procedure of "Testing fuel pressure" of HB205-1M0 and HB215LC1M0. The test point is subject to machine models. Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply pump and in the return circuit from the supply pump through the common rail and the injector to the fuel tank. Since the pressure in the high-pressure circuit from the fuel supply pump through the common rail to the injector is very high, it cannot be measured.

Install adapter G2 and nipple [1] of hydraulic tester G1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}. <4D107E-1 (PC160LC-7) as an example>

Testing fuel low-pressure circuit pressure 1) Remove fuel pressure pickup plug (1) from the fuel main filter fuel inlet. <4D107E-1 (PC160-7) as an example> <6D107E-1 (PC200-8) as an example>

107E-1 Series

SEN00250-09

30 Testing and adjusting

Run the engine at low idle and test the fuel low-pressure circuit pressure. a If the fuel low-pressure circuit pressure is in the following range, it is normal.

At Low idle

0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

At cranking

0.3 – 1.1 MPa {3.1 – 11.3 kg/cm2}

Install adapter [4] of hydraulic tester G1 between return manifold (3) and quick coupler (4) and install hydraulic tester G1 to the center with nipple [1]. a Adapter [4]: 795-790-5200

While running the engine at low idle, measure the fuel return circuit pressure. a If the fuel return circuit pressure is in the following standard range, it is normal.

When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine 20 seconds or more.

At Low idle and At cranking k

After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.2 kgm}

Checking fuel return circuit pressure (4D107E-1) 1) Disconnect quick coupler (4) of the return hose connected to the fuel filter of fuel return manifold (3).

Max. 0.02 MPa {Max. 0.19 kg/cm2}

If the engine cannot be started, you may measure while cranking the engine with the starting motor. Do not crank the engine for more than continuous 20 seconds to protect it, however.

After finishing measurement, remove the measuring instruments and return the removed parts.

107E-1 Series

30 Testing and adjusting

SEN00250-09

Check of fuel return circuit pressure (6D107E-1) 1) Remove fuel pressure pickup plug (2) from the fuel return block.

Connect nipples [3] and [1] of hydraulic tester G1 there and connect gauge G3. a Nipple [3]: 790-301-1181, 07002-11223

Measuring fuel negative-pressure circuit pressure a The figure below shows 6D107E-1 as an example. 1) Remove joint bolt (2) of fuel hose (1) between the prefilter and supply pump.

2) a

Run the engine at low idle and test the fuel return circuit pressure. a If the fuel return circuit pressure is in the following range, it is normal. At Low idle At cranking k

Connect fuel hose (1) to supply pump (3) by tool G4 instead of joint bolt (2). When installing tool G4, fit the gaskets to both sides of the fuel hose joint. 3 Tool G4: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} Connect tool G5 to tool G4.

Max. 0.02 MPa {Max. 0.19 kg/cm2}

When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine 20 seconds or more.

After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 24 ± 4 Nm {2.4 ± 0.4 kgm}

107E-1 Series

Run the engine and measure the circuit negative pressure at high idle. Circuit standard negative pressure: Max. –50.7 kPa {–380 mmHg} If the negative pressure is higher than the standard pressure, the fuel prefilter may be clogged. In this case, replace the fuel prefilter and measure again. After finishing measurement, remove the measuring instruments and return the removed parts. 3 Joint bolt (2): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

SEN00250-09 a a

Part No.

Hydraulic tester

790-261-1204

Digital hydraulic tester

795-790-4430

Adapter (10 × 1.0 mm o Rc1/8)

6215-81-9710

O-ring

799-201-2202

Boost gauge kit

795-790-5110

Screw

799-401-2320

Gauge

Place the machine on a level ground and lower the work equipment to the ground. Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/ injector to fuel tank. Testing of the high-pressure circuit connecting the supply pump, the common rail and the injector can not be performed due to the extremely high pressure generated there.

Install adapter G2 and nipple [1] of hydraulic tester G1, and connect them to oil pressure gauge [2].

Start the engine and test the pressure in the fuel low-pressure circuit with the autodeceleration OFF and the engine at low idle. a The pressure in the fuel low-pressure circuit is normal when it is within the following standard range.

Check of pressure in fuel low-pressure circuit 1) Open the side cover on the right side of the machine and remove fuel pressure pickup plug (on the fuel inlet side) (1) from the fuel main filter head.

Use oil pressure gauge of 2.5 MPa {25 kg/cm2}.

Part name

799-101-5002

Procedure of "Testing fuel pressure" of HB205-1M0 and HB215LC-1M0 is shown below. Testing tools for fuel pressure

Symbol

30 Testing and adjusting

At Low idle (1,050 rpm)

0.5 to 1.3 MPa {5.1 to 13.3 kg/cm2}

At cranking

0.3 to 1.1 MPa {3.1 to 11.3 kg/cm2}

After finishing the test, remove the testing tools and restore the machine. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.2 kgm}

107E-1 Series

30 Testing and adjusting

SEN00250-09

Testing pressure in fuel return circuit 1) Remove joint bolt (2) of the fuel return hose.

Start the engine and test the pressure in the fuel return circuit at low idle. a If the pressure in the fuel return circuit is in the following range, it is normal. At Low idle At cranking

Max. 0.02 MPa {Max. 0.19 kg/cm2}

4) 2)

Install screw G6, and nipple [1] and hose [2] of hydraulic tester G1 instead of joint bolt (2), and connect them to gauge G7. a When installing screw G6, be sure to install the seal washer. 3 Screw G6: 24 ± 4 Nm {2.45 ± 0.41 kgm} a The nipple and hose of digital hydraulic tester G1 can also be used.

Measuring fuel negative-pressure circuit pressure 1) Open the engine hood and remove joint bolt (2) of fuel hose (1) between the prefilter and supply pump from supply pump (3).

107E-1 Series

If the engine cannot be started, you may perform the measurement while rotating the engine by the starting motor. However, do not crank the engine continuously for more than 20 seconds for protection of the starting motor. After finishing the test, remove the testing tools and restore the machine. 3 Joint bolt (2): 24 ± 4 Nm {2.45 ± 0.41 kgm}

Using tool G6 instead of joint bolt (2), connect fuel hose (1) to supply pump (3). a When installing tool G6, place the gaskets to both sides of eyejoint on the fuel hose. 3 Tool G6: 19.6 to 29.4 Nm {2.0 to 3.0 kgm}

SEN00250-09

Connect tool G6 to tool G5.

Start the engine and test the circuit negative pressure at high idle. Circuit standard negative pressure: Min. -50.7 kPa {-380 mmHg} If the negative pressure is higher than the criteria, the fuel prefilter may be clogged. In this case, replace the fuel prefilter and measure the pressure again. After finishing test, remove the testing instruments and return the removed parts. 3 Joint bolt (2): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}

30 Testing and adjusting

107E-1 Series

30 Testing and adjusting

SEN00250-09

Reduced cylinder mode operation

No-injection cranking

Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage through cylinder head gasket q Defective injection q Defective piston or piston ring q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to INSITE (troubleshooting kit). Before performing, see Testing method in the shop manual for the machine or INSITE (troubleshooting kit).

107E-1 Series

No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the machine has been stored for a long period, the no-injection cranking is performed to lubricate the engine parts and protect them from seizure. Perform the no-injection cranking mode operation with the engine mounted on the machine or connected to INSITE (troubleshooting kit). Before performing, see Testing method in the shop manual for the machine or INSITE (troubleshooting kit).

SEN00250-09

30 Testing and adjusting

Testing fuel delivery, return and leak amount a

Testing tools for fuel delivery, return and leak amount.

Symbol 1

6754-71-5340

Connector

6754-71-5350

Washer

Commercially available

Measuring cylinder

Commercially available

Stopwatch

Commercially available

Hose (Inside diameter: 14 mm)

Commercially available

Hose (Inside diameter: 8 mm)

See PAGE 29 for procedure of "Testing fuel discharge, return and leakage" of HB2051M0 and HB215LC-1M0. Prepare a container of 20 l for fuel leakage during testing. Measuring supply pump delivery (4D107E-1) 1) Loosen clamp (2) of discharge tube (1) of the supply pump and disconnect tube (1).

Part name Tester kit

Part No. 795-790-4700

Install test hose H6 to the nipple on the discharge side of the supply pump. a Fix the hose with a wire etc. a Adjust the route of the test hose so that it will not slacken and put its end in an oil container.

Crank the engine for 30 seconds and measure the delivery with measuring cylinder H4. a Adjust the route of the test hose so that it will not slacken and put its end in an oil container. a Do not crank the engine for more than 30 seconds to protect the starting motor in any case other than this measurement. a If the supply pump delivery is in the following standard range, it is normal. At cranking speed (125 rpm)

Min. 75 cc

At cranking speed (150 rpm)

Min. 90 cc

After finishing measurement, remove the measuring instruments and return the removed parts. 3 Tube sleeve nut: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm}

107E-1 Series

30 Testing and adjusting

SEN00250-09

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

Install connector H3 and cap nut [1] of tester kit H1 to quick coupler (2) of the return hose to stop the fuel from flowing out. a Install the seal washer between connector H3 and cap nut [1]. Install connector H3 to the supply pump and connect test hose [2] of tester kit H1. a Adjust the route of the test hose so that it will not slacken and put its end in an oil container.

After finishing measurement, remove the measuring instruments and return the removed parts. a When measuring the leakage from the pressure limiter after the supply pump return rate, return the engine to the normal condition. a When measuring the injector return rate after the supply pump return rate, leave the engine as it is and keep the hose end in an oil container.

Measuring leakage from pressure limiter (4D107E-1) 1) Disconnect quick coupler (4) of the return hose of the pressure limiter from connector (5) of the pump side.

While running the engine at low idle, measure the returning fuel with measuring cylinder H4 for 25 seconds. a If the leakage from the supply pump is in the following standard range, it is normal. At low idle (750 rpm)

107E-1 Series

Max. 400 cc

SEN00250-09

30 Testing and adjusting

Install connector H3 and cap nut [1] of tester kit H1 to the return hose to stop the fuel from flowing out. Connect test hose [2] of tester kit H1 to the common rail side. a Adjust the route of the test hose so that it will not slacken and put its end in an oil container.

Measuring injector return rate (4D107E-1) a The injector return rate must be measured with the pressure limiter return hose connected. Accordingly, check that no fuel leaks from the pressure limiter in advance. 1) Referring to "Measuring supply pump return rate", set the supply pump under the condition for measurement. a While the injector return rate is measured, the fuel flows out of the supply pump. Accordingly, put the test hose end on the supply pump in an oil container. 2) Disconnect return hose (6) from the manifold. a Fit the seal washer to the return hose.

While running the engine at low idle, measure the leakage from the pressure limiter with measuring cylinder H4 for 1 minute. a If the leakage from the pressure limiter is in the following standard range, it is normal. At Low idle

0 cc (No leakage)

Install removed joint bolt (7) and cap nut [1] of tester kit H1 to the return hose to prevent the fuel from flowing out. Install connector H3 to the manifold and connect test hose [3] of tester kit H1. a Set the test hose so that it will not slack and put its end in an oil container.

After finishing measurement, remove the measuring instruments and return the removed parts.

107E-1 Series

30 Testing and adjusting

Run the engine at low idle and measure the return rate from the injector in 1 minute with measuring cylinder H4. a If the return rate from the injector is in the following range, it is normal.

SEN00250-09

At Low idle

Max. 120 cc

At cranking

Max. 90 cc

The fuel returning from the supply pump flows out during measurement of the return rate from the injector. Accordingly, keep the test hose end on the supply pump side in an oil container. If the engine cannot be started, you may measure the return rate while rotating the engine with the starting motor. Do not rotate for more than 20 seconds continuously, however, for protection of the starting motor.

After finishing measurement, remove the measuring tools and return the removed parts. 3 Joint bolt: 19.6 â&#x20AC;&#x201C; 29.4 Nm {2.0 â&#x20AC;&#x201C; 3.0 kgm}

107E-1 Series

Measuring supply pump delivery (6D107E-1) 1) Loosen clamp (2) of discharge tube (1) of the supply pump and disconnect tube (1).

Min. 75 cc

At cranking speed (150 rpm)

Min. 90 cc

SEN00250-09

30 Testing and adjusting

Install connector H3 and cap nut [1] of tester kit H1 to the return hose to stop the fuel from flowing out. Connect test hose [2] of tester kit H1 to the supply pump. a Adjust the route of the test hose so that it will not slacken and put its end in an oil container.

After finishing measurement, remove the measuring instruments and return the removed parts. 3 Tube sleeve nut: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}

Testing supply pump return rate (6D107E-1) 1) Disconnect return hose (1) of the supply pump.

Run the engine at low idle and measure the return rate from the supply pump with measuring cylinder H4 25 sec or more. a If the return rate from the supply pump is in the following range, it is normal. At Low idle k

400 cc

When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine 20 seconds or more.

After finishing testing, remove the testing tools and return the removed parts.

107E-1 Series

30 Testing and adjusting

SEN00250-09

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

8. 2)

Install removed joint bolt (3) and cap nut [1] of tester kit H1 to the return hose to prevent the fuel from flowing out. Install connector H3 to the common rail and connect test hose [2] of tester kit H1. a Set the test hose so that it will not slack and put its end in an oil container.

Testing return rate from injector (6D107E-1) 1) Disconnect return hose (4) from the cylinder head. a Fit the seal washer to the connector bolt.

3) 4)

Run the engine at low idle and measure the leakage in 1 minute with measuring cylinder H4. a If the leakage from the pressure limiter is in the following range, it is normal. At Low idle

107E-1 Series

0 cc (No leakage)

After finishing testing, remove the testing tools and return the removed parts. 3 Joint bolt: 24 Âą 4 Nm {2.4 Âą 0.4 kgm}

Install connector H3 to the cylinder head and connect test hose [2] of tester kit H1 and put its end in an oil container. Install removed connector bolt (5) and cap nut [1] of tester kit H1 to the return hose to prevent fuel leakage. Run the engine at low idle and test the return rate from the injector with measuring cylinder H4 1 min or more. a If the return rate from the injector is in the following range, it is normal. At Low idle

Max. 180 cc/min.

At cranking

Max. 90 cc/min.

SEN00250-09

30 Testing and adjusting

When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine 20 seconds or more.

After finishing testing, remove the testing tools and return the removed parts. 3 Joint bolt: 24 Âą 4 Nm {2.4 Âą 0.4 kgm}

107E-1 Series

30 Testing and adjusting a a

Procedure of "Testing fuel discharge, return and leakage" of HB205-1M0 and HB215LC-1M0 is shown below. Testing tools for fuel discharge, return and leakage.

Symbol 1 2

a k

SEN00250-09

Part No.

Remove clamp (2) and then disconnect connector (3).

Remove fuel spray prevention caps (4) (2 places). Remove clamps (5) (2 places), and remove high-pressure pipe (6).

Part name

795-790-4700

Tester kit

6754-71-5340

Connector

6754-71-5350

Washer

6164-81-5790

Joint

6745-71-1130

Seal washer

07206-30812

Joint bolt

Commercially available

Stopwatch

Commercially available

Measuring cylinder

Commercially available

Hose

Since fuel flows out during the test, prepare a container of approximately 20 l. Place the machine on a level ground and lower the work equipment to the ground. Testing supply pump discharge 1) Open the engine hood and remove cover (1) on the top of the counterweight.

107E-1 Series

Install test hose H8 to the nipple on the discharge side of the supply pump. a Fix the hose using a band to prevent the hose from coming off. a Arrange the route of the test hose so that it does not sag and put its end in a container.

SEN00250-09

30 Testing and adjusting a

Crank the engine for 20 seconds and measure the delivery by using measuring cylinder H7. a In order to protect the starter motor, it is prohibited to continue cranking for more than 20 seconds for any other purpose than this measurement. a If the supply pump delivery is in the following standard range, it is proper. (For 30 seconds conversion)

Engine speed

Discharge [Q]

125 rpm

Max. 75 cc

150 rpm

Max. 90 cc

Discharge [Q]: Q = Engine speed Ă&#x2014; 0.6

Adjust the route of the test hose so that it does not slacken and put its end in an container.

Start the engine, measure the leak from the pressure limiter by using the measuring cylinder H7 for 1 minute while running the engine at low idle. a Leakage from the pressure limiter is normal when it is within the following standard value range. At Low idle

After finishing the test, remove the testing tools and restore the machine. 3 Tube sleeve nut: 35 Âą 3.5 Nm {3.6 Âą 0.4 kgm}

Testing leakage from pressure limiter 1) Disconnect quick coupler (7) of the pressure limiter spill hose. 5)

0 cc (No leakage)

After finishing the test, remove the testing tools and restore the machine.

Install connector H3 and cap nut [1] of tester kit H1 to the spill hose side to stop the fuel from flowing out. Connect test hose [2] of tester kit H1 to the common rail side.

107E-1 Series

30 Testing and adjusting

SEN00250-09 k

Testing fuel return rate from injector a The fuel return rate from the injector must be measured with the pressure limiter spill hose connected. Accordingly, check that no fuel leaks from the pressure limiter in advance. 1) After removing clamp (1), remove joint bolt (check valve) (9) and disconnect spill hose (10).

6) 2)

Install cap nut [1] of tester kit H1 to spill hose (10) to prevent outflow of fuel. a When installing cap nut [1], be sure to install seal washer H5. Install joint H4 to the cylinder head side with joint bolt H6. a When installing joint H4, be sure to install seal washer H5. 3 Joint bolt H6: 24 Âą 4 Nm {2.45 Âą 0.41 kgm}

Install joint H4 to hose H9.

Start the engine and run it at low idle, and measure the fuel return rate from the injector for 1 minute by using measuring cylinder H7. a If the return rate from the injector is in the following range, it is proper.

107E-1 Series

At low idle

Max. 120 cc

At cranking

Max. 90 cc

If the engine cannot be started, you may check the machine while rotating the engine with the starting motor. Do not rotate for more than tw enty seconds cont inuously, however, for protection of the starting motor.

After finishing the test, remove the testing tools and restore the machine. 3 Joint bolt (check valve) (9): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}

SEN00250-09

Testing supply pump return rate a Subtract the pressure limiter leakage and injector return rate from overall return rate to measure the supply pump return rate. Therefore, check that the leakage from the pressure limiter and return rate from the injector are normal, and then perform the measurement. a Since fuel may flow back when disconnecting fuel return hose (12), drain the fuel from the fuel tank to the lower level than the supply pump installation position. 1) Move rubber cover (11), and disconnect fuel return hose (12).

30 Testing and adjusting

At low idle (750 rpm)

6) 2)

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

Install joint H3 to hose H8.

Start the engine and run it at low idle, and measure the return rate in 25 seconds by using measuring cylinder H7. a Supply pump return rate = (Overall return rate) - (pressure limiter leakage) - (injector return rate) a When the return rate from the supply pump is in the following range, it is normal. Max. 400 cc

After finishing the test, remove the testing tools and restore the machine.

107E-1 Series

30 Testing and adjusting

Bleeding air from fuel circuit a a

SEN00250-09

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

Loosen the knob of the priming pump (1) (remote mount side) and move it back and forth. <The photo shows PC160LC-7 as an example>

Continue moving the knob until it becomes hard to move. (If the main filter is empty, move the knob 60 â&#x20AC;&#x201C; 70 times, and the air is bled.)

Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, air may not be bled from the low-pressure circuit. In this case, repeat the above work.

107E-1 Series

SEN00250-09

30 Testing and adjusting

Testing fuel system for leakage k

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.

Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.

Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.

Run the engine at low idle.

Run the engine at high idle.

Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump.

1 9.

107E-1 Series

30 Testing and adjusting

Handling controller high-voltage circuit 1 1.

Disconnection or connection of the connector between the engine controller and engine must be done after turning off the starting switch. It is prohibited to start the engine when Tadapter is inserted or connected, for troubleshooting purpose, to the connector between the engine controller and engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

SEN00250-09

Replacing the fan belt a a

The auto-tensioner is provided for the fan belt. Thus, testing and adjustment of the belt is usually no necessary. Disconnect air conditioner compressor belt before replacing the fan belt.

Insert a wrench (a) to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (2), and rotate it to the opposite to the winding-up direction to decrease the fan belt (3) tension. k Make sure that the wrench (a) is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (2) is strong. If the wrench (a) is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing the fan belt (3), return the wrench (a) of the tensioner assembly (2) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (3) during work.

Replace the fan belt (3). Check each pulley for breakage and crack.

107E-1 Series

SEN00250-09

KOMATSU 107E-1 Series Diesel engine Form No. SEN00250-09

SEN00252-04

Engine 1SHOP MANUAL

107E-1 Series

40 Troubleshooting

General information on troubleshooting Points on troubleshooting ............................................................................................................................... 2 Error and failure code table............................................................................................................................. 3 Troubleshooting method for open circuit in wiring harness of pressure sensor system.................................. 5 Information in troubleshooting table ................................................................................................................ 7 Connection table for connector pin numbers .................................................................................................. 9 T- branch box and T- branch adapter table ................................................................................................... 45

107E-1 Series

SEN00252-04

Points on troubleshooting k k k k k k

40 Troubleshooting

Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (â&#x20AC;&#x201C;) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

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

107E-1 Series

40 Troubleshooting

SEN00252-04

Error and failure code table q

Engine controller Error code of INSITE

Failure code of applicable machine

111

CA111

Abnormality in engine controller

115

CA115

Abnormality in engine NE and Bkup speed sensors

122

CA122

Charge pressure sensor high error

123

CA123

Charge pressure sensor low error

131

CA131

Throttle sensor power supply high error

132

CA132

Throttle sensor power supply low error

Trouble

144

CA144

Coolant temperature sensor high error

145

CA145

Coolant temperature sensor low error

153

CA153

Charge temperature sensor high error

154

CA154

Charge temperature sensor low error

155

CA155

Derating of speed by charge temperature high error

187

CA187

Sensor power supply 2 low error

221

CA221

Atompspheric pressure sensor high error

222

CA222

Atompspheric pressure sensor low error

227

CA227

Sensor power supply 2 high error

234

CA234

Engine overspeed

238

CA238

Abnormallity in Ne speed sensor power supply

271

CA271

Short circuit in IMV/PCV1

272

CA272

Disconnection in IMV/PCV1

322

CA322

Disconnection, short circuit in injector No. 1

323

CA323

Disconnection, short circuit in injector No. 5

324

CA324

Disconnection, short circuit in injector No. 3

325

CA325

Disconnection, short circuit in injector No. 6

331

CA331

Disconnection, short circuit in injector No. 2

332

CA332

Disconnection, short circuit in injector No. 4

342

CA342

Calibration error in engine controller data

351

CA351

Abnormality in injector drive circuit

352

CA352

Sensor power supply 1 low error

386

CA386

Sensor power supply 1 high error

428

CA428

Water-in-fuel sensor high error

429

CA429

Water-in-fuel sensor low error

431

CA431

Abnormality in idle validation switch

432

CA432

Abnormality in idle validation processing

435

CA435

Abnormality in engine oil pressure switch

441

CA441

Abnormally low power supply voltage

442

CA442

Abnormally high power supply voltage

449

CA449

Common rail pressure high error 2

451

CA451

Common rail pressure sensor high error

452

CA452

Common rail pressure sensor low error

488

CA488

Derating of torque by charge temperature high error

553

CA553

Common rail pressure high error 1

559

CA559

No-pressure feed 1 by supply pump

107E-1 Series

Reference document No.

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

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

SEN00252-04

40 Troubleshooting

Error code of INSITE

Failure code of applicable machine

689

CA689

Abnormality in engine Ne speed sensor

731

CA731

Abnormality in engine Bkup speed sensor phase

757

CA757

Loss of all data in engine controller

778

CA778

Abnormality in engine Bkup speed sensor

1633

CA1633

Abnormality in KOMNET

2185

CA2185

Throttle sensor power supply high error

2186

CA2186

Throttle sensor power supply low error

2249

CA2249

No-pressure feed 2 by supply pump

2311

CA2311

Abnormality in IMV solenoid

2555

CA2555

Disconnection in intake air heater relay

a a

2556

CA2556

—

B@BAZG

Derating of speed by engine oil pressure reduction

—

B@BAZK

Engine oil level low

—

B@BCNS

Engine overheat

Reference document No.

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

Short circuit in intake air heater relay

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

Machine failure code

Trouble

Failure phenomenon

Rated Speed Adjustment Volume (Isochronous) High Error

Rated Speed Adjustment Volume (Isochronous) Low Error

Rated Speed Adjustment Volume (Droop) High Error

Rated Speed Adjustment Volume (Droop) Low Error

Abnormality in KOMNET (CR710 error recognition)

Droop Rate Adjustment Volume High Error

Droop Rate Adjustment Volume Low Error

Low Idle Speed Adjustment Volume High Error

Low Idle Speed Adjustment Volume Low Error

Rated Speed Median Adjustment Volume High Error

Rated Speed Median Adjustment Volume Low Error

Ramp Time Adjustment Volume High Error

Ramp Time Adjustment Volume Low Error

Reference document No.

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

107E-1 Series

40 Troubleshooting

SEN00252-04

Troubleshooting method for open circuit in wiring harness of pressure sensor system 1 a Since pressure sensors consisting not only of resistor but also electronic circuit components such as amplifiers have variation in measured value and its own polarities. So troubleshooting must be performed carefully. Failure codes applicable to this diagnosis q CA123: Charge air pressure sensor low error q CA451: Common rail pressure sensor high error Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector. 2) Measure resistances R1 and R2 between pins. a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore, when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor connector so that their polarities match these of the sensor. a If measured value is infinite, take measurements by applying the probes of opposite polarities and record the finite value obtained as a measured value. a Since measured values may be dispersed, take several measurements. Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times. Consider this dispersion when judging whether the wiring harness is open in step 3.

2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller connected. 1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor connectors first. (*) 2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side, and connect T-adapter (4) to the harness side connector. 3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins. 3. Judging open circuit If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is open". a "Apparent difference" means a difference of 10 or more times.

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List of pressure sensor measuring locations and reference values Sensor

Measuring location at sensor pin

Charge pressure sen- R2: between (2) and (4) R1: between (1) and (4) sor R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)

Measured internal resisRemarks tance of sensor (reference) Approx. 100 z Sensor is common to engine models Approx. 200 z 107 and 114 Sensor is common to engine models Approx. 23 kz 107 and 114 If polarities are inverted, resistance is Approx. 10 Mz infinite

*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each failure code) q When measuring R2' of charge pressure sensor (CA123): Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator) q When measuring R2' of common rail pressure sensor (CA451): Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator) Measurement record (For measuring locations, see circuit diagram related to each failure code.) Sensor

Sensor unit (Measuring location on sen- Measured value sor pin side connetor)

Charge pressure sen- R2: between (2) and (4) sor R1: between (1) and (4) R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)

Sensor + Wiring harness (Measuring location on wirMeasured value ing harness side connector of engine controller) R2': Between (37) and (47) (*) R1': Between (44) and (47) R2': Between (37) and (47) (*) R1': between (47)(+) and (25)(-)

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SEN00252-04

Information in troubleshooting table a

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

Failure code

Display on INSITE

Display on applicable machine

Contents of trouble

Trouble

Problem that appears on engine

Contents of trouble detected by engine controller

Action of controller

Action taken by engine controller to protect system or devices when engine controller detects trouble

Problem that appears on machine

Problem that appears on engine as result of action taken by engine controller (shown above)

Related information

Information related to detected trouble or troubleshooting Causes

Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment

2 Possible causes and standard value in normal state

107E-1 Series

<Troubles in wiring harness> • Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.

Possible causes of trouble (Given numbers are reference numbers, which do not <Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 • If connector No. has no marks of “male” and “female“, disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise 4 specified. • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or wiring harness entered on rear side.

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40 Troubleshooting

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting. â&#x20AC;˘ Connector No.: Indicates (Model â&#x20AC;&#x201C; Number of pins) and (Color).

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Connection table for connector pin numbers

(Rev. 2009.04)

The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

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T- branch box and T- branch adapter table

(Rev. 2009.03) 1

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

799-601-2600 T-box (for ECONO)

799-601-3100 T-box (for MS)

799-601-3200 T-box (for MS)

q q

799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

MS-24P

799-601-3420 Adapter for BENDIX (MS)

MS-24P

799-601-3430 Adapter for BENDIX (MS)

MS-17P

799-601-3440 Adapter for BENDIX (MS)

MS-17P

799-601-3450 Adapter for BENDIX (MS)

MS-5P

799-601-3460 Adapter for BENDIX (MS)

MS-10P

799-601-3510 Adapter for BENDIX (MS)

MS-5P

799-601-3520 Adapter for BENDIX (MS)

MS-17P

799-601-3530 Adapter for BENDIX (MS)

MS-19P

799-601-2910 Adapter for BENDIX (MS)

MS-14P

q q

799-601-3470 Case 799-601-2710 Adapter for MIC

MIC-5P

q q

799-601-2720 Adapter for MIC

MIC-13P

q q

799-601-2730 Adapter for MIC

MIC-17P

q q q

799-601-2740 Adapter for MIC

MIC-21P

q q q

799-601-2950 Adapter for MIC

MIC-9P

799-601-2750 Adapter for ECONO

ECONO2P

q q

799-601-2760 Adapter for ECONO

ECONO3P

q q

799-601-2770 Adapter for ECONO

ECONO4P

q q

799-601-2780 Adapter for ECONO

ECONO8P

q q

799-601-2790 Adapter for ECONO

12 ECONO12P q q

799-601-2810 Adapter for DLI

DLI-8P

q q

799-601-2820 Adapter for DLI

DLI-12P

q q

799-601-2830 Adapter for DLI

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

q q q

q q

q q q

799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)

799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)

799-601-7020 Adapter for X

X2P

q q q

799-601-7030 Adapter for X

X3P

q q q

q q

799-601-7040 Adapter for X

X4P

q q q

799-601-7050 Adapter for SWP

SW6P

q q q q q q

799-601-7060 Adapter for SWP

SW8P

799-601-7310 Adapter for SWP

SW12P q

M2P

q q q

M3P

q q q

799-601-7070 Adapter for SWP

SW14P

799-601-7320 Adapter for SWP

SW16P

799-601-7080 Adapter for M (T-adapter)

799-601-7090 Adapter for M

799-601-7110 Adapter for M

107E-1 Series

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40 Troubleshooting

Out of kit

799-601-4201

q q q

799-601-4101

S8P

799-601-9300

799-601-9200

799-601-7140 Adapter for S

799-601-9100

M8P

799-601-9000

799-601-8000 q

799-601-7340 Adapter for M

799-601-7500

q q q

799-601-7400

q q q

M6P

799-601-7100

M4P

799-601-7000

799-601-7130 Adapter for M

799-601-2800

799-601-7120 Adapter for M

Part name

799-601-2700

Identification symbol

Part No.

799-601-2500

Number of pins

T-adapter kit

799-601-7150 Adapter for S (White)

S10P

q q q

799-601-7160 Adapter for S (Blue)

S12P

q q q

799-601-7170 Adapter for S (Blue)

S16P

q q q

799-601-7330 Adapter for S (White)

S16PW

799-601-7350 Adapter for S (White)

S12PW

799-601-7180 Adapter for AMP040

A8P

799-601-7190 Adapter for AMP040

A12P

q q q q

799-601-7210 Adapter for AMP040

A16P

q q q

799-601-7220 Adapter for AMP040

A20P

q q q

799-601-7230 Short connector for X

—

q q q

q q

799-601-7240 Case

799-601-7270 Case 799-601-7510 Adapter for 070

07-10

799-601-7520 Adapter for 070

07-12

799-601-7530 Adapter for 070

07-14

799-601-7540 Adapter for 070

07-18

799-601-7550 Adapter for 070

07-20

799-601-7360 Adapter for relay

REL-5P

799-601-7370 Adapter for relay

REL-6P

799-601-7380 Adapter for JFC

—

799-601-9010 Adapter for DTM

DTM2

799-601-9020 Adapter for DT

DT2

799-601-9030 Adapter for DT

DT3

799-601-9040 Adapter for DT

DT4

799-601-9050 Adapter for DT

DT6

799-601-9060 Adapter for DT (Gray)

DT8GR

799-601-9070 Adapter for DT (Black)

DT8B

799-601-9080 Adapter for DT (Green)

DT8G

799-601-9090 Adapter for DT (Brown)

DT8BR

799-601-9110 Adapter for DT (Gray)

DT12GR

799-601-9120 Adapter for DT (Black)

DT12B

799-601-9130 Adapter for DT (Green)

DT12G

799-601-9140 Adapter for DT (Brown)

DT12BR

799-601-9210 Adapter for HD30-18

D18-8

q q

799-601-9220 Adapter for HD30-18

D18-14

q q

799-601-9230 Adapter for HD30-18

D18-20

q q

799-601-9240 Adapter for HD30-18

D18-21

q q

799-601-9250 Adapter for HD30-24

D24-9

q q

799-601-9260 Adapter for HD30-24

D24-16

q q

799-601-9270 Adapter for HD30-24

D24-21

q q

799-601-9280 Adapter for HD30-24

D24-23

q q

799-601-9290 Adapter for HD30-24

D24-31

q q

799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)

q q q q

q q

107E-1 Series

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

SEN00252-04

Number of pins

40 Troubleshooting

799-601-9330 Case

799-601-9340 Case 799-601-9350 Adapter for DRC

DRC-40

799-601-9360 Adapter for DRC

DRC-24

799-601-9410* Socket for engine (CRI-T2)

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor

q q

799-601-9440* Socket for engine (CRI-T2)

1,2,3

795-799-5520* Socket for engine (HPI-T2)

Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor

q q

795-799-5460 Cable for engine (HPI-T2)

—

795-799-5470 Cable for engine (HPI-T2)

—

795-799-5480 Cable for engine (HPI-T2)

—

799-601-4110 Adapter for engine (140-T3) PIM

ITT3N

q q

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

FCIN

q q

FCIG

q q

799-601-4150 Adapter for engine (CRI-T3) POIL

FCIB

q q

Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch

4160

q q

799-601-4180 Adapter for engine (CRI-T3) PEVA

4180

q q

Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure

1,2,3L

q q

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

1,2,3,G

q q

Socket for engine (CRI-T3) 799-601-4340* Pump actuator

2,PA

q q

1,2,3,4T

DTP4

799-601-9430*

795-799-5540*

799-601-4140

799-601-4230*

799-601-4380*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

Adapter for engine (CRI-T3) Atomosphere pressure

Socket for engine (CRI-T3) Air intake pressure/temperature

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

799-601-4260 Adapter for controller (ENG)

q q q

799-601-4211 Adapter for controller (ENG)

DRC50

799-601-4220 Adapter for controller (ENG)

DRC60

799-601-4390* Socket for controller (95 ENG)

—

799-601-4280* Box for controller (PUMP)

121

—

799-601-9720 Adapter for controller (HST)

HST16A

799-601-9710 Adapter for controller (HST)

HST16B

799-601-9730 Adapter for controller (HST)

HST26A

2, 3, 4,

—

799-601-9890

Multi-adapter for DT2 – 4 and DTM2

“*” Shows not T-adapter but socket.

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SEN00252-04

40 Troubleshooting

KOMATSU 107E-1 Series Diesel engine Form No. SEN00252-04

SEN00254-04

Engine 107E-1 Series

1SHOP MANUAL

40 Troubleshooting

Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 3 E-1 Code [111/CA111] Abnormality in engine controller....................................................................... 3 E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor................................................ 3 E-3 Code [122/CA122] Charge pressure sensor high error ................................................................. 4 E-4 Code [123/CA123] Charge pressure sensor low error .................................................................. 6 E-5 Code [131/CA131] Throttle sensor power supply high error ......................................................... 8 E-6 Code [132/CA132] Throttle sensor power supply low error ......................................................... 10 E-7 Code [144/CA144] Coolant temperature sensor high error ......................................................... 12 E-8 Code [145/CA145] Coolant temperature sensor low error .......................................................... 14 E-9 Code [153/CA153] Charge temperature sensor high error.......................................................... 16 E-10 Code [154/CA154] Charge temperature sensor low error ......................................................... 18 E-11 Code [155/CA155] Derating of speed by charge temperature high error .................................. 20 E-12 Code [187/CA187] Sensor power supply 2 low error ................................................................ 22 E-13 Code [221/CA221] Atompspheric pressure sensor high error ................................................... 24

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40 Troubleshooting

E-14 Code [222/CA222] Atompspheric pressure sensor low error .................................................... 26 E-15 Code [227/CA227] Sensor power supply 2 high error ............................................................... 28 E-16 Code [234/CA234] Engine overspeed ....................................................................................... 28 E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply .......................................... 29 E-18 Code [271/CA271] Short circuit in IMV/PCV1............................................................................ 30 E-19 Code [272/CA272] Disconnection in IMV/PCV1 ........................................................................ 32 E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 ............................................... 34 E-21 Code [323/CA323] Disconnection, short circuit in injector No. 5 ............................................... 36 E-22 Code [324/CA324] Disconnection, short circuit in injector No. 3 ............................................... 38 E-23 Code [325/CA325] Disconnection, short circuit in injector No. 6 ............................................... 40 E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2 ............................................... 42 E-25 Code [332/CA332] Disconnection, short circuit in injector No. 4 ............................................... 44 E-26 Code [342/CA342] Calibration error in engine controller data ................................................... 46 E-27 Code [351/CA351] Abnormality in injector drive circuit.............................................................. 47 E-28 Code [352/CA352] Sensor power supply 1 low error................................................................. 48 E-29 Code [386/CA386] Sensor power supply 1 high error ............................................................... 50 E-30 Code [428/CA428] Water-in-fuel sensor high error.................................................................... 52 E-31 Code [429/CA429] Water-in-fuel sensor low error ..................................................................... 54 E-32 Code [431/CA431] Abnormality in idle validation switch............................................................ 56 E-33 Code [432/CA432] Abnormality in idle validation processing .................................................... 58

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40 Troubleshooting

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

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

1 1

Error code

Failure code

111 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

CA111

Trouble

Abnormality in engine controller

• Abnormality occurred in memory of engine controller or power supply circuit. • None in particular.

• Engine may stop suddenly or may not be able to start.

• Method of reproducing failure code: Start engine Causes

Standard value in normal state/Remarks on troubleshooting

1 Defect in related system

If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor Error code

Failure code

115

CA115

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• None in particular. • Engine stops • Engine does not start • Method of reproducing failure code: Start engine. Standard value in normal state/Remarks on troubleshooting

Connectors of Ne speed sensor and Bkup speed sensor may be Defective connection of senconnected defectively (or to wrong connection). Check them sor connector directly.

Defective Ne speed sensor system

Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code [CA689].

Defective Bkup speed sensor system

Perform troubleshooting for failure code [CA778].

4 Defective engine controller

107E-1 Series

Abnormality in engine Ne, Bkup speed sensor

• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.

Causes

Possible causes and standard value in normal state

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

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40 Troubleshooting

E-3 Code [122/CA122] Charge pressure sensor high error Error code

Failure code

122

CA122

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Charge pressure sensor high error

• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor. • Fixes charge pressure and continues operation.

• Engine output drops. • Method of reproducing failure code: Starting switch ON. • If sensor connector is disconnected, code [123/CA123] for "Low Error" is displayed, even in normal condition. Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

Defective sensor power sup- If failure code [CA227] is indicated simultaneously, perform troubleply 2 circuit shooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT. 3. Turn starting switch to ON position.

3 Possible causes and standard value in normal state

Defective boost pressure & temperature sensor

Short circuit in wiring harness

If failure code changes from [CA122] to [CA123] ,boost pressure sensor is defective. a Failure code [CA153] for temperature sensor is displayed at the same time. Ignore this failure code since it appears because of disconnection of sensor. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (37) and (44)

Hot short circuit in wiring 5 harness (contact with 24 V circuit)

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect Tadapter to connector ECM. 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT disconnected). Between ECM (44) and (47)

6 Defective engine controller

Resistance

Voltage

Max. 1 V

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to boost pressure, temperature sensor (combination sensor)

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40 Troubleshooting

E-4 Code [123/CA123] Charge pressure sensor low error Error code

Failure code

123

CA123

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

Charge pressure sensor low error

• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor. • Fixes charge pressure and continues operation.

• Engine output drops. • Method of reproducing failure code: Starting switch ON. • Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a Tadapter). • If sensor connector is disconnected, this failure code is displayed. Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Defective sensor power supply 2 circuit

If failure code [CA187] or [CA227] is indicated simultaneously, perform troubleshooting for it first.

Short circuit in wiring harness

Possible causes and standard value in normal state Ground fault in wiring har4 ness (contact with ground circuit)

Open circuit in wiring harness

Defective boost pressure & temperature sensor 6 (improper input voltage to engine controller)

1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (37) and (47)

Resistance

Min. 100 kz

Between ECM (female) (44) and (47)

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (44) and ground

Min. 100 kz

If no failure is found by above checks, there may be open circuit in wiring harness. (*) a If no failure is found by checks on 1 - 5 and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter to connector ECM. 3. Turn starting switch to ON position. Between ECM (44) and (47)

7 Defective engine controller

Resistance

Sensor output

Voltage

0.3 - 4.7 V

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related information of troubleshooting".

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Circuit diagram related to boost pressure, temperature sensor (combination sensor)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-5 Code [131/CA131] Throttle sensor power supply high error Error code

Failure code

131

CA131

Contents of trouble

Trouble Throttle sensor power supply high error

• High voltage is detected in fuel control dial signal circuit.

Action of controller

• Depends on machine model.

Problem that appears on machine

• Depends on machine model.

Related information

• Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting

Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. Defective wiring har1 • Loose connector, broken lock, broken seal ness connector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation Defective throttle If failure code [CA2185] is indicated simultaneously, perform troubleshoot2 sensor power supply ing for it first. system 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapter to male side. 3

Defective fuel control Between P20 (male) (1) and (3) dial (throttle sensor) Between P20 (male) (2) and (3)

Resistance

Resistance 0.25 - 5.0 kz

Between P20 (male) (1) and (2)

Possible causes and standard value in normal state

Open or short circuit 4 in wiring harness

4.0 - 6.0 kz

Resistance 0.25 - 5.0 kz

1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side. Between CE02 (famale) (22) and (23)

Resistance

4.0 - 6.0 kz

Between CE02 (famale) (9) and (23)

Resistance 0.25 - 5.0 kz

a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring 2. Disconnect connectors CE02 and P20, and connect T-adapter to female 5 side of either connector. harness Between CE02 (female) (9) and (22), or between P20 (female) (1) and (2)

Resistance

Min. 1 Mz

1. Turn starting switch to OFF position. Hot short in wiring 2. Disconnect connector P20, and connect T-adapter to female side. 6 harness(contact with 3. Turn starting switch to ON position. 24 V circuit) Between P20 (female) (2) and ground Voltage Max. 1 V If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) • Reference 1. Turn starting switch to OFF position. Defective engine con- 2. Insert T-adapter into connector CE02. 7 troller 3. Turn starting switch to ON position. 4. Operate fuel control dial and perform troubleshooting. Between CE02 (22) and (23)

Power supply

Voltage

4.75 – 5.25V

Between CE02 (9) and (23)

Sensor output

Voltage

0.5 – 4.5 V

* The terminal names and pin numbers are shown as examples of PC200-8.

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to throttle sensor (PC200-8 as an example)

107E-1 Series

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40 Troubleshooting

E-6 Code [132/CA132] Throttle sensor power supply low error Error code

Failure code

132

CA132

Contents of trouble

Trouble Throttle sensor power supply low error

• Low voltage is detected in fuel control dial signal circuit.

Action of controller

• Depends on machine model.

Problem that appears on machine

• Depends on machine model.

Related information

• Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting

Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. Defective wiring harness 1 • Loose connector, broken lock, broken seal connector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 2

Defective throttle sensor power supply system

If failure code [CA2186] is indicated simultaneously, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapter to male side.

Defective fuel control dial Between P20 (male) (1) and (3) Resis4.0 - 6.0 kz (throttle sensor) Between P20 (male) (2) and (3) Resis0.25 - 5.0 kz Between P20 (male) (1) and (2) Resis0.25 - 5.0 kz 1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side. Open or short circuit in 4 wiring harness Between CE02 (famale) (22) and (23) Resis4.0 - 6.0 kz

Possible causes and standard value in normal state

Between CE02 (famale) (9) and (23) Resis0.25 - 5.0 kz a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to each female side. Open circuit in wiring harBetween CE02 (female) (22) and P20 Resisness Max. 1 z 5 tance (wire breakage or defec- (female) (1) tive contact of connector) Between CE02 (female) (9) and P20 ResisMax. 1 z (female) (2) tance Between CE02 (female) (23) and P20 (female) (3)

Resistance

Max. 1 z

a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connectors CE02 and P20, and connect T-adapter to 6 female side of either connector. ness Between CE02 (female) (9) and (23), or between P20 (female) (2) and (3) Ground fault of wiring harness 7 (contact with ground circuit)

Resistance

Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of either connector. Between CE02 (female) (9) or P20 (female) (2) and ground

Resistance

Min. 1 Mz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Standard value in normal state/Remarks on troubleshooting

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) • Reference 1. Turn starting switch to OFF position. Possible 2. Insert T-adapter into connector CE02. causes and standard value 8 Defective engine control- 3. Turn starting switch to ON position. ler 4. Operate fuel control dial and perform troubleshooting. in normal state Power supBetween CE02 (22) and (23) Voltage 4.75 – 5.25V ply Between CE02 (9) and (23)

Sensor output

Voltage

0.5 – 4.5 V

* The terminal names and pin numbers are shown as examples of PC200-8. Circuit diagram related to throttle sensor (PC200-8 as an example)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-7 Code [144/CA144] Coolant temperature sensor high error Error code

Failure code

144

CA144

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble Coolant temperature sensor high error

• High voltage is detected in coolant temperature sensor signal circuit. • Fixes coolant temperature and continues operation. • Engine does not start easily at low temperature. • Overheat prevention function does not function. • Method of reproducing failure code: Starting switch ON. • This failure code is displayed if temperature sensor connector is disconnected. • Since troubleshooting "socket" for this sensor features the female connector alone, it is not connectable to wiring harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter). Causes

Defective wiring harness connector

Standard value in normal state/Remarks on troubleshooting Connecting parts among coolant temperature, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal.

Possible causes and standard value in normal state

Defective coolant tempera2 Between COOLture sensor ANT TEMP (male) (A) and (B) a Coolant temperatureResistance characteristics

0 °C

Resistance

30 - 37 kz

25 °C

Resistance

9.3 - 10.7 kz

50 °C

Resistance

3.2 - 3.8 kz

80 °C

Resistance

1.0 - 1.3 kz

95 °C

Resistance

700 – 800 z

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3

Open or short circuit in wir- Between ECM (female) (15) and (38) (Coolant temperature: Min. 0°C) ing harness a Use "Coolant temperature-Resistance characteristics" table shown above as resistance criteria.

4 Defective engine controller

Resistance

700 z – 37 kz

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to coolant temperature sensor

107E-1 Series

SEN00254-04

40 Troubleshooting

E-8 Code [145/CA145] Coolant temperature sensor low error Error code

Failure code

145

CA145

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble Coolant temperature sensor low error

• Low voltage is detected in coolant temperature sensor signal circuit. • Fixes coolant temperature and continues operation. • Engine does not start easily at low temperature. • Overheat prevention function does not function. • Method of reproducing failure code: Starting switch ON. • If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA144] for "High Error" is displayed. Causes

Standard value in normal state/Remarks on troubleshooting

Connecting parts among coolant temperature, engine wiring harness, and engine controller are suspected. Inspect them directly. Defective wiring har1 • Loose connector, broken lock, broken seal ness connector • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Defective coolant 2 temperature sensor Possible causes and standard value in normal state

Between COOLANT TEMP (male) (A) and (B) a Coolant temperature- Resistance characteristics Between (B) and ground

0 °C

Resistance

30 – 37 kz

25 °C

Resistance

9.3 – 10.7 kz

50 °C

Resistance

3.2 – 3.8 kz

80 °C

Resistance

1.0 – 1.3 kz

95 °C

Resistance

700 – 800 z

Whole coolant Resistance temperature range

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3

Short circuit in wiring Between ECM (female) (15) and (38) (Coolant temperature: Min. 0 °C) harness a Use "Coolant temperature-Resistance characteristics" table shown above as resistance criteria.

Resistance

700 z – 37 kz

1. Turn starting switch to OFF position. Ground fault in wiring 2. Disconnect connectors ECM and COOLANT TEMP, and connect Tharness adapter to female side of ECM. 4 (contact with ground Resiscircuit) Between ECM (female) (15) and ground Min. 100 kz tance 5

Defective engine con- If no failure is found by above checks, engine controller is defective. troller (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

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SEN00254-04

Circuit diagram related to coolant temperature sensor

107E-1 Series

SEN00254-04

40 Troubleshooting

E-9 Code [153/CA153] Charge temperature sensor high error Error code

Failure code

153

CA153

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble Charge temperature sensor high error

• High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor. • Fixes charge temperature and continues operation. • Exhaust smoke is white since auto preheat does not operate at low temperature. • Boost temperature-based engine protection function does not function. • Method of reproducing failure code: Starting switch ON. • Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable to wiring harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter). • This failure code is displayed if temperature sensor connector is disconnected. Causes

Defective wiring harness connector

Standard value in normal state/Remarks on troubleshooting Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side. -40 °C

Possible causes and standard value in normal state

Defective boost temperature sensor

Between BOOST PRESS & IMT (male) (3) and (4) a Boost temperature -Resistance chariacteristic

Resistance

41 – 48 kz

-20 °C

Resistance

14 – 16 kz

0 °C

Resistance

5.4 – 6.1 kz

30 °C

Resistance

1.6 – 1.8 kz

60 °C

Resistance

560 – 600 z

90 °C

Resistance

230 – 250 z

130 °C

Resistance

80 – 90 z

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3

Open or short circuit in wir- Between ECM (female) (23) and (47) ing harness a Use "boost temperature-Resistance characteristics" table shown above as resistance criteria.

4 Defective engine controller

Resistance

80 z – 48 kz

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to boost pressure, temperature sensor (combination sensor)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-10 Code [154/CA154] Charge temperature sensor low error Error code

Failure code

154

CA154

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble Charge temperature sensor low error

• Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor. • Fixes charge temperature and continues operation. • Exhaust smoke is white since auto preheat does not operate at low temperature. • Boost temperature-based engine protection function does not function. • Method of reproducing failure code: Starting switch ON. • If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA153] for "High Error" is displayed. Causes

Defective wiring harness connector

Defective boost temperature sensor

Possible causes and standard value in normal state

Between BOOST PRESS & IMT (male) (3) and (4) a Boost temperature -Resistance chariacteristic

-40 °C Resistance

41 – 48 kz

-20 °C Resistance

14 – 16 kz

0 °C

Resistance

30 °C

Resistance

1.6 – 1.8 kz

60 °C

Resistance

560 – 600 z

90 °C

Resistance

230 – 250 z

130 °C Resistance

Short circuit in wiring harness

5.4 – 6.1 kz

80 – 90 z

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (23) and (47) a Use "boost temperature-Resistance characteristics" table shown above as resistance criteria.

Resistance

80 z – 48 kz

a If no failure is found by checks on cause 3, this check is not required. Ground fault in wiring har- 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and 4 ness connect T-adapter to female side of ECM. (contact with ground circuit) ResisBetween ECM (female) (23) and ground Min. 100 kz tance 5 Defective engine controller

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to boost pressure, temperature sensor (combination sensor)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-11 Code [155/CA155] Derating of speed by charge temperature high error 1 Error code

Failure code

155

CA155

Contents of trouble Action of controller Problem that appears on machine Related information

Derating of speed by charge temperature high error

• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit. • Limits output and continues operation. • Engine stops • Output drops. • Method of reproducing failure code: Start engine. Causes

Possible causes and standard value in normal state

Trouble

Standard value in normal state/Remarks on troubleshooting

Inspect following directly. Drop in cooling performance • Loose, broken fan belt 1 of aftercooler. • Lack of cooling air • Clogged aftercooler fin 2

Abnormally high temperature Inspect related parts directly. at turbocharger outlet

If no failure is found by above checks, boost temperature sensor Defective boost temperature system may be defective. Perform troubleshooting for failure codes sensor [CA153] and [CA154].

107E-1 Series

40 Troubleshooting

107E-1 Series

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40 Troubleshooting

E-12 Code [187/CA187] Sensor power supply 2 low error Error code

Failure code

187

CA187

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Sensor power supply 2 low error

• Low voltage is detected in sensor power supply 2 circuit. • Fixes charge (boost) pressure and charge (boost) temperature, and continues operation. • Limits output and continues operation. • Engine output drops. • Engine starting performance becomes deteriorated. • Method of reproducing failure code: Starting switch ON.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among each sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect following connectors sequentially one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to 1.

Possible causes and standard value in normal state

Defective sensor or wiring harness

3 Defective engine controller

If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA187]. Sensor or harness

Connector

Boost pressure & temperature sensor

BOOST PRESS & IMT

Common rail pressure sensor

FUEL RAIL PRESS

Bkup sensor

CAM SENSOR

Engine wiring harness

ECM

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (37) and (47)

Voltage

4.75 - 5.25 V

107E-1 Series

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SEN00254-04

Circuit diagram related to sensor power supply 2

107E-1 Series

SEN00254-04

40 Troubleshooting

E-13 Code [221/CA221] Atompspheric pressure sensor high error Error code

Failure code

221

CA221

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Atompspheric pressure sensor high error

• High voltage is detected in atmospheric pressure sensor • Fixes atmospheric pressure and continues operation. • Engine output drops. • Starting performance is poor. • Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Defective sensor power sup- If failure code [CA352] or [CA386] is displayed simultaneously, perply 1 system form troubleshooting for it first.

3 Possible causes and standard value in normal state 4

Defective ambient pressure sensor

Short circuit in wiring harness

Hot short circuit in wiring 5 harness (contact with 24 V circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Turn starting switch to ON position. If failure code changes from [CA221] to [CA222], sensor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Between ECM (female) (33) and (3), or between AMB. AIR PRESSURE (female) (1) and (3)

6 Defective engine controller

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or insert T-adapter in connector ECM. 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE disconnected). Between ECM (3) and (38), or between AMB. AIR PRESSURE (female) (3) and (2)

Voltage

Max. 1 V

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to atmospheric pressure sensor

107E-1 Series

SEN00254-04

40 Troubleshooting

E-14 Code [222/CA222] Atompspheric pressure sensor low error Error code

Failure code

222

CA222

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Atmospheric pressure sensor low error

• Low voltage is detected in atmospheric pressure sensor • Fixes atmospheric pressure and continues operation. • Engine output drops. • Starting performance is poor. • Method of reproducing failure code: Starting switch ON. • If sensor connector is disconnected, this failure code is displayed. Causes

Standard value in normal state/Remarks on troubleshooting

Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them Defective wiring harness con- directly. 1 nector • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective power supply line of 2. Disconnect connector AMB. AIR PRESSURE and connect T2 ambient pressure sensor adapter to female side. 3. Turn starting switch to ON position. Between AMB. AIR PRESSURE (female) (1) and (2)

Possible causes and standard value in normal state

Power input

Voltage

4.75 –5.25 V

1. Turn starting switch to OFF position. 2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect T-adapter to each female side. a If power supply input in checks on cause 2 is normal, this check is not required. Resistance Between ECM (female) (33) and Short circuit in wiring harness AMB. AIR PRESSURE (female) (1) 3 (wire breakage or defective a If power supply input in checks on contact of connector) cause 2 is normal, this check is not required. Resistance Between ECM (female) (38) and AMB. AIR PRESSURE (female) (2) Between ECM (female) (3) and AMB. AIR PRESSURE (female) (3) (sensor output)

Resistance

Max. 10 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Ground fault in wiring harness 4 (contact with ground circuit) Between ECM (female) (3) and ground, or between AMB. AIR PRES- Resistance Min. 100 kz SURE (female) (3) and ground

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

5 Short circuit in wiring harness

Possible causes and standard value in normal state

Defective ambient pressure 6 sensor (improper input voltage to engine controller)

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Between ECM (female) (3) and (38), or between AMB. AIR PRESSURE Resistance Min. 100 kz (female) (2) and (3) a If no failure is found by checks on causes 1 to 5 and check result for cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter to connector ECM. 3. Turn starting switch to ON position. Between ECM (3) and (38)

7 Defective engine controller

Sensor output

Voltage

0.5 â&#x20AC;&#x201C; 4.5 V

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to atmospheric pressure sensor

107E-1 Series

SEN00254-04

40 Troubleshooting

E-15 Code [227/CA227] Sensor power supply 2 high error Error code

Failure code

227

CA227

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

Sensor power supply 2 high error

• High voltage is detected in sensor power supply 2 circuit. • Fixes charge (boost) pressure and charge (boost) temperature, and continues operation. • Limits output and continues operation. • Engine output drops. • Engine starting performance becomes deteriorated. • Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for failure code [CA187].

E-16 Code [234/CA234] Engine overspeed Error code

Failure code

234

CA234

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Engine overspeed

• Engine speed is above upper control limit. • Stops injection of injector until engine speed drops to normal level.

• Engine speed fluctuates.

• Method of reproducing failure code: Start engine and run it at high idle. Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

1 Use of improper fuel

Check fuel used directly (for high viscosity).

2 Improper way of use

Machine may be used improperly. Instruct operator on proper way to use.

3 Defective engine controller

If no failure is found by checks on causes 1 and 2, engine controller may be defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

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E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply Error code

Failure code

238

CA238

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Abnormallity in Ne speed sensor power supply

• Low voltage is detected in engine Ne speed sensor power supply circuit. • Controls Ne speed sensor with signals of Bkup speed sensor. • Starting performance is poor • There is hunting from engine. • Method of reproducing failure code: Starting switch ON.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among each sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1.

Possible causes and standard value in normal state

Defective sensor or wiring 2 harness

3 Defective engine controller

If this failure code is not displayed when sensor is disconnected, sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA238]. Sensor or harness

Connector

Ne speed sensor

CRANK SENSOR

Engine wiring harness

ECM

Voltage

4.75 – 5.25 V

Circuit diagram related to engine Ne speed sensor

107E-1 Series

SEN00254-04

40 Troubleshooting

E-18 Code [271/CA271] Short circuit in IMV/PCV1 Error code

Failure code

271

CA271

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Short circuit in IMV/PCV1

• There is short circuit in supply pump actuator drive circuit. • None in particular. • Engine speed does not rise from low idle. • Engine output drops. • Common rail fuel pressure is above command value. • Method of reproducing failure code: Starting switch ON.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

1. Turn starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. Defective supply pump actu- 3. Turn starting switch to ON position. 2 ator If failure code changes from [CA271] to [CA272] , supply pump actuator is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3 Possible causes and standard value in normal state

Short circuit or ground fault in wiring harness

Short circuit in wiring harness

Between ECM (female) (2) and (32)

Resistance

1–5z

Between ECM (female) (2) and ground

Resistance

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect T-adapter to female side of ECM. Between ECM (female) (2) and (32)

Ground fault in wiring har5 ness (contact with ground circuit)

Min. 100 kz

6 Defective engine controller

Resistance

Min. 100 kz

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to supply pump actuator (metering unit)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-19 Code [272/CA272] Disconnection in IMV/PCV1 Error code

Failure code

272

CA272

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection in IMV/PCV1

• There is disconnection in supply pump actuator drive circuit. • None in particular. • Engine speed runs, but in unstable condition. • Common rail fuel pressure is above command value. • Method of reproducing failure code: Starting switch ON. • Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable to harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter).

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

1. Turn starting switch to OFF position. Defective supply pump actu- 2. Disconnect connector CP3 PUMP REGULATOR. 2 ator Between CP3 PUMP REGULATOR (male) Resis(1) and (2) tance Possible causes and standard value in normal state

Open or short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (2) and (32)

Hot short circuit in wiring 4 harness (contact with 24 V circuit)

Resistance

Max. 5 z

1. 2. 3. 4.

Turn starting switch to OFF position. Disconnect connector CP3 PUMP REGULATOR. Insert T-adapter to connector ECM. Turn starting switch to ON position and perform troubleshooting after one minute or longer (with connector CP3 PUMP REGULATOR disconnected). a Average voltage is displayed because of PWM. Between ECM (2) and (32)

5 Defective engine controller

Max. 5 z

Voltage

Max. 3 V

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to supply pump actuator (metering unit)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1 Error code

Failure code

322

CA322

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 1

• There is disconnection or short circuit in drive circuit of injector No. 1. • None in particular. • There is irregular combustion or hunting. • Output drops. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 1, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect Tadapter to male side.

2 Defective No. 1 injector

Between INJECTOR CYL 1&2 (male) (3) and (4)

Resistance

Max. 2 z

Between INJECTOR CYL 1&2 (male) (3) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (45) and (53)

Resistance

Max. 2 z

Between ECM (female) (45) and ground

Resistance

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to each female side. Between ECM (female) (45) and INJECTOR CYL 1&2 (female) (3)

Resistance

Max. 2 z

Between ECM (female) (53) and INJECTOR CYL 1&2 (female) (4)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of either one. Between ECM (female) (45) or INJECTOR CYL 1&2 (female) (3) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (45) and each pin other than (45)

No continuity (no sound is heard.)

Between ECM (female) (53) and each pin other than (53)

No continuity (no sound is heard.)

If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by checks on causes 1 to 7, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to injector No. 1

107E-1 Series

SEN00254-04

40 Troubleshooting

E-21 Code [323/CA323] Disconnection, short circuit in injector No. 5 Error code

Failure code

323

CA323

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 5

• There is disconnection or short circuit in drive circuit of injector No. 5. • None in particular. • There is irregular combustion or hunting. • Output drops. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 5, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect Tadapter to male side.

2 Defective No. 5 injector

Between INJECTOR CYL 5&6 (male) (3) and (4)

Resistance

Max. 2 z

Between INJECTOR CYL 5&6 (male) (3) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (46) and (60)

Resistance

Max. 2 z

Between ECM (female) (46) and ground

Resistance

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to each female side. Between ECM (female) (46) and INJECTOR CYL 5&6 (female) (3)

Resistance

Max. 2 z

Between ECM (female) (60) and INJECTOR CYL 5&6 (female) (4)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of either one. Between ECM (female) (46) or INJECTOR CYL 5&6 (female) (3) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (46) and each pin other than (46)

No continuity (no sound is heard.)

Between ECM (female) (60) and each pin other than (60)

No continuity (no sound is heard.)

If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

* This code is not applicable to 4D107E-1. Circuit diagram related to injector No. 5

107E-1 Series

SEN00254-04

40 Troubleshooting

E-22 Code [324/CA324] Disconnection, short circuit in injector No. 3 Error code

Failure code

324

CA324

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 3

• There is disconnection or short circuit in drive circuit of injector No. 3. • None in particular. • There is irregular combustion or hunting. • Output drops. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 3, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect Tadapter to male side.

2 Defective No. 3 injector

Between INJECTOR CYL 3&4 (male) (3) and (4)

Resistance

Max. 2 z

Between INJECTOR CYL 3&4 (male) (3) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (55) and (52)

Resistance

Max. 2 z

Between ECM (female) (55) and ground

Resistance

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to each female side. Between ECM (female) (55) and INJECTOR CYL 3&4 (female) (3)

Resistance

Max. 2 z

Between ECM (female) (52) and INJECTOR CYL 3&4 (female) (4)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of either one. Between ECM (female) (55) or INJECTOR CYL 3&4 (female) (3) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (55) and each pin other than (55)

No continuity (no sound is heard.)

Between ECM (female) (52) and each pin other than (52)

No continuity (no sound is heard.)

Circuit diagram related to injector No. 3

107E-1 Series

SEN00254-04

40 Troubleshooting

E-23 Code [325/CA325] Disconnection, short circuit in injector No. 6 Error code

Failure code

325

CA325

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 6

• There is disconnection or short circuit in drive circuit of injector No. 6. • None in particular.

• There is irregular combustion or hunting. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of apporx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 6, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect Tadapter to male side.

2 Defective injector No. 6

Between INJECTOR CYL 5&6 (male) (1) and (2)

Resistance

Max. 2 z

Between INJECTOR CYL 5&6 (male) (1) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (57) and (59)

Resistance

Max. 2 z

Between ECM (female) (57) and ground

Resistance

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&amp;6, and connect T-adapters to each female side. Between ECM (female) (57) and INJECTOR CYL 5&6 (female) (1)

Resistance

Max. 2 z

Between ECM (female) (59) and INJECTOR CYL 5&6 (female) (2)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of either one. Between ECM (female) (57) or INJECTOR CYL 5&6 (female) (1) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

No continuity (no sound is heard.)

Between ECM (female) (59) and each pin other than (59)

No continuity (no sound is heard.)

* This code is not applicable to 4D107E-1. Circuit diagram related to injector No. 6

107E-1 Series

SEN00254-04

40 Troubleshooting

E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2 Error code

Failure code

331

CA331

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 2

• There is disconnection or short circuit in drive circuit of injector No. 2. • None in particular. • There is irregular combustion or hunting. • Output drops. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 2, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect Tadapter to male side.

2 Defective No. 2 injector

Between INJECTOR CYL 1&2 (male) (1) and (2)

Resistance

Max. 2 z

Between INJECTOR CYL 1&2 (male) (2) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (54) and (51)

Resistance

Max. 2 z

Between ECM (female) (54) and ground

Resistance

Min. 100 kz

Resistance

Max. 2 z

Between ECM (female) (51) and INJECTOR CYL 1&2 (female) (1)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of either one. Between ECM (female) (54) or INJECTOR CYL 1&2 (female) (2) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

No continuity (no sound is heard.)

Between ECM (female) (51) and each pin other than (51)

No continuity (no sound is heard.)

Circuit diagram related to injector No. 2

107E-1 Series

SEN00254-04

40 Troubleshooting

E-25 Code [332/CA332] Disconnection, short circuit in injector No. 4 Error code

Failure code

332

CA332

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Disconnection, short circuit in injector No. 4

• There is disconnection or short circuit in drive circuit of injector No. 4. • None in particular. • There is irregular combustion or hunting. • Output drops. • Method of reproducing failure code: Start engine. • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among injector No. 4, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect Tadapter to male side.

2 Defective No. 4 injector

Between INJECTOR CYL 3&4 (male) (1) and (2)

Resistance

Max. 2 z

Between INJECTOR CYL 3&4 (male) (2) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Possible causes and standard value in normal state

Open circuit or ground fault in wiring harness

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring har5 ness (contact with ground circuit)

Between ECM (female) (56) and (58)

Resistance

Max. 2 z

Between ECM (female) (56) and ground

Resistance

Min. 100 kz

Resistance

Max. 2 z

Between ECM (female) (58) and INJECTOR CYL 3&4 (female) (1)

Resistance

Max. 2 z

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of either one. Between ECM (female) (56) or INJECTOR CYL 3&4 (female) (2) and ground

Resistance

Min. 100 kz

107E-1 Series

40 Troubleshooting

SEN00254-04

Causes

Possible causes and standard value in normal state

Short circuit in wiring harness

Defective other cylinder injectors or wiring harness

8 Defective engine controller

No continuity (no sound is heard.)

Between ECM (female) (58) and each pin other than (58)

No continuity (no sound is heard.)

Circuit diagram related to injector No. 4

107E-1 Series

SEN00254-04

40 Troubleshooting

E-26 Code [342/CA342] Calibration error in engine controller data Error code

Failure code

342

CA342

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

Calibration error in engine controller data

• Matching error occurred in engine controller data. • None in particular.

• Normal operation or engine stops and engine cannot be started.

• Method of reproducing failure code: Starting switch ON. Causes 1 Defect in related system 2

Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltPerform troubleshooting for failure code [CA441]. age system

107E-1 Series

40 Troubleshooting

SEN00254-04

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

Failure code

351

CA351

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

107E-1 Series

Trouble

Abnormality in injector drive circuit

• Abnormality occurred in injector drive power supply circuit. • Runs engine with engine output limited. • • • •

Exhaust smoke is black There is irregular combustion. Engine output drops. Engine does not start

• Method of reproducing failure code: Start engine. Causes 1 Defective related system 2

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, perform troubleshooting for it.

Defective power supply voltPerform troubleshooting for failure code [CA441]. age system

SEN00254-04

40 Troubleshooting

E-28 Code [352/CA352] Sensor power supply 1 low error Error code

Failure code

352

CA352

Contents of trouble Action of controller Problem that appears on machine Related information

Sensor power supply 1 low error

• Low voltage is detected in sensor power supply 1 circuit. • Fixes atmospheric pressure and continues operation. • Engine output drops. • Starting performance is poor. • Method of reproducing failure code: Starting switch ON.

Possible causes and standard value in normal state

Trouble

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1.

Defective sensor or wiring 2 harness

3 Defective engine controller

If this failure code is not displayed when sensor is disconnected, sensor or engine wiring harness is defective. a Other failure codes are displayed as well. This is because connector is unplugged. Ignore all failure codes other than [CA352]. Sensor or harness

Connector

Ambient pressure sensor

AMB. AIR PRESSURE

Engine wiring harness

ECM

Voltage

4.75 5.25V

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to sensor power supply 1

107E-1 Series

SEN00254-04

40 Troubleshooting

E-29 Code [386/CA386] Sensor power supply 1 high error Error code

Failure code

386

CA386

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

Sensor power supply 1 high error

• High voltage is detected in sensor power supply 1 circuit. • Fixes atmospheric pressure and continues operation. • Engine output drops. • Starting performance is poor. • Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for failure code [CA352]

107E-1 Series

40 Troubleshooting

107E-1 Series

SEN00254-04

40 Troubleshooting

E-30 Code [428/CA428] Water-in-fuel sensor high error Error code

Failure code

428

CA428

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Water-in-fuel sensor high error

• High voltage occurred in water-in-fuel sensor • None in particular.

• Water separator monitor does not indicate normally.

• Method of reproducing failure code: Starting switch ON.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among fuel water sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapter to female side. Defective water-in-fuel sen2 sor installed to fuel pre-filter a If water is in water separator, drain it. ResisMin. Between P47 (female) (1) and (2) tance 100 kz

Open or short circuit in wiring harness

Possible causes and standard value in normal state Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (14) and (47) (Resistance of water-in-fuel sensor)

Min. 100 kz

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapter to each female side. Between ECM (female) (14) and P47 (female) (1)

Resistance

Max. 10 z

Between ECM (female) (47) and P47 (female) (2)

Resistance

Max. 10 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (14) and each pin other than (14)

6 Defective engine controller

Resistance

No continuity (no sound is heard.)

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to water-in-fuel sensor

The terminal names and pin numbers are shown as examples of PC200-8 .

107E-1 Series

SEN00254-04

40 Troubleshooting

E-31 Code [429/CA429] Water-in-fuel sensor low error Error code

Failure code

429

CA429

Contents of trouble Action of controller Problem that appears on machine Related information

Water-in-fuel sensor low error

• Low voltage occurred in water-in-fuel sensor • None in particular.

• Water separator monitor does not indicate normally.

• Method of reproducing failure code: Starting switch ON.

Possible causes and standard value in normal state

Trouble

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Defective water-in-fuel sensor installed to fuel pre-filter

1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapter to female side. a If water is in water separator, drain it. Between P47 (female) (1) and (2)

Resistance

Min. 100 kz

Between P47 (female) (1) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3

Short circuit or ground fault in wiring harness

Short circuit in wiring harness

Between ECM (female) (14) and (47) (Resistance of water-in-fuel sensor)

Resistance

Min. 100 kz

Between ECM (female) (14) and ground

Resistance

Min. 100 kz

Ground fault in wiring har5 ness (contact with ground circuit)

6 Defective engine controller

No continuity (no sound is heard.)

a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapter to female side of either one. Between ECM (female) (14) and ground or between P47 (female) (1) and ground

Resistance

Min. 100 kz

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to water-in-fuel sensor

The terminal names and pin numbers are shown as examples of PC200-8.

107E-1 Series

SEN00254-04

40 Troubleshooting

E-32 Code [431/CA431] Abnormality in idle validation switch Error code 431 Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA431

Trouble

Abnormality in idle validation switch

• Abnormality occurred in idle validation switch circuit • Sets throttle angle to certain value and continues operation (depending on each model). • Engine speed may not rise from low idle. • Method of reproducing failure code: Starting switch ON, accelerator ON. Causes

Defective wiring harness connector

2 Defective accelerator pedal

Possible causes and standard value in normal state

Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Short circuit in wiring harness (With another wiring harness)

5 Defective engine controller

Standard value in normal state/Remarks on troubleshooting Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. WAS1 (Male) Accelerator pedal Resistance Release Max. 1 z Between (5) – (4) Press Min. 1 Mz Release Min. 1 Mz Between (6) – (4) Press Max. 1 z a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. Between J2 (female) (11) – WAS1 (female) ResisMax. (5) tance 10 z Between J2 (female) (1) – WAS1 (female) ResisMax. (6) tance 10 z Between J2 (female) (32) – WAS1 (female) ResisMax. (4) tance 10 z a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. Between J2 (female) (11) – J2 (female) ResisMin. (each pin) (With also WAS1 disconnected) tance 100 kz Between J2 (female) (1) – J2 (female) ResisMin. (each pin) (With also WAS1 disconnected) tance 100 kz Between J2 (female) (11) – J3 (female) (3) ResisMin. (With also WAS1 disconnected) tance 100 kz ResisMin. Between J2 (female) (1) – J3 (female) (3) (With also WAS1 disconnected) tance 100 kz a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. J2 (Female) Accelerator pedal Resistance Release Max. 1 z Between (11) – (32) Press Min. 1 Mz Release Min. 1 Mz Between (1) – (32) Press Max. 1 z

* The terminal names and pin numbers are shown as an example.

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to accelerator pedal (as an example)

107E-1 Series

SEN00254-04

40 Troubleshooting

E-33 Code [432/CA432] Abnormality in idle validation processing Error code

Failure code

432

CA432

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Abnormality in processing of idle validation processing

• Abnormality occurred in processing of idle validation switch circuit. • Sets throttle angle to certain value and continues operation (depending on each model).

• Engine speed may not rise from low idle.

• Method of reproducing failure code: Starting switch ON, accelerator ON.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON.

2 Defective accelerator pedal

WAS1 (Male) Between (2) – (1)

Possible causes and standard value in normal state

Accelerator pedal

Resistance

Release

1.5 – 3.0 kz

Press

0.25 – 1.5 kz

a Prepare with starting switch OFF, then perform troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Between J2 (female) (22) – WAS1 (female) ResisMax. 3 (Disconnection in wiring or (1) tance 10 z defective contact in connecBetween J2 (female) (9) – WAS1 (female) ResisMax. tor) (2) tance 10 z a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. 4

Short circuit in wiring harness Between J2 (female) (22) – J2 (female) (With another wiring harness) (each pin) (With also WAS1 disconnected)

Resistance

Min. 100 kz

Between J2 (female) (9) – J2 (female) (each pin) (With also WAS1 disconnected)

Resistance

Min. 100 kz

a Prepare with starting switch OFF, then perform troubleshooting without turning starting switch ON. 5 Defective engine controller

J2 (Female) Between (22) – (9)

Accelerator pedal

Resistance

Release

1.5 – 3.0 kz

Press

0.25 – 1.5 kz

* The terminal names and pin numbers are shown as an example.

107E-1 Series

40 Troubleshooting

SEN00254-04

Circuit diagram related to accelerator pedal (as an example)

107E-1 Series

SEN00254-04

40 Troubleshooting

KOMATSU 107E-1 Series Diesel engine Form No. SEN00254-04

SEN00255-04

Engine 1SHOP MANUAL

107E-1 Series

40 Troubleshooting

Troubleshooting of electrical system (E-mode), Part 2 E-34 Code [435/CA435] Abnormality in engine oil pressure switch................................................................ 3 E-35 Code [441/CA441] Abnormally low power supply voltage...................................................................... 4 E-36 Code [442/CA442] Abnormally high power supply voltage .................................................................... 6 E-37 Code [449/CA449] Common rail pressure high error 2 .......................................................................... 7 E-38 Code [451/CA451] Common rail pressure sensor high error ................................................................. 8 E-39 Code [452/CA452] Common rail pressure sensor low error................................................................. 10 E-40 Code [488/CA488] Derating of torque by charge temperature high error ............................................ 12 E-41 Code [553/CA553] Common rail pressure high error 1 ........................................................................ 12 E-42 Code [559/CA559] No-pressure feed 1 by supply pump...................................................................... 13 E-43 Code [689/CA689] Abnormality in engine Ne speed sensor ................................................................ 15 E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase.................................................. 17 E-45 Code [757/CA757] Loss of all data in engine controller ....................................................................... 18 E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor ............................................................ 19 E-47 Code [1633/CA1633] Abnormality in KOMNET.................................................................................... 22

107E-1 Series

SEN00255-04

40 Troubleshooting

E-48 Code [2185/CA2185] Throttle sensor power supply high error ............................................................ 23 E-49 Code [2186/CA2186] Throttle sensor power supply low error.............................................................. 24 E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump .................................................................. 25 E-51 Code [2311/CA2311] Abnormality in IMV solenoid ............................................................................... 25 E-52 Code [2555/CA2555] Disconnection in intake air heater relay ............................................................. 26 E-53 Code [2556/CA2556] Short circuit in intake air heater relay................................................................. 28 E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction ............................................ 30 E-55 Code [---/B@BAZK] Engine oil level low .............................................................................................. 30 E-56 Code [---/B@BCNS] Engine overheat .................................................................................................. 31 E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error ............................................... 32 E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error ................................................ 34 E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error......................................................... 36 E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error.......................................................... 38 E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) ........................................................... 40 E-62 Code [b6] Droop Rate Adjustment Volume High Error ........................................................................ 44 E-63 Code [b7] Droop Rate Adjustment Volume Low Error .......................................................................... 46 E-64 Code [b8] Low Idle Speed Adjustment Volume High Error ................................................................... 48 E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error.................................................................... 50 E-66 Code [bc] Rated Speed Median Adjustment Volume High Error .......................................................... 52 E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error........................................................... 54 E-68 Code [bE] Ramp Time Adjustment Volume High Error......................................................................... 56 E-69 Code [bF] Ramp Time Adjustment Volume Low Error.......................................................................... 58

107E-1 Series

40 Troubleshooting

SEN00255-04

E-34 Code [435/CA435] Abnormality in engine oil pressure switch Error code

Failure code

435

CA435

Contents of trouble Action of controller Problem that appears on machine

Related information

Abnormality in engine oil pressure switch

• Abnormality occurred in engine oil pressure switch signal circuit. • None in particular.

• Engine oil pressure switch-based engine protection function does not function. • Method of reproducing failure code: Starting switch ON or start engine • Engine oil pressure switch is closed (ON) when oil pressure is low (when engine is stopped), but is open (OFF) when high (when engine is running). • To generate this failure code, engine controller checks if engine oil pressure switch is closed (ON), that is, if signal voltage is at GND level or not only while engine is stopped. • When engine is running, engine oil pressure switch error is shown by failure code [B@BAZG].

Possible causes and standard value in normal state

Trouble

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among engine oil pressure switch, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

Defective engine oil pressure switch

Open or short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH and connect Tadapter to male side. Between OIL PRESSURE SWITCH (male) (1) and ground

Max. 10 z

1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (17) and ground

4 Defective engine controller

Resistance

Max. 10 z

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch

107E-1 Series

SEN00255-04

40 Troubleshooting

E-35 Code [441/CA441] Abnormally low power supply voltage Error code

Failure code

441

CA441

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Abnormally low power supply voltage

• Low voltage occurred in controller power supply circuit. • None in particular. • Engine stops • Starting performance is poor • Method of reproducing failure code: Starting switch ON. Causes 1

Standard value in normal state/Remarks on troubleshooting

Loose, corroded battery terInspect battery terminal directly for loose and corrosion. minal

Loose terminal or partial 2 open circuit at terminal

Defective wiring harness connector

4 Improper battery voltage Possible causes and standard value in normal state

1. Turn starting switch to OFF position. Check terminals of alternator, battery relay, ground terminal (T12), etc. Connecting parts among fuse No. 19, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Perform troubleshooting with starting switch at OFF position and at engine cranking. Between battery terminals (+) and (-).

5 Defective alternator

Between E12 (1) and ground

6 Defective engine controller

Voltage

20 – 30 V

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector E12. 3. Start engine (Engine speed: Middle or faster). Voltage

27.5 – 29.5 V

If no failure is found by above checks, engine controller is defective. • Reference 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter in connector CE03. 3. Connect ground cable. 4. Measure voltage with starting switch at ON position and when starting engine. Between CE03 (3) and (1)

Starting switch: ON

Voltage

20 – 30 V

Between CE03 (3) and (1)

Starting switch: START

Voltage

Min. 12 V

* The terminal names and pin numbers are shown as examples of PC200-8.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to engine controller power supply (PC200-8, as an example)

107E-1 Series

SEN00255-04

40 Troubleshooting

E-36 Code [442/CA442] Abnormally high power supply voltage Error code

Failure code

442

CA442

Contents of trouble

• None in particular.

Problem that appears on machine

• Engine may stop.

Possible causes and standard value in normal state

Abnormally high power supply voltage

• High voltage (min. 36V) occurred in controller power supply circuit.

Action of controller

Related information

Trouble

• Method of reproducing failure code: Starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for failure code [CA441].

107E-1 Series

40 Troubleshooting

SEN00255-04

E-37 Code [449/CA449] Common rail pressure high error 2 Error code

Failure code

449

CA449

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Common rail pressure high error 2

• Pressure (2) in common rail circuit is abnormally high. • Limits output and continues operation. • Engine sound becomes larger under no load or light load. • Engine output drops. • Method of reproducing failure code: Start engine. Causes

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, perform troubleshooting for it.

2 Air in low-pressure circuit

Inspect it for air entry directly according to the following procedure. 1) Remove pressure pickup plug (outlet side) from fuel main filter. 2) Operate feed pump of fuel pre-fuel filter. 3) Inspect fuel and air from pressure pickup plug for leakage level.

Defective fuel return circuit device

Defective common rail pressure sensor

5 Defective pressure limiter

a For check of pressure in fuel return circuit, see TESTING AND ADJUSTING, Testing fuel pressure. Fuel return circuit pressure

6 Defective supply pump

At low idle or cranking

Max. 0.02 MPa {Max. 0.19 kg/cm2}

Perform troubleshooting for failure codes [CA451] and [CA452] a For testing of leakage from pressure limiter, see TESTING AND ADJUSTING, Testing leakage from pressure limiter and return rate from injector. Leakage from pressure limiter

107E-1 Series

At low idle

0 cc (No leakage)

If causes 1 – 5 are not detected, supply pump may be defective.

SEN00255-04

40 Troubleshooting

E-38 Code [451/CA451] Common rail pressure sensor high error Error code

Failure code

451

CA451

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

Common rail pressure sensor high error

• High voltage occurred in common rail pressure sensor. • Limits output and continues operation. • Engine speed or output drops. • Engine does not start. • Method of reproducing failure code: Starting switch ON. • This failure code is displayed if common rail pressure sensor connector is disconnected. • Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a Tadapter).

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

Defective common rail presIf failure code [CA227] or [CA187] is also displayed, perform trou2 sure sensor power supply bleshooting for it first. line

Short circuit in wiring harness

Possible causes and standard value in normal state

Hot short circuit in wiring 4 harness (contact with 24 V circuit)

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS, and connect Tadapter to connector ECM. 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS disconnected). a Pin (25) of ECM is connected to 5V line via resistor inside engine controller. Between ECM (25) and (47)

Open circuit in wiring har5 ness

Resistance

Voltage

Approx. 5 V

If no failure is found by above checks, there may be open circuit in wiring harness. (*)

a If no failure is found by checks on causes 1 to 5 and check result for cause 6 is abnormal, sensor is defective. Defective common rail pres- 1. Turn starting switch to OFF position. sure sensor 2. Insert T-adapter to connector ECM. 6 (improper input voltage to 3. Turn starting switch to ON position. engine controller) Sensor Between ECM (25) and (47) Voltage 0.2 – 4.6 V output 7 Defective engine controller

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related information of troubleshooting".

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to common rail pressure sensor

107E-1 Series

SEN00255-04

40 Troubleshooting

E-39 Code [452/CA452] Common rail pressure sensor low error Error code

Failure code

452

CA452

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Common rail pressure sensor low error

• Low voltage occurred in common rail pressure sensor. • Limits output and continues operation. • Engine speed or output drops. • Engine does not start • Method of reproducing failure code: Starting switch ON. • If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error" is displayed.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Defective common rail presIf failure code [CA187] (ground fault in sensor power supply line) or 2 sure sensor power supply [CA227] is indicated, perform troubleshooting for it first. line

Possible causes and standard value in normal state

a Check that failure code [CA187] (Ground fault in sensor power supply line) is not displayed. Defective common rail pres- 1. Turn starting switch to OFF position. 3 2. Disconnect connector FUEL RAIL PRESS. sure sensor 3. Turn starting switch to ON position. If failure code [CA452] changes to [CA451] , sensor is defective. Ground fault in wiring har4 ness (contact with ground circuit)

Short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and ground

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and (47)

6 Defective engine controller

Resistance

Min. 100 kz

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to common rail pressure sensor

107E-1 Series

SEN00255-04

40 Troubleshooting

E-40 Code [488/CA488] Derating of torque by charge temperature high error 1 Error code

Failure code

488

CA488

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit. • Limits output and continues operation.

• Output drops.

• Method of reproducing failure code: Start engine. Causes

Possible causes and standard value in normal state

Derating of torque by charge temperature high error

Standard value in normal state/Remarks on troubleshooting

Inspect following directly. Drop in cooling performance • Loose, broken fan belt 1 of aftercooler. • Lack of cooling air • Clogged aftercooler fin 2

Abnormally high temperature Outlet temperature of turbocharger may be abnormally high. Check at turbocharger outlet related parts directly.

Defective charge (boost) temperature sensor

Perform troubleshooting for failure codes [CA153] and [CA154].

E-41 Code [553/CA553] Common rail pressure high error 1 Error code

Failure code

553

CA553

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

• None in particular. • Engine sound becomes larger under no load or light load. • Engine output drops. • Method of reproducing failure code: Start engine. Causes

Common rail pressure high error 1

• Voltage (1) in common rail circuit is abnormally high.

1 Defective related system

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, perform troubleshooting for it.

Defective connection of ground terminal

Inspect following directly for connection of ground terminal. • Ground terminal (battery (–)) of machine main unit. • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor

Defective O-ring of supply pump actuator

O-ring of supply pump actuator may be damaged. Check it directly.

Defective common rail presPerform troubleshooting for failure codes [CA451] and [CA452] sure sensor system

107E-1 Series

40 Troubleshooting

SEN00255-04

E-42 Code [559/CA559] No-pressure feed 1 by supply pump Error code

Failure code

559

CA559

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

No-pressure feed 1 by supply pump

• No-pressure feed (1) occurred in common rail circuit. • None in particular. • Engine does not start or starting performance is poor • Exhaust smoke is black • Engine output drops. • Method of reproducing failure code: Start engine. Causes

Standard value in normal state/Remarks on troubleshooting

1 Use of improper fuel

Fuel used may be improper. Check it directly (for high viscosity).

2 Fuel leakage to outside

Fuel may leak to outside. Check it directly (Check visually while running engine at low idle). a For contents of troubleshooting, see “Note 1”. a For measurement of pressure in fuel low-pressure circuit, see TESTING AND ADJUSTING, “Measurement of fuel pressure”.

Defective fuel low-pressure circuit parts

Fuel supply pump inlet negative pressure (Fuel prefilter outlet side)

Fuel main filter inlet pressure

Possible causes and standard value in normal state

4 Defective pressure limiter

At high idle (When engine can be started)

Max. –50.7 kPa {Max. –380 mmHg}

During cranking (When engine cannot be started)

0.3 – 1.1 MPa {3.1 – 11.3 kg/cm2}

At low idle (When engine can be started)

0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

a For testing of leakage from pressure limiter, see Testing and adjusting, “Testing fuel delivery, return and leak amount”. Leakage from pressure limiter

At low idle

0 cc (No leakage)

a For testing of return rate from injector, see Testing and adjusting, “Testing fuel delivery, return and leak amount”. Defective injector 5 (High-pressure piping in head included)

Return rate from injector

At cranking (When engine cannot be started)

Max. 90 cc/min.

At low idle (When engine can be started)

Max. 180 cc/min.

a For testing of return rate from supply pump, see Testing and adjusting, “Testing fuel delivery, return and leak amount”.

6 Defective supply pump

107E-1 Series

Defective common rail pressure sensor system

Return rate from supply pump

At cranking (When engine cannot be started)

Max. 140 cc/min.

At low idle (When engine can be started)

Max. 1,000 cc/min.

Perform troubleshooting for failure codes [CA451] and [CA452]

SEN00255-04

40 Troubleshooting

Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Leaking or clogging of fuel low-pressure piping 4) Clogging of fuel prefilter 5) Clogging of fuel main filter 6) Replace the fuel filters when trouble does not cancel it even if clogging is checked.

107E-1 Series

40 Troubleshooting

SEN00255-04

E-43 Code [689/CA689] Abnormality in engine Ne speed sensor Error code

Failure code

689

CA689

Trouble

Abnormality in engine Ne speed sensor

Contents of trouble

• Abnormality occurred in signals from engine Ne speed sensor.

Action of controller

• Controls Ne speed sensor with signals of Bkup speed sensor.

Problem that appears on machine

Related information

• There is hunting from engine. • Starting performance is poor. • Engine output drops. • Method of reproducing failure code: Start engine. • Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. • Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured with multimeter. • Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of crankshaft vibration damper and rotated by crankshaft. Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among engine Ne speed sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

Defective Ne speed sensor power supply line

If failure code [CA238] is also displayed, perform troubleshooting for it first.

Breakage or improper instalEngine Ne speed sensor may be broken or may have improper 3 lation (looseness) of engine installation (looseness). Check it directly. Ne speed sensor

Defective Ne speed sensor power supply input

1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CRANK SENSOR (female) (1) and (2)

Possible causes and standard value in normal state

Power input

Voltage

4.75 - 5.25V

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR.

Open circuit in wiring harness 5 (wire breakage or defective contact of connector)

a If no failure is found by checks on cause 4, this check is not required. Between ECM (female) (16) and CRANK SENSOR (female) (1)

Resistance

Max. 10 z

a If no failure is found by checks on cause 4, this check is not required. Between ECM (female) (48) and CRANK SENSOR (female) (2)

Resistance

Max. 10 z

Between ECM (female) (27) and CRANK SENSOR (female) (3)

Resistance

Max. 10 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. 6

107E-1 Series

Short circuit in wiring harness

Between ECM (female) (16) and (27) or CRANK SENSOR (female) (1) and (3)

Resistance

Min. 100 kz

Between ECM (female) (27) and (48) or CRANK SENSOR (female) (2) and (3)

Resistance

Min. 100 kz

SEN00255-04

40 Troubleshooting

Causes Ground fault in wiring har7 ness (contact with ground circuit)

Possible causes and standard value in normal state

Hot short circuit in wiring 8 harness (contact with 24 V circuit)

Damage or loose mounting of wheel for speed sensing

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. Between ECM (female) (27) or CRANK SENSOR (female) (3) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR. 3. Turn starting switch to ON position. Between CRANK SENSOR (female) (3) and ground

Voltage

Max. 1 V

Check speed sensing wheel directly.

10 Defective Ne speed sensor

If no failure is found by above checks, Ne speed sensor is defective. (Since this is internal failure, troubleshooting cannot be performed.)

11 Defective engine controller

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor

107E-1 Series

40 Troubleshooting

SEN00255-04

E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase 1 Error code

Failure code

731

CA731

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Abnormality in engine Bkup speed sensor phase

• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor. • Controls with signals of engine Ne speed sensor. • Engine does not start or is difficult to start. • Idle speed is unstable. • Exhaust smoke is black. • Method of reproducing failure code: Start engine. Causes

Standard value in normal state/Remarks on troubleshooting

Broken engine Ne speed sensor

Inspect engine Ne speed sensor for breakage directly.

Broken engine Bkup speed sensor

Inspect engine Bkup speed sensor for breakage directly.

Speed sensing wheel on crankshaft side may be installed defectively or broken. Check it according to following procedure. 1. Align paint mark (M1) on damper with Ne speed sensor top (M2). Defective or broken mount of a Do not align with mark of No. 1 cylinder compression top 3 rotation sensing wheel on dead center. (Approx. 80 ° before compression top dead crankshaft side center) 2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed sensor top (M2), installation is correct. Possible causes and standard value in normal state

Speed sensing ring on camshaft side may be installed defectively or broken. Check it according to the following procedure. 1. Align paint mark (M1) on damper with Ne speed sensor top (M2). a Do not align with mark of No. 1 cylinder compression top Defective or broken mount of dead center. (Approx. 80 ° before compression top dead 4 rotation sensing ring on camcenter) shaft side 2. Remove Bkup speed sensor. 3. If you can see double-slot part (with one crest) (B) on speed sensing ring through sensor mounting hole (H), speed sensing ring is installed correctly. 5

107E-1 Series

Defective timing between crankshaft and camshaft

Inspect crankshaft and camshaft for timing directly.

Defective connection of ground terminal

SEN00255-04

40 Troubleshooting

E-45 Code [757/CA757] Loss of all data in engine controller Error code

Failure code

757

CA757

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

Loss of all data in engine controller

• All data in engine controller are lost. • None in particular.

• Engine stops and sometimes cannot be started.

• Method of reproducing failure code: Starting switch ON. Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

107E-1 Series

40 Troubleshooting

SEN00255-04

E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor Error code

Failure code

778

CA778

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

Abnormality in engine Bkup speed sensor

• Abnormality is detected in signals of engine Bkup speed sensor. • Controls with signals of Ne speed sensor. • Starting performance is poor. • Output drops. • Method of reproducing failure code: Start engine. • Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by using multimeter. • Speed sensor scans rotating slot of speed sensing ring mounted on the camshaft. Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among engine Bkup speed sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

Defective sensor power sup- If failure code [CA187] or [CA227] is also displayed, troubleshoot it ply 2 line first.

Damage or incorrect (loose) Engine Bkup speed (cam) sensor directly as it may be damaged or 3 installation of engine Bkup incorrectly (loosely) installed. Check it directly. speed (cam) sensor

Possible causes and standard value in normal state

1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapter Defective power supply input to female side. 4 to engine Bkup speed sen- 3. Turn starting switch to ON position. sor Between CAM SENSOR Power 4.75 Voltage (female) (1) and (2) supply 5.25V 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to each female side. Open circuit in wiring harness 5 (wire breakage or defective contact of connector)

Between ECM (female) (37) and CAM SENSOR (female) (1)

Resistance

Max. 10 z

Between ECM (female) (47) and CAM SENSOR (female) (2)

Resistance

Max. 10 z

Between ECM (female) (26) and CAM SENSOR (female) (3)

Resistance

Max. 10 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to female side of either connector. 6

107E-1 Series

Short circuit in wiring harness

Between ECM (female) (26) and (37) or CAM SENSOR (female) (1) and (3)

Resistance

Min. 100 kz

Between ECM (female) (26) and (47) or CAM SENSOR (female) (2) and (3)

Resistance

Min. 100 kz

SEN00255-04

40 Troubleshooting

Causes Ground fault in wiring har7 ness (contact with ground circuit)

Possible causes and standard value in normal state

Hot short circuit in wiring 8 harness (contact with 24 V circuit)

9 Loose speed sensing ring

Defective engine Bkup speed (cam) sensor

11 Defective engine controller

Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to female side of either connector. Between ECM (female) (26) or CAM SENSOR (female) (3) and ground

Resistance

Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CAM SENSOR (female) (3) and ground

Voltage

Max. 1 V

Remove engine Bkup speed (cam) sensor, and check ring directly through hole (H). a If speed sensing ring (B) is loosely installed, follow instructions given in the "Reference" column. If no failure is found by above checks, engine Bkup speed (cam) sensor is defective. (Since this is internal failure, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor

107E-1 Series

40 Troubleshooting

Reference for troubleshooting for CA778 (107 series engine) Checking camshaft ring for loose installation Remove the front cover and check the camshaft ring for looseness. a See "Removal and installation of front seal" in Disassembly and assembly. a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand. Removal 40-190 1. Remove the fan and fan belt. For details, see "Removal and installation of front seal" in Disassembly and assembly. 2. Remove damper assembly (1). (DP): Dowel pin

3. Remove front cover (2). 4. Remove front seal (3). (RING): Ring

107E-1 Series

SEN00255-04

5. Check mounting bolt (4) of camshaft ring (5) for looseness. 3 Mounting bolt (4): 10 Âą 2 Nm (DP): Dowel pin

Connection 40-190 a See the figures in "Removal" for installation. 1. Install front cover (2). 3 Front cover: Liquid gasket (LG-7) 2. Install the front seal according to the following procedure. For details, see "Removal and installation of front seal" in Disassembly and assembly. 1) Install front seal (3). 2) Install the damper with the dowel pin (DP) assembly. 3) Install fan belt, and install the fan. 4) Install the cooling system assembly.

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40 Troubleshooting

E-47 Code [1633/CA1633] Abnormality in KOMNET Error code

Failure code

1633

CA1633

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

Abnormality in KOMNET

• Engine controller detected abnormality in KOMNET (CAN) communication circuit to controllers on applicable machine side. • Depends on machine model. • If problem is removed, circuit is returned to normal operating state. • KOMNET communication information may not be transmitted correctly to cause incorrect operation of machine. (Problem depends on failure occurrence location.) • Method of reproducing failure code: Starting switch ON.

Causes Standard value in normal state/Remarks on troubleshooting Possible causes and Perform troubleshooting for CAN communication of machine side. standard value • PC series : failure code [DA2RMC] in normal state • WA, bulldozer and dump truck series : [DB2RKR]

Circuit diagram related to KOMNET communication (PC200-8, as an example)

107E-1 Series

40 Troubleshooting

SEN00255-04

E-48 Code [2185/CA2185] Throttle sensor power supply high error Error code

Failure code

2185

CA2185

Contents of trouble Action of controller Problem that appears Related information

Trouble Throttle sensor power supply high error

• High voltage (min. 5.25 V) occurred in throttle sensor power supply circuit. • Depends on machine model. • Depends on machine model. • Method of reproducing failure code: Starting switch ON. Causes

Possible causes and standard value in normal state

Defective wiring harness connector

Defective throttle sensor (fuel control dial)

Short circuit in wiring harness

Hot short circuit in wiring 4 harness (contact with 24 V circuit)

Standard value in normal state/Remarks on troubleshooting Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position. If this failure code is not displayed, throttle sensor is defective. a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA2185]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02, CE03 and P20, and connect Tadapters to each female side of connectors CE02 and CE03. Between CE02 (female) (22) and each Resistance Min. 1 Mz pin other than (22) Between CE02 (female) (22) and CE03 Resistance Min. 1 Mz (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between P20 (female) (1) and ground

Voltage

4.75 - 5.25V

1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to male side. 5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.

* The terminal names and pin numbers are shown as examples of PC200-8. Circuit diagram related throttle sensor (PC200-8, as an example)

107E-1 Series

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40 Troubleshooting

E-49 Code [2186/CA2186] Throttle sensor power supply low error Error code

Failure code

2186

CA2186

Contents of trouble Action of controller Problem that appears Related information

Trouble

Throttle sensor power supply low error

• Low voltage occurred in throttle sensor power supply circuit. • Depends on machine model. • Depends on machine model. • Method of reproducing failure code: Starting switch ON. Causes

Possible causes and standard value in normal state

Defective wiring harness connector

Defective throttle sensor (fuel control dial)

Ground fault of wiring har3 ness (contact with ground circuit)

Short circuit in wiring harness

5 Defective engine controller

Standard value in normal state/Remarks on troubleshooting Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position. If this failure code is not displayed, throttle sensor is defective. a Other failure code is displayed too. This is because of disconnection of connector. Ignore failure codes other than [CA2186]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of either connector. Between CE02 (female) (22) or P20 ResisMin. 1 Mz (female) (1) and ground tance 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of connector CE02. 3. Turn starting switch to ON position. Between CE02 (female) (22) and each ResisMin. 1 Mz pin other than (22) tance 1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to male side. 3. Turn starting switch to ON position with wiring harness disconnected. Between CE02 (male) (22) and (23)

Voltage

4.75 - 5.25V

Circuit diagram related to throttle sensor (PC200-8, as an example)

107E-1 Series

40 Troubleshooting

SEN00255-04

E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump Error code

Failure code

2249

CA2249

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

No-pressure feed 2 by supply pump

• No-pressure feed (2) occurred in common rail circuit. • Limits output and continues operation. • Starting performance is poor • Exhaust smoke is black • Output drops. • Method of reproducing failure code: Start engine. Causes 1

Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for failure code [CA559].

E-51 Code [2311/CA2311] Abnormality in IMV solenoid Error code

Failure code

2311

CA2311

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

107E-1 Series

Trouble

Abnormality in IMV solenoid

• Resistance in supply pump actuator is abnormally high or low. • None in particular.

• Engine output drops.

• Method of reproducing failure code: Start engine. Causes

Standard value in normal state/Remarks on troubleshooting

Perform troubleshooting for failure codes [CA271] and [CA272].

SEN00255-04

40 Troubleshooting

E-52 Code [2555/CA2555] Disconnection in intake air heater relay Error code

Failure code

2555

CA2555

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble Disconnection in intake air heater relay

• Open circuit is detected in drive circuit (primary circuit) of preheater relay. • None in particular. • Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes) • Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) • Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit (coil) of preheater relay R18. • For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see [Emode] in Troubleshooting of each machine shop. Causes

Defective wiring harness connector

Defective preheater relay R18

Standard value in normal state/Remarks on troubleshooting Connecting parts among auto preheat relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapter to male side. ResisBetween R18 (male) (1) and (2) 200 – 400 z tance 1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side.

Possible Open or short circuit in wir3 Between CE02 (female) (40) and (42) causes and ing harness Resisa Resistance of preheater relay R18 coil 200 – 400 z standard value tance resistance in normal state a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter Open circuit in wiring harto each female side. 4 ness Between CE02 (female) (40) and R18 ResisMax. 1 z (female) (1) tance ResisBetween R18 (female) (2) and CE02 (42) Max. 1 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter to female side of CE02. Short circuit in wiring har5 a Check by using multimeter in continuity mode. ness Between CE02 (female) (40) and each pin No continuity other than (40) (No sound is heard) 6 Defective engine controller If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

* The terminal names and pin nambers are shown as examples of PC200-8.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)

107E-1 Series

SEN00255-04

40 Troubleshooting

E-53 Code [2556/CA2556] Short circuit in intake air heater relay Error code

Failure code

2556

CA2556

Contents of trouble Action of controller

Trouble

Short circuit in intake air heater relay

• Short circuit is detected in drive circuit (primary circuit) of preheater relay. • None in particular.

Problem that appears on machine

• Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes)

Related information

• Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) • Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit (coil) of preheater relay R18. • For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see [Emode] in Troubleshooting of each machine shop.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective wiring harness connector

Connecting parts among auto preheat relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapter to male side. Between R18 (male) (1) and (2)

Defective preheater relay R18

Possible causes and standard value in normal state

Resistance

200 – 400 z

1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective.

Ground fault in wiring harness

Short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect Tadapter to female side of either connector. Between CE02 (female) (40) or R18 (female) (1) and ground

Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect Tadapter to female side of CE02. a Check by using multimeter in continuity mode. Between CE02 (female) (40) and each pin other than (40)

5 Defective engine controller

Resistance

No continuity (No sound is heard)

If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)

* The terminal names and pin numbers are shown as examples of PC200-8.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to preheating, starting and charging engine (PC200-8, as an example)

107E-1 Series

SEN00255-04

40 Troubleshooting

E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction Error code

Failure code

---

B@BAZG

Contents of trouble Action of controller Problem that appears on machine

Trouble

Derating of speed by engine oil pressure reduction

• Engine oil pressure is below operating range. • Limits engine output and continues operation (Limits fuel injection rate and engine speed). • Output of engine drops. • If machine is operated as it is, engine may be damaged.

Related information Possible causes and standard value in normal state

Causes 1

Standard value in normal state/Remarks on troubleshooting

perform troubleshooting on machine side

This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depend on machine model. See Shop manual for machine.

E-55 Code [---/B@BAZK] Engine oil level low Error code

Failure code

---

B@BAZK

Contents of trouble Action of controller Problem that appears on machine

Trouble

Engine oil level low

• Engine oil level is below operating range. • Limits engine output and continues operation (Limits fuel injection rate and engine speed). • Outpu of engine drops. • If machine is operated as it is, engine may seize up.

Related information Possible causes and standard value in normal state

Causes 1

perform troubleshooting on machine side

Standard value in normal state/Remarks on troubleshooting This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depend on machine model. See Shop manual for machine.

107E-1 Series

40 Troubleshooting

SEN00255-04

E-56 Code [---/B@BCNS] Engine overheat Error code

Failure code

---

B@BCNS

Contents of trouble Action of controller Problem that appears on machine

Trouble

Engine overheat

• Engine coolant temperature is above operating range. • Limits engine output and continues operation. • Output of engine drops. • If machine is operated as it is, engine may seize up.

Related information Possible causes and standard value in normal state

107E-1 Series

Causes 1

perform troubleshooting on machine side

SEN00255-04

40 Troubleshooting

E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error 1 a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble Action of controller Problem on machine Related information

Trouble

Rated Speed Adjustment Volume (Isochronous) High Error (Generator controller system)

• Voltage from the rated speed adjustment volume is kept above 4.7 V for 1 second. • Fixes the median of adjustable range. •

The rated speed changes .

• Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal. Causes

Defective 5 V power supply 1 for adjustment volume (generator controller)

Standard value in normal state/Remarks on troubleshooting 1. 2. 3.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Between CN1 (female) (7) and (22)

Resistance

Min. 450 z

Resistance

Min. 450 z

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the rated speed adjustment (Isochronous) volume between Min. and Max.

Between CN1 (7) and (21) 4 Defective generator controller

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed adjustment (Isochronous) volume between Min. and Max.

Defective rated speed 3. adjustment (Isochronous) 2 volume or open circuit or short circuit in wiring harness Between CN1 (female) (7) and (21)

1. 2. Hot short circuit in wiring har- 3. 3 4. ness

Voltage

0.5 - 4.5 V

If cause is not found by above checks, generator controller is defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rated speed adjustment (Isochronous) volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error 1 a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Rated Speed Adjustment Volume (Isochronous) Low Error (Generator controller system)

• Voltage from the rated speed adjustment (Isochronous) volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The rated speed changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Defective rated speed adjustment (Isochronous) 2 volume or open circuit or short circuit in wiring harness

Voltage

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed adjustment (Isochronous) volume between Min. and Max.

Between CN1 (female) (7) and (21)

Resistance

Min. 450 z

Between CN1 (female) (7) and (22)

Resistance

Min. 450 z

1. Turn starting switch to OFF position. 2. Disconnect connector CN1 and connect T-adapter to female Ground fault in wiring harside. 3 ness (Contact with ground circuit) ResisMin. Between CN1 (female) (7) and ground tance 1 Mz If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. Defective generator control- 2. Insert T-adapter into connector CN1. 4 ler 3. Turn starting switch to ON position. 4. Turn the rated speed adjustment (Isochronous) volume between Min. and Max. Between CN1 (7) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rated speed adjustment (Isochronous) volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error 1 a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Rated Speed Adjustment Volume (Droop) High Error (Generator controller system)

• Voltage from the rated speed adjustment (Droop) volume is kept below 4.7 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The rated speed changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Between CN1 (female) (13) and (22)

Hot short circuit in wiring 3 harness

Resistance

Min. 450 z

Resistance

Min. 450 z

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the rated speed adjustment (Droop) volume between Min. and Max.

Between CN1 (13) and (21) 4

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed adjustment (Droop) volume between Min. and Max.

Defective rated speed 3. adjustment (Droop) volume 2 or open circuit or short circuit in wiring harness Between CN1 (female) (13) and (21)

1. 2. 3. 4.

Voltage

0.5 - 4.5 V

Defective generator control- If cause is not found by above checks, generator controller is ler defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rated speed adjustment (Droop) volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Rated Speed Adjustment Volume (Droop) Low Error (Generator controller system)

• Voltage from the rated speed adjustment (Droop) volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The rated speed changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed adjustment (Droop) volume between Min. and Max.

Defective rated speed 3. adjustment (Droop) volume 2 or open circuit or short circuit in wiring harness Between CN1 (female) (13) and (21)

Between CN1 (female) (13) and (22)

Resistance

Min. 450 z

Resistance

Min. 450 z

1. Turn starting switch to OFF position. 2. Disconnect connector CN1 and connect T-adapter to female Ground fault in wiring harside. 3 ness (Contact with ground circuit) ResisBetween CN1 (female) (13) and ground Min. 1 z tance

Defective generator controller

If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN1. 3. Turn starting switch to ON position. 4. Turn the rated speed adjustment (Droop) volume between Min. and Max. Between CN1 (1) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rated speed adjustment (Droop) volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition) Failure rank

Failure code Trouble

Serious Contents of trouble

AF •

Abnormality in KOMNET (CR710 error recognition) (Generator controller system)

No data has been received through KOMNET (CAN) communicat for 3 seconds. (Generator controller can not communicate with engine controller.)

Action of controller Problem on machine

• Engine stops or does not start.

• Method of reproducing failure code: Turn starting switch to ON position. • Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. • Since each controller is connected to battery directly, power is supplied even while starting switch is at OFF position. Related infor- • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using mation multimeter. • Since failure code is displayed, power is supplied to generator controller, thus 5A and 30 A fuse is not broken. • There are 2 CAN terminal resistors; One on engine side and the other on controller side. Although these do not have respective connector labels, they will be called CAN1 and CAN2 in troubleshooting. Cause

Improper power supply to engine controller

Possible causes and standard value 2 Defective relay RyA in normal state

Standard value in normal state/Remarks on troubleshooting a Check ground terminal T12 for looseness and rust. 1. Turn starting switch to OFF position. 2. Disconnect connector J3, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between J3 (female) (3) and (1) Voltage 20 – 30 V Between J3 (female) (4) and (2) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Replace relay RyA. 3. Turn starting switch to ON position. a If this failure code is not displayed, original relay RyA is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors CAN1 and CAN2, and connect Tadapter to each male side.

Defective CAN terminating resistor 3 (open or short circuit in inter- Between CAN1 (male) (A) and (B) nal wiring) Between CAN2 (male) (A) and (B)

Resistance

120 ± 12 z

Resistance

120 ± 12 z

107E-1 Series

40 Troubleshooting

SEN00255-04

Cause

Standard value in normal state/Remarks on troubleshooting q

CAN communication line a CAN terminating resistor of 120 z is also installed inside machine monitor. Since 120 z resistors are connected in parallel, if combined resistance measured at connector of controller is 60 z, CAN communication line has no open circuit. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect connectors J2 or CN2 one by one, and connect Tadapter to female side of connector disconnected. a If short circuit occurs (if resistance between terminals is 1 z or Open or short circuit in wiring 4 less), disconnect all of connectors J2 and CN2. Then, check harness whether failure is short circuit between wiring harnesses or within controller. Approx. Between J2 (female) (46) and (47) Resistance 60 z Approx. Between CN2 (female) (32) and (22) Resistance 60 z Approx. Between CAN1 (female) (A) and (B) Resistance 120 z Approx. Between CAN2 (female) (A) and (B) Resistance 120 z a If no failure is found by checks on cause 4 , this check is not required. 1. Turn starting switch to OFF position and disconnect battery ground cable. Possible 2. Disconnect connectors CN2, J2, CAN1 and CAN2 one by one, causes and and connect T-adapter to each female side. standard value Between CN2 (female)( 32) and J2 Resistance Max. 1 z in normal state (female) (46) Between CN2 (female) (22) and J2 Resistance Max. 1 z (female) (47) Between CN2 (female) (32) and CAN2 Resistance Max. 1 z (female) (A) Between CN2 (female) (22) and CAN2 Resistance Max. 1 z (female) (B) Between J2 (female) (46) and CAN1 Resistance Max. 1 z Open circuit in wiring harness (female) (A) 5 (wire breakage or defective Between J2 (female) (47) and CAN1 Resistance Max. 1 z (female) (B) contact of connector) q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Insert T-adapters into connector J2. 3. Connect battery ground cable and turn starting switch to ON position. Between J2 (39) and ground Voltage 20 â&#x20AC;&#x201C; 30 V a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect connector J2 and connect T-adapter to female side. Between starting switch (ACC) and Resistance Max. 1 z relay RyA input Between relay RyA output and J2 Resistance Max. 1 z (female) (39)

107E-1 Series

SEN00255-04

40 Troubleshooting

Cause

Ground fault in wiring har6 ness (contact with ground circuit)

Possible causes and Short circuit or hot short cirstandard value in normal state 7 cuit in wiring harness (contact with 24 V circuit)

Standard value in normal state/Remarks on troubleshooting a If no failure is found by checks on cause 4 (no open circuit), measure resistance at one connector. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect connectors CN2 and J2 and connect T-adapter to female side of connector disconnected. Between CN2 (female) (32) or J2 Resistance Min. 1 Mz (female) (46) and ground Between CN2 (22) or J2 (47) and Resistance Min. 1 Mz ground a If no failure is found by checks on cause 4 (no open circuit), measure voltage at one connnector. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Insert T-adapter into connector J2 or CN2. 3. Connect battery ground cable. 4. Turn starting switch to ON position. a CAN_H and CAN_L lines are considered to be normal if their voltage are between 1 to 4 V. Since their normal voltage is 2.5 ± 1 V. Between CN2 (32) or J2 (46) and Voltage 1–4V ground Between CN2 (22) or J2 (47) and ground

8 Defective engine controller

Defective generator controller

Voltage

1–4V

If no failure is found by above checks , engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) If no failure is found by above checks, generator controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to CAN communication line

107E-1 Series

SEN00255-04

40 Troubleshooting

E-62 Code [b6] Droop Rate Adjustment Volume High Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble Action of controller Problem on machine Related information

Trouble

Droop Rate Adjustment Volume High Error (Generator controller system)

• Voltage from the droop rate adjustment volume is kept above 4.7 V for 1 second. • Fixes the median of adjustable range. •

The droop rate changes.

• Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal. Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Between CN1 (female) (8) and (22)

Defective generator controller

Resistance

Min. 450 z

Resistance

Min. 450 z

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the droop rate adjustment volume between Min. and Max.

Between CN1 (8) and (21) 4

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the droop rate adjustment volume between Min. and Max.

Defective droop rate adjust- 3. ment volume or open circuit 2 or short circuit in wiring harness Between CN1 (female) (8) and (21)

1. 2. Hot short circuit in wiring har- 3. 3 4. ness

Voltage

0.5 - 4.5 V

If cause is not found by above checks, generator controller is defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to droop rate adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-63 Code [b7] Droop Rate Adjustment Volume Low Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Droop Rate Adjustment Volume Low Error (Generator controller system)

• Voltage from the droop rate adjustment volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The droop rate changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Defective droop rate adjustment volume or open circuit 2 or short circuit in wiring harness

Voltage

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the droop rate adjustment volume between Min. and Max.

Between CN1 (female) (8) and (21)

Resistance

Min. 450 z

Between CN1 (female) (8) and (22)

Resistance

Min. 450 z

1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connector CN1 and connect T-adapter to female 3 ness side. (Contact with ground circuit) Between CN1 (female) (8) and ground Voltage 0.5 - 4.5 V

Defective generator controller

If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN1. 3. Turn starting switch to ON position. 4. Turn the droop rate adjustment volume between Min. and Max. Between CN1 (8) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to droop rate adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-64 Code [b8] Low Idle Speed Adjustment Volume High Error a

1 1

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Low Idle Speed Adjustment Volume high Error (Generator controller system)

• Voltage from the low idle speed adjustment volume is kept below 4.7 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The low idle speed changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Between CN1 (female) (19) and (22)

Hot short circuit in wiring 3 harness

Resistance

Min. 450 z

Resistance

Min. 450 z

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the low idle speed adjustment volume between Min. and Max.

Between CN1 (19) and (21) 4

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the low idle speed adjustment volume between Min. and Max.

Defective low idle speed 3. adjustment volume or open 2 circuit or short circuit in wiring harness Between CN1 (female) (19) and (21)

1. 2. 3. 4.

Voltage

0.5 - 4.5 V

Defective generator control- If cause is not found by above checks, generator controller is ler defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to low idle speed adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Low Idle Speed Adjustment Volume Low Error (Generator controller system)

• Voltage from the low idle speed adjustment volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The low idle speed changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Defective low idle speed adjustment volume or open 2 circuit or short circuit in wiring harness

Voltage

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the low idle speed adjustment volume between Min. and Max.

Between CN1 (female) (19) and (21)

Resistance

Min. 450 z

Between CN1 (female) (19) and (22)

Resistance

Min. 450 z

Defective generator controller

If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN1. 3. Turn starting switch to ON position. 4. Turn the low idle speed adjustment volume between Min. and Max. Between CN1 (19) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to low idle speed adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-66 Code [bc] Rated Speed Median Adjustment Volume High Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Rated Speed Median Adjustment Volume High Error (Generator controller system)

• Voltage from the rated speed median adjustment volume is kept above 4.7 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The target rated speed changes after the engine is started.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Defective rated speed median adjustment volume 2 or open circuit or short circuit in wiring harness

Hot short circuit in wiring 3 harness

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed median adjustment volume between Min. and Max.

Between CN1 (female) (1) and (21)

Resistance

Min. 450 z

Between CN1 (female) (1) and (22)

Resistance

Min. 450 z

1. 2. 3. 4.

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the rated speed median adjustment volume between Min. and Max.

Between CN1 (1) and (21) 4

Voltage

0.5 - 4.5 V

Defective generator control- If cause is not found by above checks, generator controller is ler defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rate speed median adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Rated Speed Median Adjustment Volume Low Error (Generator controller system)

• Voltage from the rated speed median adjustment volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The target rated speed changes after the engine is started.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Voltage

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the rated speed median adjustment volume between Min. and Max.

Defective rated speed 3. median adjustment volume 2 or open circuit or short circuit in wiring harness Between CN1 (female) (1) and (21)

Between CN1 (female) (1) and (22)

Resistance

Min. 450 z

Resistance

Min. 450 z

Defective generator controller

If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN1. 3. Turn starting switch to ON position. 4. Turn the rated speed median adjustment volume between Min. and Max. Between CN1 (1) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to rated speed median adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-68 Code [bE] Ramp Time Adjustment Volume High Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble Action of controller Problem on machine Related information

Trouble

Ramp Time Adjustment Volume High Error (Generator controller system)

• Voltage from the ramp time adjustment volume is kept above 4.7 V for 1 second. •

Fixes the median of adjustable range.

• The ramp time changes. Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

•

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2. Possible causes and standard value in normal state

Between CN1 (female) (2) and (22)

Hot short circuit in wiring 3 harness

Resistance

Min. 450 z

Resistance

Min. 450 z

Turn starting switch to OFF position. Insert T-adapter into connector CN1. Turn starting switch to ON position. Turn the ramp time adjustment volume between Min. and Max.

Between CN1 (2) and (21) 4

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the ramp time adjustment volume between Min. and Max.

Defective ramp time adjust- 3. ment volume or open circuit 2 or short circuit in wiring harness Between CN1 (female) (2) and (21)

1. 2. 3. 4.

Voltage

0.5 - 4.5 V

Defective generator control- If cause is not found by above checks, generator controller is ler defective.

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to ramp time adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

E-69 Code [bF] Ramp Time Adjustment Volume Low Error a

Exclusive for generator Failure rank

Failure code

Mild

Contents of trouble

Trouble

Ramp Time Adjustment Volume Low Error (Generator controller system)

• Voltage from the ramp time adjustment volume is kept below 0.3 V for 1 second.

Action of controller

•

Fixes the median of adjustable range.

Problem on machine

•

The ramp time changes.

•

Since there is 510 z on each side of the 5 kz variable resistor, voltage from the adjustment volume is 0.5 - 4.5 V if system is normal.

Related information

Causes

Standard value in normal state/Remarks on troubleshooting 1. 2.

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to male side. Turn starting switch to ON position.

Defective 5 V power supply 1 for adjustment volume (gen- 3. erator controller) Between CN1 (male) (22) and (21) 1. 2.

Possible causes and standard value in normal state

Voltage

Approx. 5V

Turn starting switch to OFF position. Disconnect connector CN1 and connect T-adapter to female side. Turn the ramp time adjustment volume between Min. and Max.

Defective ramp time adjust- 3. ment volume or open circuit 2 or short circuit in wiring harness Between CN1 (female) (2) and (21)

Between CN1 (female) (2) and (22)

Resistance

Min. 450 z

Resistance

Min. 450 z

Defective generator controller

If cause is not found by above checks, generator controller is defective. - Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN1. 3. Turn starting switch to ON position. 4. Turn the ramp time adjustment volume between Min. and Max. Between CN1 (2) and (21)

Voltage

0.5 - 4.5 V

107E-1 Series

40 Troubleshooting

SEN00255-04

Circuit diagram related to ramp time adjustment volume

107E-1 Series

SEN00255-04

40 Troubleshooting

KOMATSU 107E-1 Series Diesel engine Form No. SEN00255-04

SEN00253-02

Engine 1SHOP MANUAL

107E-1 Series

40 Troubleshooting

Troubleshooting of mechanical system (S-mode) Troubleshooting of mechanical system (S-mode)........................................................................................... 4 Method of using troubleshooting charts ............................................................................................... 4 S-1 Starting performance is poor ......................................................................................................... 8 S-2 Engine does not start..................................................................................................................... 9 S-3 Engine does not pick up smoothly............................................................................................... 12 S-4 Engine stops during operations ................................................................................................... 13 S-5 Engine does not rotate smoothly ................................................................................................. 14 S-6 Engine lacks output (or lacks power)........................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 17 S-9 Oil becomes contaminated quickly .............................................................................................. 18 S-10 Fuel consumption is excessive.................................................................................................. 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 20 S-12 Oil pressure drops ..................................................................................................................... 21

107E-1 Series

SEN00253-02

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 22 S-14 Coolant temperature becomes too high (overheating) .............................................................. 23 S-15 Abnormal noise is made ............................................................................................................ 24 S-16 Vibration is excessive ................................................................................................................ 25

107E-1 Series

40 Troubleshooting

107E-1 Series

SEN00253-02

40 Troubleshooting

Troubleshooting of mechanical system (S-mode)

Method of using troubleshooting charts

The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Items to be simply checked by the serviceman to narrow down causes. They correspond to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections.

107E-1 Series

40 Troubleshooting

SEN00253-02

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E : Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the â&#x20AC;&#x153;causesâ&#x20AC;&#x153;, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

107E-1 Series

SEN00253-02

40 Troubleshooting

<Example of troubleshooting> Exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

107E-1 Series

40 Troubleshooting

SEN00253-02

If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

107E-1 Series

SEN00253-02

40 Troubleshooting

S-1 Starting performance is poor

General causes why starting performance is poor Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck, seized supply pump plunger

Clogged fuel filter, element

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Clogged air cleaner element

Defective contact of valve and valve seat

Causes

Confirm recent repair history Degree of use of machine Operated for long period

Q w w

E w

Engine starts easily when warm

Q Q Q

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w Q Q w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w w w

During operation, charge level monitor indicates abnormal charge (if monitor is installed) w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q w

Starting motor cranks engine slowly

Check items

While engine is cranked with starting motor,

If air bleeding plug of fuel filter is removed, fuel does not flow out

w w

Much fuel returns from the injector

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q Q

Engine does not pick up smoothly and combustion is irregular

w Q w Q

There is hunting from engine (rotation is irregular) w

Blow-by gas is excessive q

Inspect air cleaner directly

q q

When compression pressure is measured, it is found to be low

Troubleshooting

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q

When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle?

Yes

q Replace

Replace

Correct

Clean

Replace

Clean

Remedy

Replace

When specific gravity of electrolyte and voltage of battery are measured, they are low

Replace

Questions

Starting performance

Became worse gradually

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

107E-1 Series

40 Troubleshooting

SEN00253-02

S-2 Engine does not start

Degree of use of machine

Operated for long period

Condition of horn when starting switch is turned ON

Horn does not sound

Defective steering circuit wiring

Defective starting motor (motor section)

Defective safety relay

Defective starting switch

E E Q

When starting switch is turned to START, starting pinion does not move out

Speed of rotation is low w

Makes grating noise

w w

Soon disengages again Q

Makes rattling noise and does not turn

Q Q

There is not voltage (20 – 30 V) between battery relay terminal B and terminal E

When terminal B and terminal C of starting switch are connected, engine starts

When terminal B and terminal C at safety relay outlet are connected, engine starts

Replace

Remedy

Replace

q Replace

When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace

Replace

Even if terminal B and terminal C at safety relay outlet are connected, engine does not start

—

When specific gravity of electrolyte and voltage of battery are measured, they are low

Carry out troubleshooting on applicable machine

Inspect flywheel ring gear directly

107E-1 Series

w Q

Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

When starting switch is turned ON, there is no operating sound from battery relay

When starting switch is turned to START, starting pinion moves out, but

Horn volume is low

Battery terminal is loose

Check items

Defective battery relay

Confirm recent repair history

Battery electrolyte is low

Troubleshooting

Defective connection of battery terminal

Defective or deteriorated battery

Broken flywheel ring gear

Causes

Correct

Questions

a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See “S-4 Engine stops during operations” q Defective electrical system q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

Defective fuel injector

Defective common rail pressure limiter

Defective operation of overflow valve (Does not close)

Defective supply pump MPROP

Stuck, seized supply pump plunger

Broken supply pump shaft

Seized, abnormally worn feed pump

Clogged fuel filter element

Leaking or clogged fuel piping, entry of air

Causes

Clogged air breather hole of fuel tank cap

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Insufficient fuel in tank

40 Troubleshooting

Use of improper fuel

SEN00253-02

E E

Operated for long period

w Q w w

Exhaust smoke suddenly stopped coming out (when starting again) Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

Q w

Rust and water are found when fuel tank is drained w

Check items

When fuel filter is removed, there is not fuel in it

Q E

E E

Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q

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

w Q

w w w

When air is bled from fuel system, air comes out

Inspect fuel filter directly Troubleshooting

Fuel other than specified one is used

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in Emode

q q

Carry out troubleshooting according to “Abnormality in supply pump PCV (*2)” in Emode

q q

Inspect pressure relief valve directly

q Replace

Replace

Correct

Clean

Add

Remedy

Replace

Fuel flows out when pressure limiter return piping is disconnected

Replace

Degree of use of machine

Replace

Questions

Confirm recent repair history

*1: Code [559/CA559] and code [2249/CA2249] in E mode *2: Code [271/CA271] and code [272/CA272] in E mode

107E-1 Series

40 Troubleshooting

SEN00253-02

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor, wiring harness

Defective, deteriorated battery

Clogged injector, defective spray

Stuck, seized supply pump plunger

Clogging of fuel filter

Leaking or clogged fuel system, entry of air

Clogged air breather hole of fuel tank cap

Use of improper fuel

Worn piston ring, cylinder

Worn dynamic valve system (Valve, rocker lever, etc.)

Clogged air cleaner element

Causes

Confirm recent repair history E

Operated for long period

Suddenly failed to start

E w

Q Q

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q w

Check items

Starting motor cranks engine slowly w

When engine is cranked, abnormal sound is generated around cylinder head If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

w q

Inspect air cleaner directly

Inspect dynamic valve system directly Troubleshooting

When compression pressure is measured, it is found to be low

When air is bled from fuel system, air comes out

Inspect fuel filter directly

Carry out troubleshooting according to â&#x20AC;&#x153;No-pressure feed by supply pump (*1)â&#x20AC;? in E-mode

When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed)

q q Replace

Replace

Correct

Clean

Replace

Clean

Remedy

Replace

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

107E-1 Series

SEN00253-02

40 Troubleshooting

S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged injector, defective spray

Stuck, seized supply pump plunger

Clogging of fuel filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Improper valve clearance

Defective contact of valve and valve seat

Clogged air cleaner element

Seized turbocharger, interference of turbocharger

Causes

Confirm recent repair history E E

Operated for long period

E w

Engine pick-up suddenly became worse

E Q Q

Q w w w

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w

Oil must be added more frequently w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

Q w w

Blue under light load w Q

Black

w w

When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied

There is hunting from engine (rotation is irregular)

Blow-by gas is excessive q

Inspect air cleaner directly

When compression pressure is measured, it is found to be low Troubleshooting

When engine is cranked, abnormal sound is generated around cylinder head

q q

Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Carry out troubleshooting according to â&#x20AC;&#x153;No-pressure feed by supply pump (*1)â&#x20AC;? in E-mode

q Replace

Replace

Correct

Clean

Replace

Adjust

Clean

Remedy

Replace

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

Replace

Questions

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

107E-1 Series

40 Troubleshooting

SEN00253-02

S-4 Engine stops during operations General causes why engine stops during operations q Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side

Defective starting switch wiring

Defective hydraulic pump

Defective engine controller power supply wiring

Broken auxiliary equipment (pump, compressor, etc.)

Stuck, seized supply pump plunger

Broken supply pump shaft

Q w Q w

Broken, seized feed pump

Clogging feed pump gauze filter

Clogging of fuel filter, strainer

Leaking, clogged fuel piping

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Broken, seized gear train

Broken, seized crankshaft bearing

Broken, seized piston, connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes

Confirm recent repair history E E

Operated for long period

Condition when engine stopped

w w w w w Q

Engine overheated and stopped

Engine stopped slowly

Q Q

There was hunting and engine stopped

w Q

Q Q Q Q Q Q

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w w

When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping

w w

Rust and water are found when fuel tank is drained Check items

Q Q

Non-specified fuel is being used

Fuel level monitor indicates low level

Metal particles are found when oil pan is drained

w w

Does not turn at all

w w

When engine is cranked by Turns in opposite direction hand Moves by amount of gear backlash

Q Q

w w

Supply pump shaft does not turn

Engine turns, but stops when load is applied to machine q

Inspect dynamic valve system directly

Inspect piston, connecting rod directly

Inspect crankshaft bearing directly

Inspect gear train directly Troubleshooting

Q Q

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode

q q

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

Check controller power supply wiring

q q Correct

—

Replace

Clean

Correct

Clean

Add

Replace

Remedy

Replace

Check starting switch wiring

Correct

Questions

Abnormal noise was heard and engine stopped suddenly

Carry out troubleshooting on applicable machine

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

107E-1 Series

SEN00253-02

40 Troubleshooting

S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Defective G speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Clogging of fuel filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Clogged injector, defective spray (dirt in injector)

Causes

Confirm recent repair history E

Operated for long period

Q Q

Occurs at a certain speed range Q

Occurs even when speed is raised

Q Q

Occurs on slopes

Replacement of filters has not been carried out according to Operation and Maintenance Manual w

When fuel tank is inspected, it is found to be empty Check items

Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q

Troubleshooting

Air breather hole of fuel tank cap is clogged

When air is bled from fuel system, air comes out

Rust and water are found when fuel tank is drained

Inspect fuel filter, strainer directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in E-mode

q Replace

Replace

Add

Remedy

Clean

Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in E-mode

Replace

Hunting

Q Q Q Q Q

Occurs at low idle

Replace

Questions

Degree of use of machine

*1: Code [689/CA689] in E-mode *2: Code [778/CA778] in E-mode

107E-1 Series

40 Troubleshooting

SEN00253-02

S-6 Engine lacks output (or lacks power) General causes why engine lacks output Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged fuel spill piping

Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor (air leakage)

Defective drive of injector (signal, solenoid)

Clogged injector, defective spray (dirt in injector)

Stuck, seized supply pump plunger

Clogging of fuel filter

Leaking, clogged fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Improper valve clearance

Defective contact of valve and valve seat

Air leakage from air intake piping

Clogged air cleaner element

Seized turbocharger, interference of turbocharger

Causes

Confirm recent repair history E

Q w Q

Gradually

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w Q

w w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

w w

Fuel is leaking from fuel piping w

Output becomes insufficient after short stop of operation

Black

w w

Blue under light load

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items

Q Q

w Q

Oil must be added more frequently

w w w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

High idle speed is too high Q

High idle speed under no load is normal, but speed suddenly drops when load is applied w w

Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular)

Blow-by gas is excessive

w Q Q

Q Q

Q Q Q

Q Q

Inspect air cleaner directly

Inspect air intake piping directly

q q q

When boost pressure is measured, it is found to be low

When compression pressure is measured, it is found to be low

q q

Inspect valve clearance directly Troubleshooting

Q Q

Q Q Q

Non-specified fuel is being used

Color of exhaust gas is

Inspect fuel piping

Inspect fuel filter, strainer directly

Inspect spill port check valve directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in Emode

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Inspect boost pressure sensor mount directly Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)” in E-mode

Correct

Replace

Correct

Clean

Replace

Adjust

Replace

Clean

Correct

Remedy

q Replace

Power was lost

Operated for long period Suddenly

Replace

Questions

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [122/CA122] and code [123/CA123] in E-mode

107E-1 Series

SEN00253-02

40 Troubleshooting

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Abnormally worn injector

Clogged, seized injector

Stuck, seized supply pump plunger

Worn piston ring, cylinder

Crushed, clogged muffler

Improper valve clearance

Defective contact of valve and valve seat

Seized turbocharger, interference of turbocharger

Clogged air cleaner element

Leakage of air between turbocharger and cylinder head

Causes

Confirm recent repair history E

Operated for long period

Questions

Color of exhaust gas is

Suddenly became black

Gradually became black

Q w

Blue under light load

Q Q

Non-specified fuel is being used w

Oil must be added more frequently Power was lost

E Q Q Q

Suddenly Gradually

Dust indicator is red (if indicator is installed)

Q Q

Q Q Q

Muffler is crushed w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Q w w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal

Engine does not pick up smoothly and combustion is irregular

Q Q Q

Q Q w w

Blow-by gas is excessive

Much fuel returns from the injector q

Inspect air cleaner directly

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

Troubleshooting

When compression pressure is measured, it is found to be low

q q

Inspect valve clearance directly

When muffler is removed, exhaust sound improves

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode

q q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in Emode

Replace

Correct

Replace

Adjust

Correct

Clean

Replace

Remedy

Replace

q q

Confirm with INSITE or with monitoring function on applicable machine side

Replace

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [144/CA144] and code [145/CA145] in E-mode

107E-1 Series

40 Troubleshooting

SEN00253-02

S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system

1 Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn, damaged rear oil seal

Worn piston ring, cylinder

Broken piston ring

Clogged breather, breather hose

Turbocharger Worn seal at blower end

Worn seal at turbine end

Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

E E E

Operated for long period

E w

Oil consumption suddenly increased

Oil must be added more frequently

Oil becomes contaminated quickly

Q Q w

Q w w w w w

Outside of engine is dirty with oil w

There are loose piping clamps in intake system

Inside of turbocharger intake outlet pipe is dirty with oil Q w

There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w w

Exhaust smoke is blue under light load

w w w

None q

When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting

q q

Excessive play of turbocharger shaft

Check breather and breather hose directly

q q

When compression pressure is measured, it is found to be low

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q q

107E-1 Series

Replace

Correct

Replace

Clean

Replace

Correct

Remedy

Correct

There is external leakage of oil from engine

Correct

Amount of blow-by gas

Excessive

Correct

Check items

Inside of turbocharger exhaust outlet pipe is dirty with oil

Correct

Degree of use of machine

Correct

Questions

Confirm recent repair history

SEN00253-02

40 Troubleshooting

S-9 Oil becomes contaminated quickly

Exhaust smoke is bad

Oil must be added more frequently Metal particles are found when oil filter is drained

Q Q

Inside of exhaust pipe is dirty with oil

w w

Color of exhaust gas is Amount of blow-by gas

Blue under light load

Black Q Q w

Excessive

Q w

None q

Excessive play of turbocharger shaft

q q

When compression pressure is measured, it is found to be low

Check breather and breather hose directly

Inspect oil cooler directly

Inspect oil filter directly

Spring of oil filter safety valve is hitched or broken

q Replace

Replace

Clean

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

E E E

Operated for long period

Non-specified fuel is being used

See S-7

Degree of use of machine

â&#x20AC;&#x201D;

Check items

Clogged oil filter

Confirm recent repair history

Engine oil temperature rises quickly

Troubleshooting

Clogged oil cooler

Clogged breather, breather hose

Worn piston ring, cylinder

Worn valve, valve guide

Defective seal at turbocharger turbine end

Causes

Clean

Questions

General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

107E-1 Series

40 Troubleshooting

SEN00253-02

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective fuel supply pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Defective coolant temperature sensor, wiring harness

Causes

E E

Operated for long period

Condition of fuel consumption

E Q

More than for other machines of same model Q

Gradually increased

Q Q

Suddenly increased

There is external leakage of fuel from engine

Combustion is irregular w

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Low idle speed is high

Torque converter stall speed or pump relief speed is high

Color of exhaust gas is

Q Q

Black

Q Q

White

Remove head cover and inspect directly

Inspect fuel supply pump oil seal directly

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

Much fuel returns from the injector

Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in E-mode Replace

Replace

Correct

Remedy

q Replace

Confirm with INSITE or with monitoring function on applicable machine side

Correct

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q

Replace

Degree of use of machine

Replace

Questions

Confirm recent repair history

*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [144/CA144] and code [145/CA145] in E-mode

107E-1 Series

SEN00253-02

40 Troubleshooting

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler on applicable machine side

Broken oil cooler core, O-ring

Holes caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Degree of use of machine Oil level

E E

Operated for long period Q

Suddenly rose

Q Q Q Q Q w

There are excessive air bubbles in radiator, coolant spurts back Hydraulic oil or power train oil on applicable machine side is milky

When hydraulic oil or power train oil is drained, water is found

q q

Carry out troubleshooting on applicable machine q Replace

Inspect cylinder block directly

Replace

Pressure-tightness test of cylinder head shows there is leakage Pressure-tightness test of oil cooler shows there is leakage Remedy

Replace

Troubleshooting

Check items

Oil level has risen and oil is milky

Q Q

Gradually rose

Hard water is being used as coolant

Replace

Questions

Confirm recent repair history

â&#x20AC;&#x201D;

107E-1 Series

40 Troubleshooting

SEN00253-02

S-12 Oil pressure drops

General causes why oil pressure drops q Leakage, clogging, wear or lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating

Defective oil level sensor, wiring harness

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective regulator valve

Defective oil pump

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Coolant, fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes

Degree of use of machine

Operated for long period

E Q w

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q

Non-specified oil is being used

Replacement of filters has not been carried out according to Operation and Maintenance Manual w

Indicates pressure drop at low idle Oil pressure monitor (if installed)

Indicates pressure drop at low, high idle

Indicates pressure drop on slopes

w w w Q w

Oil level monitor indicates oil level drop (if monitor is installed)

Oil level in oil pan is low

Q w w

External hydraulic piping is leaking, crushed w

Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

Metal particles are found when oil filter is drained

Metal particles are found in oil filter

Inspect oil pan strainer, pipe directly

See S-13

Troubleshooting

Check items

Sometimes indicates pressure drop

Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly

q q q q q q

107E-1 Series

Correct

Replace

Adjust

Replace

Clean

â&#x20AC;&#x201D;

Add

Remedy

Replace

If oil level sensor is replaced, oil level monitor indicates normally

Replace

Questions

Confirm recent repair history

SEN00253-02

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for â&#x20AC;&#x153;S-11 Oil is in coolantâ&#x20AC;?

Degree of use of machine

Check items

E E

Coolant must be added more frequently

There is oil in coolant

Q Q Q Q

Q w

Oil is milky

When engine is started, drops of water come from muffler

w Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back

Q Q

Exhaust smoke is white

Oil level in clutch chamber or damper chamber is low

Oil level in hydraulic tank of machine is low q

When compression pressure is measured, it is found to be low

Remove injector and inspect O-ring.

q q

Inspect cylinder block directly

Inspect rear oil seal directly

Pressure-tightness test of oil cooler shows there is leakage

Remove and inspect supply pump directly

q Replace

Replace

Correct

Replace

Remedy

Replace

Inspect seal of auxiliary equipment directly

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Broken oil cooler core, O-ring

Worn, damaged rear oil seal

Holes caused by pitting

Cracks inside cylinder block

Operated for long period

Fuel must be added more frequently

Oil smells of diesel fuel

Troubleshooting

Broken injector, O-ring

Confirm recent repair history

Replace

Questions

Broken cylinder head, head gasket

Causes

107E-1 Series

40 Troubleshooting

SEN00253-02

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Rise in oil temperature in power train o Carry out troubleshooting on applicable machine

1 Rise in power train oil temperature on applicable machine side

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken fan pulley bearing

Lack of coolant

Clogged, broken oil cooler

Holes caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Degree of use of machine Condition overheating Coolant temperature gauge (if installed)

Operated for long period

E E Q w

Sudden overheated Always tends to overheat

Rises quickly

Q Q w w

w w

Does not go down from red range

Radiator coolant level monitor indicates drop of coolant level (if monitor is installed)

Engine oil level has risen, oil is milky

w w Q

Fan belt tension is low w

When fan pulley is turned, it has play Q Q w

Milky oil is floating on coolant w

Check items

There are excessive air bubbles in radiator, coolant spurts back When light bulb is held behind radiator core, no light passes through

Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud

Coolant is leaking because of cracks in hose or loose clamps

Coolant flows out from radiator overflow hose

Fan belt whines under sudden acceleration Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)

When compression pressure is measured, it is found to be low

Inspect oil cooler directly

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

q q

Temperature difference between upper and lower tanks of radiator is slight

Inspect radiator core directly

When operation of radiator cap is carried out, its cracking pressure is low

Inspect fan belt, pulley directly

107E-1 Series

Correct

Replace

Correct

Replace

Add

Replace

Remedy

Replace

When coolant temperature is measured, it is found to be normal

Replace

Troubleshooting

Carry out troubleshooting on applicable machine

q q

Inspect cylinder block directly

â&#x20AC;&#x201D;

Questions

Confirm recent repair history

SEN00253-02

40 Troubleshooting

S-15 Abnormal noise is made

General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan belt

Removed, seized bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder

Improper valve clearance

Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of machine Condition of abnormal noise

Operated for long period

Gradually occurred

Q Q

Non-specified fuel is being used Oil must be added more frequently

Metal particles are found when oil filter is drained

Air leaks between turbocharger and cylinder head

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

w w

When engine is cranked, beat noise is generated around muffler Check items

Q Q

Suddenly occurred

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

w Q w

Blue under light load Q w

Black

Q w

Engine does not pick up smoothly and combustion is irregular Q

Abnormal noise is loud when engine is accelerated

Q Q

When turbocharger is rotated by hand, it is found to be heavy

Inspect dynamic valve system directly

When muffler is removed, abnormal noise disappears Troubleshooting

Q w

Blow-by gas is excessive

Inspect valve clearance directly

When compression pressure is measured, it is found to be low

q q

Inspect gear train directly

Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Abnormal noise is heard only when engine is started

Replace

Correct

Replace

Adjust

Replace

Remedy

Replace

Confirm with INSITE or with monitoring function on applicable machine side

Replace

Questions

Confirm recent repair history

107E-1 Series

40 Troubleshooting

SEN00253-02

S-16 Vibration is excessive

General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for â&#x20AC;&#x153;S-15 Abnormal noise is madeâ&#x20AC;&#x153;, too.

Broken output shaft, parts in damper on applicable machine side

Misalignment between engine and devices on applicable machine side

Loose engine mounting bolts, broken cushions

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Worn camshaft bushing

Improper gear train backlash

Worn main bearing, connecting rod bearing

Stuck dynamic valve system (valve, rocker lever)

Causes

Degree of use of machine Condition of vibration

Operated for long period

E Q

Non-specified oil is being used

Metal particles are found when oil filter is drained

Metal particles are found when oil pan is drained

Oil pressure is low at low idle

Gradually increased

Vibration occurs at mid-range speed Q

Vibration follows engine speed Exhaust smoke is black

Inspect dynamic valve system directly

Q Q Q Q

Inspect main bearing and connecting rod bearing directly Troubleshooting

Suddenly increased

Inspect gear train directly

Inspect camshaft bushing directly

Confirm with INSITE or with monitoring function on applicable machine side

Inspect engine mounting bolts and cushions directly

When alignment is checked, radial runout or facial runout is detected

107E-1 Series

Adjust

Replace

Remedy

Replace

Inspect output shaft or inside of damper directly

Replace

Check items

Questions

Confirm recent repair history

SEN00253-02

KOMATSU 107E-1 Series Diesel engine Form No. SEN00253-02

40 Troubleshooting

SEN00257-06

Engine 1SHOP MANUAL

107E-1 Series

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

107E-1 Series

SEN00257-06

50 Disassembly and assembly

How to read this manual 1.

(Rev. 2009.1) 1

Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

* *** ****

Removal q 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. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : Amount of oil or coolant to be drained 4:

Weight of part or component

Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. k

: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools q Various special tools are illustrated for the local manufacture.

107E-1 Series

50 Disassembly and assembly

SEN00257-06

Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

* *** ****

Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k

: Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained

Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k

: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools Various special tools are illustrated for the local manufacture.

107E-1 Series

SEN00257-06

50 Disassembly and assembly

Coating materials list a a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

Adhesive

LT-3

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

790-129-9140

Can

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

50 cc

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.

1 kg

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-5

Gasket sealant

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

LT-4

ThreeBond 1735

790-129-9080

LG-6

790-129-9160

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9170

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

LG-8 ThreeBond 1207B

(Rev. 2009.02) 1

419-15-18131

100 g

107E-1 Series

50 Disassembly and assembly

Gasket sealant

CateKomatsu code gory

Molybdenum disulfide lubricant

Container

Main features and applications

790-129-9310

200 g

Tube

• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

Can

• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc.

—

Can

• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.

—

LC-G NEVER-SEEZ

09940-00040

09995-00250

—

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)

Grease

Q'ty

LG-9 ThreeBond 1206D

LM-P

Seizure prevention compound

Part number

SEN00257-06

Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)

Hyper White Grease G2-T, G0-T (*)

SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*)

107E-1 Series

200 g

190 g

• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg

400 g 16 kg

• Bellows-type container Can •

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.

Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.

SEN00257-06

G2-U-S ENS grease

—

427-12-11871

SUNSTAR PAINT PRIMER 580 SUPER

Caulking material

Adhesive

Primer

SUNSTAR GLASS PRIMER 580 SUPER

SUNSTAR PAINT PRIMER 435-95

Q'ty

Container

Main features and applications

Tube

• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.

2 kg

Can

• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

200 g

417-926-3910

22M-54-27230

Adhesive for cab glass

G2-S ThreeBond 1855

Part number

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Grease

CateKomatsu code gory

50 Disassembly and assembly

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)

107E-1 Series

50 Disassembly and assembly

SEN00257-06

Special tools list

Work item

Symbol

A Disassembly and assembly of engine assembly

Part No.

790-501-2001 795-799-1150

Part name

Repair stand

Adapter

Removal and installation of piston ring

Installation of piston Removal of injector

795-102-2103

Specialized for Komatsu repair stand

Specialized for CUMMINS repair stand

t 1

795-799-7210 Removal and installation of air intake and exhaust valves

Spring pusher

q 1

795-100-2800

Piston ring tool

t 1

795-921-1100

Piston holder

t 1

795-799-6700

Puller

t 1 N

Removal and installation of rear seal

795-799-6500

Seal driver

q 1 N

Removal and installation of front seal

795-799-6400

Seal driver

q 1 N

Angle tightening of bolt

Adjusting valve clearance

795-799-8800

790-331-1120

Wrench (angle)

795-799-2240

Angle gauge

Commercially available

Clearance gauge

q 1

Adjusting gear backlash and end play

Commercially available

Dial gauge and stand

q 1

Removal of fuel inlet connector

795-799-8150

Remover

q 1 N

Removal and installation of main bearing

795-799-2270

Remover and installer q 1

Rotation of crankshaft

795-799-1131

Gear

q 1

Tightening of injector harness nut

795-799-7110

Torque wrench

q 1 N

Measurement of cylinder head bolt length

795-790-4510

Gauge

q 1 N

Removal and installation of fuel supply pump gear

795-799-6130

Support

t 1

107E-1 Series

Remarks

t 1

— B

Sketches

New/Remodel

Q'ty

* *** ****

Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See “Sketches of special tools”). Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are CUMMINS part Nos. Necessity

φ75 – 175 mm

q 1

SEN00257-06

KOMATSU 107E-1 Series Diesel engine Form No. SEN00257-06

SEN00258-07

Engine 1SHOP MANUAL

107E-1 Series

50 Disassembly and assembly Disassembly and assembly, Part 1 General disassembly of engine....................................................................................................................... 2

107E-1 Series

SEN00258-07

General disassembly of engine 1 a

This disassembly manual is a general disassembly manual for the SAA4D107E-1 and SAA6D107E-1 engines. Since the shapes, numbers, locations, etc. of the parts depend on each applicable machine, check them before starting the work. The photos and illustrations show the 6D107E1, unless otherwise specified. Preparation work 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 or remove the openings, electric parts, and wiring connectors so that water will not enter them. 1) Prepare stable 2 engine stands (Blocks [1]) for the right and left and secure the engine assembly on them so that it will not tip over. 2) Remove oil gauge assembly (2).

50 Disassembly and assembly

Installation to engine repair stand 1) Install tool B to engine assembly (1). q Mounting bolt on engine side M12 x 1.75 3 Mounting bolt: 77 Âą 12 Nm {7.9 Âą 1.2 kgm} 2) Sling engine assembly (1) and install it to tool A. 4 Engine assembly: Approx. 430 kg (4D107E-1) (Weight depends on each applicable machine) 4 Engine assembly: Approx. 520 kg (6D107E-1) (Weight depends on each applicable machine) 3) Drain the engine coolant and engine oil. 6 6

Engine oil: Approx. 16 l (4D107E-1) Engine oil: Approx. 23 l (6D107E-1)

<4D107E-1>

<6D107E-1>

107E-1 Series

50 Disassembly and assembly

SEN00258-07

Starting motor assembly Remove mounting bolt (1) and then remove starting motor assembly (2). <4D107E-1>

<Generator> Remove rear engine sling bracket (1) from the flywheel housing (FWH).

5. <6D107E-1>

Engine sling bracket on rear side <All engine except for generator> Remove rear engine sling bracket (1) from the cylinder head.

107E-1 Series

Fan pulley 1) Remove fan belt (1). q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (2), and rotate it to the opposite to the winding-up direction to decrease the fan belt (1) tension, then remove. k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (2) is strong. If the wrench is loosely inserted, the wrench may accidentally come off w h i l e b e i n g r o ta t e d a n d i t i s extremely dangerous.) k After removing the fan belt (1), return the tensioner assembly (2) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (1) during work. 2) Remove bolt (3) and then remove fan pulley (4).

SEN00258-07

Vibration damper and crankshaft pulley q 4D107E-1 (Without damper) Remove bolts (1) and crankshaft pulley (2). <4D107E-1>

6D107E-1 (With damper) Remove bolts (1) and vibration damper (2). <6D107E-1> q

50 Disassembly and assembly

Fan hub Remove 4 bolts (1) and then remove fan hub (2).

Alternator 1) Remove plate (1). 2) Remove bolt (2) and then remove alternator (3).

3) 7.

Belt tensioner Remove bolt (1) and then remove belt tensioner (2).

Remove alternator bracket (4) and front side sling bracket (5).

107E-1 Series

50 Disassembly and assembly

10. Thermostat 1) Remove coolant outlet connector (1). <4D107E-1>

SEN00258-07

11. Water pump 1) Remove coolant inlet connector (1). 2) Remove water pump (2).

<6D107E-1> 12. Turbocharger and exhaust manifold <4D107E-1> 1) Remove turbocharger heat insulation cover (1) and lubricating oil inlet tube (2). a When loosening the flange nut of tube (2), fix the connectors on the turbocharger or oil cooler side with a spanner to prevent them from being dragged. <4D107E-1>

Remove thermostat (2).

107E-1 Series

SEN00258-07 a

In the case of water-cooled turbocharger, remove water-cooled inlet tube (11), outlet tube (12) and (13).

Remove head cover (5) and oil return tube flange bolt (on the head cover side). 3) Remove turbocharger assembly mounting nuts (3) and place turbocharger assembly (4) on the stud bolts. <4D107E-1>

50 Disassembly and assembly

5) Remove exhaust manifold (10). <4D107E-1>

(6D107E-1) 1) Remove turbocharger lubricating oil inlet tube (1) and drain tube (2). <6D107E-1>

Remove turbocharger assembly (3) and exhaust manifold (4). <6D107E-1> 4)

Since there is not sufficient clearance on the exhaust manifold side, move turbocharger assembly (4) to the right and remove the flange bolts (6) of drain tube (7) with hexagonal wrench [1]. <4D107E-1>

107E-1 Series

50 Disassembly and assembly

13. Fuel filter assembly <4D107E-1> Since the fuel prefilter and main filter are installed to the chassis, they do not need to be removed for general disassembly of the engine. <6D107E-1> 1) Disconnect hoses (1) and (2) from the filter. 2) Disconnect drain hose (3) from filter bracket (4). 3) Remove fuel filter assembly (5). q Removal of hose While pressing the adapter (by the right and left sides) at the hose end, pry off the hose end face with a screwdriver. k The internal parts of the adapter may be damaged when the hose is removed. Accordingly, do not reuse the adapter but always use new one when installing the hose again. <6D107E-1>

SEN00258-07

14. Harness assembly < O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 , PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC-8M0> Disconnect the harness from the sensor and controller, and then remove the clamp to remove harness assembly (1).

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0 only> Disconnect three connectors (2) of the injector harness. a To disconnect connector (2), pull it out in the direction of the arrow while pressing claw lock (a).

<6D107E-1>

107E-1 Series

SEN00258-07

15. Fuel high-pressure piping and common rail <4D107E-1> 1) Remove boots (8) of high-pressure pipings (1) to (5) and then remove the highpressure pipings. 2) Remove fuel drain hose (9). 3) Remove common rail (7). <6D107E-1> 1) Remove boots (9) of high-pressure pipings (1) to (7) and then remove the highpressure pipings. 2) Remove fuel drain hose (8). 3) Remove common rail (10). q Removal of hose Remove the hose by prying the hose end face with screwdriver while pushing the mouthpiece (on both sides) of the hose termination. k Do not use the hose again, because inside of the mouthpiece may be damaged when the hose is removed. Always use a new hose when assembling. <4D107E-1>

<6D107E-1>

50 Disassembly and assembly

16. Air intake manifold cover 1) Remove tube (1) and electrical intake air heater (2). 2) Remove manifold covers (3) and (4). <4D107E-1>

<6D107E-1>

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

107E-1 Series

50 Disassembly and assembly

SEN00258-07

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0 only> 1) Remove bolts (2) and then remove head cover (3) together with duct (1). 2) Remove duct (1) from head cover (3).

Remove nuts (4) of the harness from injector. a

Harness installation position Color of cable

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

Note: No.5 and 6 cylinders are equipped with 6D107E-1 only. 4)

Remove bolt (5) and then remove rocker housing assembly (6). a Do not remove the injector harness connector (7) from rocker housing unless it is required.

107E-1 Series

Remove nuts (4) of the harness from injector. a The injector harness and nut have no positional distinction. (Their right and left sides may be reversed) Remove gasket assembly (4a).

SEN00258-07

50 Disassembly and assembly

19. Push rod Remove push rods (1).

18. Rocker arm assembly and crosshead 1) Remove bolts (1) and rocker arm assembly (2). a Loosen the locknut and then loosen the adjustment screw fully so that the tension of the valve spring will not be applied to the rocker arm assembly mounting bolts. 2) Remove crosshead (3).

Record the position of the crosshead and the shapes of holes "a" and "b" (to install the crosshead in the same direction again).

20. Fuel injector assembly 1) Remove retainer (5) and then remove 6 inlet connectors (1). q Use tool M when removing the inlet connector. 2) Remove mounting bolts (3) of injector (2) and then remove holder (4). 3) Remove injector (2).

Lift and remove the injector using tool F. (Don't try to pry the top of the injector.)

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21. Cylinder head assembly Remove bolts (1) and cylinder head assembly (2). 4 4

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Cylinder head assembly: 50 kg (4D107E-1) Cylinder head assembly: 70 kg (6D107E-1)

Disassemble the cylinder head assembly according to the following procedure. 1) Using tool C, compress valve spring (3) to remove valve cotter (4).

22. Oil cooler 1) Remove oil filter (1). (When filter is installed to engine) a The oil filter of 4D107E-1 is installed to the chassis.

2) 2)

Raise the cylinder head assembly, pull and remove valve (6) and then remove valve seal (7). a Apply a marking to valve (6) to make it identifiable to which cylinder head it should be combined.

Remove upper seat (5) and valve spring (3).

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Remove mounting bolts (6), cover (2) and cover gasket (3). Remove oil cooler (4) and cooler gasket (5).

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23. Engine controller 1) Remove engine controller (1). 2) Disconnect ground cable (2).

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24. Fuel supply pump 1) Remove 3 hoses (1). 2) Remove 3 nuts (2) and then remove supply pump (3). <4D107E-1>

Remove cooling plate (3). <6D107E-1>

When disassembling the fuel pump drive gear from the fuel supply pump, follow the procedure described below. 1] Use a support Y and a 1/2 inch breaker bar (10) to retain the gear, then loosen the nut (11). a Do not remove the nut (11) from the shaft.

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Install a puller [1] between the flange and gear (12).

Install a puller [2] onto the puller [1] and the shaft. Rotate the center bolt (13) until the gear is separated from the shaft. Remove the pullers [1], [2].

4] 5]

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25. Flywheel <Generator> 1) Remove lock nut (1). 2) Remove speed sensor (2). 3) Remove boss (3).

Install guide bolt [1] and then remove flywheel (1). 4

Flywheel:

35 kg <6D107E-1> 15 kg <4D107E-1> 110 kg <Generator> Be careful not to injure your finger with the flywheel that can fall off from the shallow spigot joint.

Remove the nut (11), lock washer (15), and gear (16) from the shaft (14).

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26. Rear oil seal 1) Install tool G to the crankshaft. 2) Screw in tapping screw [1] of tool G to the seal carrier section of rear oil seal (1). 3) Turn the handle counterclockwise to remove rear oil seal (1).

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28. Oil pan 1) Remove bolts (1) and then remove oil pan (2).

2) 3)

27. Flywheel housing Remove bolts (1) and then remove flywheel housing (2).

Remove suction tube (3). Remove plate (4) and 3 plates (5). a Plates (5) are not installed in 4D107E-1.

29. Front cover 1) Remove engine Bkup speed sensor (1). 2) Remove bolts (2) and then remove front cover (3). 3) Remove front seal (4).

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30. Oil pump assembly Remove bolts (1) and then remove oil pump assembly (2).

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Remove thrust plate (2).

Rotate camshaft (3) when removing the plate.

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

32. Gear housing Remove bolts (1) and then remove gear housing (2).

Remove gear (1).

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33. Piston and connecting rod assembly 1) Rotate the crankshaft and bring the piston to be removed to the bottom dead center. 2) Scrub the carbon off the top wall of the cylinder liner with fine sandpaper. 3) Apply a marking to each of connecting rod cap (1) assembly position on respective cylinders. a Before removing the piston and connecting rod assembly, measure the side clearance between the connecting rod and crankshaft using tool K.

4) 5)

Remove bolt (2). Hit connecting rod cap (1) with a plastic hammer lightly, and remove connecting rod cap (1) and connecting rod bearing as a unit. Keep the connecting rod and connecting rod cap so that their mating faces will not be damaged. If their mating faces are damaged, replace them.

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Push in and remove the piston and connecting rod assembly with a wood bar, etc. from the oil pan side, while supporting piston (6) on the cylinder head side. a Take care in the removal so that inner surface of the cylinder liner may not be damaged by corners of the connecting rod. a Make a cylinder No. mark on the piston.

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

Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove snap ring (3). 2] Separate piston (6) from connecting rod by pulling out piston pin (5) while supporting connecting rod (4) with hand. 3] Remove the snap ring on the opposite side.

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50 Disassembly and assembly

Using tool D, remove piston ring (7). a Keep the piston, connecting rod, connecting rod bearing, piston rings, and piston pin by cylinder.

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Remove mounting bolts (2) of main cap (1). 2) Insert the bolts in the bolt holes of main cap (1) and remove the cap, while shaking it. a Installation position numbers are marked on the main cap. No. 1 starts from the front side of the cylinder block. <4D107E-1>

34. Crankshaft a Before removing the crankshaft, measure its end play X with dial gauge. <6D107E-1>

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Check that the position No. of the main cap (stamped at part A) is directed toward the oil cooler.

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Remove bottom lower bearing (3) from main cap (1). a Mark the installation position number on claw (A) of the removed bearing. (Don't apply the number on the sliding surface of the bearing.)

Lift off crankshaft (4) using the nylon sling. a When lifting and removing the crankshaft, take care not to damage it by bumping against the cylinder block. a Keep the crankshaft in a safe place so that its sliding portions will not be damaged. 4 4

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Remove upper thrust bearing (5) and upper bearings (6).

Mark the assembly position on the main cap, upper bearing and upper thrust bearing (in the claw of the bearing). It is advised to maintain the bearings of a main cap separately from that for another main cap. And take care not to damage these parts. 35. Piston cooling nozzle Remove bolt (1) and then remove piston cooling nozzles (2).

Crankshaft: 45 kg (4D107E-1) Crankshaft: 60 kg (6D107E-1)

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36. Tappet Remove tappets (1) and then mark the installation position on them. a When reusing the camshafts and tappets, be sure to install them in the original position.

37. Cylinder block Remove cylinder block (1) from tool A. 4 Cylinder block: 100 kg (4D107E-1) 4 Cylinder block: 140 kg (6D107E-1)

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KOMATSU 107E-1 Series Diesel engine Form No. SEN00258-07

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Engine 1SHOP MANUAL

107E-1 Series

50 Disassembly and assembly Disassembly and assembly, Part 2 General assembly of engine ........................................................................................................................... 2

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General assembly of engine a

a a

This document describes the general assembly procedure of SAA4D107E-1 and SAA6D107E-1. The shapes, quantity, locations, etc. of the parts depend on each applicable machine. When reusing a part, be sure to install it to its original position. Unspecified photos and drawings show those of 6D107E-1.

Don't invert the cylinder block by 90° or more. Otherwise, the tappet may fall off from the mounting hole during assembly.

Preparation work 1) Install tool B. 2) Install cylinder block (1) to tool A. 3 Mounting bolt: 77 ± 12 Nm {7.9 ± 1.2 kgm} 4 Cylinder block: 100 kg (4D107E-1) 4 Cylinder block: 140 kg (6D107E-1) 3.

Piston cooling nozzle Set piston cooling nozzles (2) and then tighten them using mounting bolt (1). 3 Mounting bolt: 15 ± 2 Nm {1.5 ± 0.2 kgm}

Crankshaft 1) Install upper bearings (6) and an upper thrust bearing (5). a Set the projection of each bearing to the notch of the cylinder block. a When installing the bearings, check that their back sides are free from foreign matter. a Apply engine oil to inner surface of metal. Don't apply the oil to the backside. 2 Inside of bearing: Engine oil (EO15W-40) a When reusing the bearings, check the marks made on them when removed and install them to their original positions.

Tappet 1) Apply engine oil (EO15W-40) to tappets (1). 2 Tappet: Engine oil (EO15W-40)

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Install tappets (1). a When reusing the camshafts and tappets, be sure to install them in the original position.

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Apply engine oil (EO15W-40) to the journal surfaces of the crankshaft. 5) Before installation, check the No. stamped on main cap (1). q Installation shall start from the front side of the cylinder block in a numerical order. <4D107E-1>

Using a nylon sling, lift up and install crankshaft (4). a When installing, take care not to damage the upper thrust bearing. 4 Crankshaft: 45 kg (4D107E-1) 4 Crankshaft: 60 kg (6D107E-1) <6D107E-1>

Fit lower bearing (3) to the main cap, matching the projection of the former to the notch of the latter. a Make sure ring dowel (7) is installed on the main cap.

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In the installation, make sure the stamped No. (section A) is faced to the oil cooler. Push in each main cap by hitting it lightly with a plastic hammer or rubber hammer.

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50 Disassembly and assembly a

Before tightening the main cap mounting bolt (2), check the following. 1] Using tool X, measure stem length (a) of every bolt and check that it is less than the using limit. q Using limit length of bolt stem: Less than 120.0 mm a If a bolt is longer than the using limit, do not reuse it but replace it.

Tighten the bolts of 6D107E-1 in the order [1] o [14] shown in the figure.

When new bolts are used: 1] 120 ± 5 Nm {12.2 ± 0.5 kgm} 2] Loosen by 360° 3] 60 ± 5 Nm {6.1 ± 0.5 kgm} 4] 85 ± 5 Nm {8.7 ± 0.5 kgm} 5] 120° ± 5° (When angle tightening tool J is used)

Tightening procedure of main cap mounting bolts (2). a Apply engine oil to the bolts. 2 Main cap mounting bolt: Engine oil (EO15W-40) a Tighten the bolts of 4D107E-1 in the order [1] o [10] shown in the figure.

Main cap mounting bolt When current bolts are used again: 1] 60 ± 5 Nm {6.1 ± 0.5 kgm} 2] 80 ± 5 Nm {8.2 ± 0.5 kgm} 3] 90° ± 5° (When angle tightening tool J is used)

When tool J is not used: Mark the main cap and each bolt with paint and then tighten the bolt by 90° ± 5° (when the bolt is reused) or 120° ± 5° (when a new bolt is used).

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50 Disassembly and assembly

8) 9)

After tightening the bolts, make sure that the crankshaft turns smoothly. Measure the end play of the crankshaft with a dial gauge. a End play X: 0.24 Âą 0.175 mm

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Installation of oil ring Set the oil ring (9) so that its abutment joint comes in a position at 180Â° to the end of expander (8).

Fit second ring (10) with the stamp of "TOP" near the abutment joint up. Fit top ring (11) with the "dot" mark near the abutment joint up. When fitting each ring, set the abutment joint off the thrust, anti-thrust, and piston axis directions.

4) 5)

Piston and connecting rod assembly 1) Using tool D, fit piston rings (7) to the piston.

6) 7)

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Apply engine oil (EO15W-40) to piston ring and piston skirt. Set the piston and connecting rod. q When "FRONT" mark of piston (6) head is set at the top, connecting rod (4) must be facing to the direction shown in the figure.

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50 Disassembly and assembly

Install the bearing to the connecting rod and connecting rod cap. q Check that the back side of the bearing is free from foreign matter. q Fit the bearing to the connecting rod and cap, matching the projection of the former to the notch of the connecting rod and cap.

Apply engine oil to the piston pin hole and piston pin. 2 Piston pin and pin hole: Engine oil (EO15W-40)

2] 3]

Insert piston pin (5) and then assemble piston (6) to connecting rod (4). Install snap ring (3) to both sides.

Set the crankshaft to the bottom dead center of the cylinder to install the piston and apply engine oil to the inside of the cylinder. 2 Inside of cylinder: Engine oil (EO15W-40) 10) Insert the piston and connecting rod assembly setting "FRONT" mark of piston (6) to the front side of the cylinder. a Check the directions of the abutment joints of the piston rings again. a When inserting the connecting rod, take care not to damage the wall of the cylinder. a When installing the assembly, take care not to hit the cooling nozzle.

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Using tool E, reduce the piston rings and push in the piston head with a wood bar, etc.

When not using tool J Make marks on the main cap and bolt with paint and then tighten the bolt by 60° ± 5°.

11) Install connecting rod cap (2) by tightening bolt (1) in the following procedure. a Apply engine oil to the threaded portions of the bolts and inside of the connecting rod bearings. 2 Threaded portions of bolts: Engine oil (EO15W-40) 2 Inside of connecting rod bearings: Engine oil (EO15W-40)

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

Tighten the bolts with angle tightening tool J (wrench and angle gauge). 3 Mounting bolts (Tighten both bolts alternately): 1] 30 ± 3 Nm {3.06 ± 0.31 kgm} 2] 60 ± 5 Nm {6.12 ± 0.51 kgm} 3] 60° ± 5° (When angle tightening tool J is used)

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50 Disassembly and assembly

Gear housing 1) Apply gasket sealant to part A of the mounting face of housing (2). 2 Housing: Gasket sealant (LG-7) q Diameter of gasket sealant line shall be 1 – 2 mm. a If too much gasket sealant is applied near blowby oil groove B, the groove may be clogged. Accordingly, keep the gasket sealant line diameter strictly. 2) Make sure that each of the dowel ring of the gear housing is correctly inserted to the dowel hole at both the top and bottom (indicated with ∗ mark). a Otherwise, they can be damaged when bolt-tightened. 3) Press the gear housing against the cylinder block so that its entire mating surface with the cylinder block is closely contacted. a Don't apply torque to the mounting bolts until the entire mating surface is closely contacted.

Camshaft a Rotate the crankshaft to set the No. 1 cylinder to the top dead center. 1) Apply engine oil (EO15W-40) to the camshaft bore, camshaft journal and lobed surface. Then lightly push in and rotate camshaft (3) to install. 2 Sliding surfaces of camshaft: Engine oil (EO15W-40)

Tighten the mounting bolts. Bolts tightening procedure Tighten the bolts according to the numbers [1] o [10] shown in the figure. a 4 types of bolts are used. Make sure when tightening that specified torque is applied. 3 Mounting bolt: 1] M12: 77 ± 7 Nm {7.9 ± 0.7 kgm} (No marking)

M10: 43 ± 5 Nm {4.4 ± 0.5 kgm}

M8: 24 ± 4 Nm {2.5 ± 0.4 kgm}

(Q mark l = 30, T mark l = 50)

(E mark)

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50 Disassembly and assembly

Install thrust plate (2). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

When installing, fit in the thrust plate to timing mark A on camshaft gear (1) as well as to the chamfered tooth (a single location) of crankshaft gear (4). 3 Mounting bolt: 36 ± 4 Nm {3.7 ± 0.4 kgm}

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Flywheel housing 1) Install flywheel housing (2) using bolt (1). a Apply gasket sealant (LG-7) to the flanged housing installation surface as well as ci rc umfer enc e of th e mounting bolt hole. Diameter of gasket sealant line shall be 1 – 3 mm. 2 Flywheel housing: Gasket sealant (LG-7)

Tighten the mounting bolts in the numeric order [1] o [20] shown in the figure. <All engine except for generator> a 2 types of bolts are used. Make sure when tightening that the specified torque is used. 1] M12: 85 ± 10 Nm {8.7 ± 1.0 kgm} (E mark) 2] M10: 49 ± 5 Nm {5.0 ± 0.5 kgm} (T mark)

Measure the end play and backlash of the camshaft with a dial gauge. a End play: 0.10 – 0.36 mm q The end play is determined by thickness of the thrust plate and groove of the camshaft. a Backlash: 0.076 – 0.280 mm

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50 Disassembly and assembly a

<Generator> a 2 types of bolts are used. Make sure when tightening that the specified torque is used. 3] M12: 85 ± 10 Nm {8.7 ± 1.0 kgm} (E mark) 4] M10: 49 ± 5 Nm {5.0 ± 0.5 kgm} (T mark)

Make sure after rotating the crankshaft by a turn that the gauge pointer is returned to the position where it had situated when the crankshaft was started to turn.

Measurement of facial runout 1] Like in measurement of the radial runout, contact the probe of the dial gauge at right angle against the end face of the flywheel housing. a Before conducting the measurement, move the crankshaft either in the front or rear side in order to prevent errors due to the end play. 2] Set graduations of the dial gauge to "0" and then rotate the crankshaft by a turn to measure the difference in the maximum deflections of the gauge pointer.

After installing the flywheel housing, measure the radial runout and facial runout with tool L. a Radial runout: Max. 0.20 mm <All engine except for generator> Max. 0.5 mm <Generator> a Facial runout: Max. 0.20 mm <All engine except for generator> Max. 0.28 mm <Generator> Measurement of radial runout 1] Install tool L to the crankshaft end face. 2] Contact the probe of the dial gauge at right angle against part of the spigot joint of the flywheel housing. 3] Set graduations of the dial gauge to "0" and then rotate the crankshaft by a turn to measure differences in the maximum deflections of the gauge pointer.

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50 Disassembly and assembly

Rear oil seal 1) Insert pilot [2] to rear oil seal (4). a Before inserting the pilot, clean, degrease and dry the oil seal lip surface.

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Using tool G, insert the oil seal until it is flush with the flywheel housing end face.

Insert oil seal (4), together with pilot [2], to the crankshaft and then push in the seal carrier of oil seal (4) to the flywheel housing (1). a Before inserting the oil seal, clean, degrease and dry the surface where the seal is contacted against the crankshaft. Pull out pilot [2] and then further push in oil seal (4).

When pushing in the oil seal, make sure that the seal carrier is free from bending. Installed dimension X = Max. 0.38 mm

10. Flywheel 1) Install guide bolt [1] and flywheel (1). 2 Flywheel mounting bolt: Engine oil (EO30) 4 Flywheel assembly: 35 kg <6D107E-1> 15 kg <4D107E-1> 110 kg <Generator>

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50 Disassembly and assembly

Tighten the mounting bolts in the order indicated in the figure. 3 Mounting bolt: 137 Âą 7 Nm {14.0 Âą 0.7 kgm}

After installing the flywheel, measure the radial runout and facial runout with tool L. a Radial runout: Max. 0.13 mm a Facial runout: Max. 0.20 mm Measurement of radial runout 1] Install tool L to the flywheel housing. 2] Contact the probe of the dial gauge at right angle against section (a) of the spigot joint or periphery of the flywheel housing. 3] Rotate the flywheel by a turn to measure the differences in the maximum deflections of the dial gauge pointer. a Make sure after rotating the flywheel by a turn that the dial gauge pointer is returned to the position where it had situated when the flywheel was started to turn. Measurement of facial runout 1] Like in measurement of the radial runout, contact the probe of the dial gauge at right angle against end face (b) situated near the periphery of the flywheel housing. a Before conducting the measurement, move the crankshaft either in the front or rear side in order to prevent errors due to the end play. 2] Rotate the flywheel by a turn to measure the differences in the maximum deflections of the dial gauge pointer.

<Generator> a Installation procedure for speed sensor 2 Threads of sensor: Adhesive (LT-2) 1) Install boss (3) on the flywheel housing 2) Screw the sensor (2) into the flywheel housing to touch it to the ring gear. 3) Return the sensor by 1/2-2/3 turns. (Clearance between the sensor and ring gear: 0.75-1 mm) 4) Tighten Sensor locknut (1) 3 Sensor locknut (1): 39.2 - 44.1 Nm {4 - 4.5 kgm}

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50 Disassembly and assembly

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11. Oil pump assembly a Fill up the oil pump rotor space and the idler shaft bore with engine oil (EO15W40) and then rotate the rotor by two turns.

Install oil pump assembly (2) with bolts (1).

Tighten the mounting bolts in the order indicated in the figure. 3 Mounting bolt: 1st time: 8 ± 1 Nm {0.8 ± 0.1 kgm} (Fig.a) 2nd time: 24 ± 4 Nm {2.4 ± 0.4 kgm} (Fig.b) Measurement of backlash Stop move of a gear of either side and then measure backlash (C) of the pump and idler gear. a Total amount of backlash (C): 0.2 ± 0.05 mm

107E-1 Series

12. Front cover 1) Apply gasket sealant to installation surface (A) of cover (2). 2 Front cover: Gasket sealant (LG-7) q Diameter of gasket sealant line shall be 1 – 2 mm.

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Tighten the mounting bolts according to the numbers [1] o [13] shown in the figure. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

Using tool H, install front seal (3). a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft.

The deviation of seal (3) from cover (2) must be as follows: q Extrusion (x): Max. 0.38 mm q Facial runout (TIR) (y): Max. 0.25 mm

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4) a

Install engine Bkup speed sensor (1). Adjustment of installing position of the sensor is unnecessary. 3 Mounting bolt: 8 ± 2 Nm {0.82 ± 0.20 kgm}

13. Oil pan 1) Install plate (4) and 3 plates (5). 3 Mounting bolt: 43 ± 5 Nm {4.4 ± 0.5 kgm} q Plate (5) is not installed to 4D107E-1. 2) Install suction tube (3). 3 Flange mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

Remove the gasket sealant projected from between the cylinder block and front cover and between the cylinder block and gear housing (4 places marked with A) with a scraper. a When removing only the oil pan, remove the used gasket sealant filled in the borders (4 places marked with A) with a scraper, too. 4) Apply gasket sealant between the cylinder block and front cover and between the cylinder block and gear housing (4 places marked with A). 2 Oil pan part A: Gasket sealant (LG-7) q Diameter of gasket sealant line: 3 mm 107E-1 Series

50 Disassembly and assembly

Apply gasket sealant to installation surface (A). 2 Oil pan: Gasket sealant (LG-7) q Diameter of gasket sealant line: Straight line: 3 mm, curved line: 1 mm

Install oil pan (2) with bolts (1).

Tighten the mounting bolts according to the numbers shown in the figure. 3 Mounting bolt: 28 ± 2 Nm {2.9 ± 0.2 kgm}

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<4D107E-1>

<6D107E-1>

14. Crankshaft pulley and vibration damper 1) Install crankshaft pulley (4D107E-1) and vibration damper (6D107E-1) by fitting in their knock holes to dowel pin (a) of the crankshaft. 2) Bolt (1) tightening procedure 1] Tighten the bolt's opposing corner sequentially with 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2] Loosen the bolt by 180°. 3] Tighten the bolt's opposing corner sequentially with 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4] 90° ± 5° (When angle tightening tool J is used)

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50 Disassembly and assembly

When not using angle tightening tool: Make marks on the crankshaft pulley or vibration damper and each bolt with paint and then tighten the bolt by 90° ± 5°.

15. Fuel supply pump 1) How to install the gear (16) a The shaft (14) and gear (16) mating face must be clean (without dirt or foreign material) and dry prior to assembly. 1] Install the gear (16) onto the shaft (14). 2] Install the lock washer (15) and nut (11) and finger tighten.

Use the support Y and 1/2 inch breaker bar (10) to hold the gear in place while tightening the nut (11). 3 Mounting nut of fuel supply pump gear: 105 ± 5 Nm {10.7 ± 0.51 kgm}

Install supply pump (3) with 3 nuts (2). k If grease is applied too much to the O-ring when the supply pump is installed, it will ooze out during operation. Accordingly, do not apply grease too much. (Apply grease to O-ring groove area A.) k When removing and installing the supply pump mounting stud bolts of the gear housing, apply LOCTITE to the root side.

Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm} Install new 3 hoses (1). k The internal parts of the adapter may be damaged when the hose is removed. Accordingly, do not reuse the adapter but always use new one when installing the hose again, as a rule.

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<4D107E-1>

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Install engine controller (1) and tighten mounting bolts (5). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Install ground wire (3).

<6D107E-1>

17. Oil cooler 1) Install gaskets (5) and (3), oil cooler (4) and cover (2) with bolts (6).

16. Engine controller 1) Install cooling plate assembly (2) and tighten mounting bolts (4). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} a

Tighten the bolts in the numeric order shown in the figure. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

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50 Disassembly and assembly

For a model such as WA380-6 which has the oil filter on its engine, select oil filter (1). a Apply engine oil to the seal. 2 Oil filter seal: Engine oil (EO15W-40) 3 Filter: 13 Âą 2 Nm {1.3 Âą 0.2 kgm} Or tighten 3/4 turns after contacting mating part. <6D107E-1>

18. Cylinder head assembly 1) Assemble the cylinder head assembly according to the following procedure. 1] Install valve seal (7). 2] Apply engine oil to the valve stem and inside of valve guide and install valve (6). 2 Valve stem and valve guide: Engine oil (EO15W-40)

Raise the cylinder head and install valve spring (3) and upper seat (5).

Using tool C, compress valve spring (3) to install valve cotter (4).

Hit the valve stem lightly with a plastic hammer to make sure that the valve collet is positively fitted to the groove of the valve stem. Before tightening the cylinder head mounting bolt, check the following. 1] Measure stem length (a) of every bolt to make sure that they are less than the using limit. q Using limit length of bolt stem (a): Max. 132.1 mm a If a bolt is longer than the using limit, do not reuse it but replace it.

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Check that the cylinder head mounting face and inside of the cylinder are free from foreign matter and then set cylinder head gasket (8). a Make sure that the gasket is fitted in the hole on the cylinder head.

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<4D107E-1>

<6D107E-1>

Set cylinder head assembly (2) on the cylinder block and then tighten it using mounting bolts (1).

When the angle tightening tool J is not used: After applying a paint marking to the cylinder head and bolt, tighten the bolt by 90° ± 5°.

First, tighten the mounting bolts by 2 – 3 turns or more by hand, and then tighten them according to the following procedure. 2 Apply engine oil (EO15W-40) to the threaded portion and head seat of each bolt. 3 Mounting bolt: a Tighten the bolts 3 times in the order shown in the figure. 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 3] 90° ± 5° (When tightened with angle tightening tool J)

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50 Disassembly and assembly

19. Fuel injector assembly a When replacing the injector, replace the inlet connector, too. a Make sure that the injector sleeve is free from damages or dirt. 1) Attach the gasket (6) and O-ring (7) to injector (2). 2) Apply engine oil (EO15W-40) to the O-ring (7) of injector (2) as well as the head side. 3) Insert injector (2) to the cylinder head while directing its fuel inlet hole to the manifold. 4) Install holder (4) and then tighten bolt (3) 3 to 4 threads.

Check the inlet connector for the following items. If it is defective, replace it. 1] When there is a burr or a worn part at front end (a) or rear end (b) of the inlet connector. 2] When there is foreign matter in the edge filter at rear end (c) of the inlet connector. 3] When there is a crack or a deteriorated part on the O-ring at top (d) of the inlet connector.

8) 9)

Where there is a worn part or an uneven contact part on seat surface (e) of the inlet connector. a If high-pressure fuel leaks through the inlet connector, seat surface is eroded and fine streaks or flaws are made on it.

Apply engine oil (EO15W-40) to the O-ring of inlet connector (1) as well as the head side. Insert inlet connector (1) in the mounting hole of injector (2) and tighten retainer (5) temporarily. 3 Retainer: 15 ± 5 Nm {1.5 ± 0.5 kgm} a The above is temporary tightening torque. Tighten permanently in step 9). Tighten bolts (3) alternately. 3 Bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} Tighten retainer (5). 3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}

107E-1 Series

50 Disassembly and assembly

SEN00259-10

Apply liquid gasket (LG-7) onto O-ring (8) of injector harness connector (6) and flange surface (9) prior to installation. Apply liquid gasket (LG-7) (with 3 mm width) until the groove for O-ring is fully filled. If O-ring is damaged, replace the harness as an assembly. 3 Mounting bolt of injector harness connector (7): 10 ± 2 Nm {1.0 ± 0.2 kgm} <Other than WA380Z-6, PC200-8M0, PC200LC8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0>

21. Rocker arm assembly 1) Install crosshead (3). 2) Install rocker arm assembly (2) and tighten bolts (1). a Before tightening the mounting bolts, check that the ball of the adjustment screw is fitted to the socket of the push rod. 3 Bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm}

Shape of the holes (a) and (b) on the crosshead is not identical. Thus when using this part again, the same air intake and exhaust valves must be assembled in the same direction.

20. Push rod 1) Install push rod (1). a Check that the push rod is fitted in the tappet. a Refill the push rod socket with engine oil (EO15W-40).

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50 Disassembly and assembly

22. Adjusting valve clearance Adjust the valve clearance according to the following procedure. a As the valve clearance, adjust the clearance between the crosshead and rocker arm to the following value. a Valve clearance (when cold) Unit: mm Air intake valve

Exhaust valve

0.25 ± 0.05

0.51 ± 0.05

Remove plug (1) on the top of the starting motor and install tool V. a The position of plug (1) is subject to the applicable machine. <PC160-7, PC200-8 as examples>

Rotating tool V, rotate the crankshaft forward and set wide slit (b) on the disc having the revolution sensor slits at the rear of the crankshaft pulley to projection top (a) of the front cover. a Seeing from the air intake manifold side, set projection top (a) into wide slit (b). k Be aware that each cylinder is not set to the top dead center after this positioning. (Each cylinder is set 76 – 88° before the top dead center.) q 4D107E-1: No. 1 cylinder or No. 4 cylinder q 6D107E-1: No. 1 cylinder or No. 6 cylinder Reference: The position for wide slit (b) on the damper of 6D107E-1 is painted white. <4D107E-1>

107E-1 Series

50 Disassembly and assembly

SEN00259-10

Insert clearance gauge K in the clearance between rocker arm (2) and crosshead (3). Loosen locknut (4) and adjust the valve clearance with adjustment screw (5). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the clearance gauge lightly. While fixing adjustment screw (5), tighten locknut (4). 3 Locknut: 20 – 28 Nm {2.04 – 2.86 kgm} a After tightening the locknut, check the valve clearance again.

<6D107E-1>

Rotate the crankshaft forward by 1 turn with tool V and set wide slit (b) to projection top (a) according to step 2). Adjust the other valve clearances according to steps 3) – 5). a If the valves marked with Q in the valve arrangement drawing were adjusted in steps (4) and (5), adjust the valves marked with q.

23. Rocker housing and head cover < O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 , PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC-8M0> 1) Install rocker housing assembly (6) with bolt (5). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 2) Install nuts (4) of the harness. a Harness installation position Color of cable

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

Cylinders No. 5 and No. 6 are applied for 6D107E-1 only.

107E-1 Series

SEN00259-10 a

Check that the injector harness does not interfere with the rocker arm. 3 Mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

50 Disassembly and assembly

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0 only> 1) Install gasket assembly (4a). 2) Install nuts (4) of the harness. a The injector harness and nut have no positional distinction. (Their right and left sides may be reversed) a Check that the injector harness does not interfere with the rocker arm. 3 Mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

Install duct (1) to head cover (3). 3 Duct (1) mounting bolt: 7 ± 2 Nm {0.71 ± 0.20 kgm} Fit the gasket (3a) and then install head cover (3) together with duct (1) using nuts (2). 3 Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm} a Head cover (3) of 4D107E-1 will be i n s tal l ed aft er th e t ur b oc h ar g er assembly is installed. Accordingly, install the head cover temporarily at this time.

Install duct (1) to head cover (3). 3 Duct (1) mounting bolt: 7 ± 2 Nm {0.71 ± 0.20 kgm} Install head cover (3) together wit ducts (1) using bolts (2). 3 Mounting bolt: 24 ± 0.25 Nm {0.15 ± 0.03 kgm} a Head cover (3) of 4D107E-1 will be i ns tal l ed a ft er th e tu r b oc h ar g er assembly is installed. Accordingly, install the head cover temporarily at this time.

107E-1 Series

50 Disassembly and assembly

SEN00259-10

24. Air intake manifold cover 1) Fit the gasket and then install manifold covers (3) and (4). 2) Fit the gasket and then install tube (1) and electrical intake air heater (2). 3 Tube mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} <4D107E-1>

<6D107E-1>

<PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC-8M0 only> a If oil filler tube (7) is removed, install oil filler tube according to the following procedure. 1] Install O-ring (8) to oil filler tube (7). 2] Apply liquid adhesive (LOCTITE 263) (a) to contact surface of oil filler tube (7) and head cover (3). 3] Install oil filler tube (7). 3 Oil filler tube: 15 ± 3 Nm {1.53 ± 0.31 kgm}

107E-1 Series

SEN00259-10

25. Fuel pressure sensor and relief valve 1) Replace fuel pressure sensor (2), if necessary, according to the following procedure. a Do not remove fuel pressure sensor (2) from common rail (1) for a purpose other than replacement. a Once the fuel pressure sensor is removed from the common rail, be sure to replace it. 1] Before removing the fuel pressure sensor, remove mud etc. from around it thoroughly and clean it. 2] Remove the fuel pressure sensor. 3] Check the fuel pressure sensor 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 fuel pressure sensor. 2 Threaded part of fuel pressure sensor: Gear oil (#90) 3 Fuel pressure sensor: 70 ± 5 Nm {7.1 ± 0.5 kgm} 5] Connect the engine wiring harness. At this time, take care not to connect the wiring harness in reverse. 6] Start the engine and check that fuel does not leak. For the testing procedure, see Testing and adjusting, "Testing fuel system for leakage". <Fuel pressure sensor of 4D107E-1 is shown below>

Replace relief valve (3), if necessary, according to the following procedure. 1] Before removing the relief valve, remove mud etc. from around it thoroughly and clean it. 2] Remove the relief valve. 3] If the leakage from the relief valve exceeds the specified value, do not reuse it. 4] Check that high-pressure seal surfaces (A) of the relief valve and rail are free from damage.

50 Disassembly and assembly

Install the relief valve. 2 Threaded part of relief valve: Gear oil (#90) 3 Relief valve: 100 ± 4 Nm {10.2 ± 0.4 kgm} Excessive tightening can cause leakage. Take care not to tighten too strongly. Start the engine and check that fuel does not leak. For the testing procedure, see Testing and adjusting, "Testing fuel system for leakage".

26. Common rail and fuel high-pressure piping (4D107E-1) k It is prohibited to bend high-pressure pipings used. k The clamps used for fixing high-pressure pipings must be the genuine part. And the specified tightening torque must be strictly observed. k A clearance of 10 mm minimum must be provided between the installed highpressure piping and harness. a Fuel leakage can occur on a high-pressure piping that has visible lengthwise slits (b) or dents such as patchy damages (c) on its taper seal of the piping connection (part (a): 2 mm space from the tip). The same holds true for a high-pressure piping that catches claw because of fatigued steps in part (d) (end of the taper seal: a 2 mm space from the tip). Such high-pressure piping must be replaced.

107E-1 Series

50 Disassembly and assembly

SEN00259-10

<4D107E-1>

Temporarily install common rail (8) and high-pressure pipings (1) to (5). 3 Sleeve nut and mounting bolt (Temporary tighten): 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten high-pressure pipings (1) to (5) according to the following procedure. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 1] Head side of high-pressure pipings (1) and (4) 2] Rail side of high-pressure pipings (1) and (4) 3] Head side of high-pressure pipings (2) o (3) 4] Rail side of high-pressure pipings (2) o (3) 5] Pump side of high-pressure piping (5) and then its rail side Tighten clamp mounting bolts (11) of high-pressure pipe (5). 3 Mounting bolt (11): 24 ± 4 Nm {2.4 ± 0.4 kgm} Tighten common rail (7) with 4 bolts. a Apply sealant (LG-7) to the threaded part of 2 bolts inside the engine. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Install boots (8). k Set the slits of each boots out and down. a The boots are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. Install fuel return hose (9). 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

107E-1 Series

<4D107E-1>

27. Common rail and fuel high-pressure piping (6D107E-1) k It is prohibited to bend high-pressure pipings used. k The clamps used for fixing high-pressure pipings must be the genuine part. And the specified tightening torque must be strictly observed. k A clearance of 10 mm minimum must be provided between the installed highpressure piping and harness. a Fuel leakage can occur on a high-pressure piping that has visible lengthwise slits (b) or dents such as patchy damages (c) on its taper seal of the piping connection (part (a): 2 mm space from the tip). The same holds true for a high-pressure piping that catches claw because of fatigued steps in part (d) (end of the taper seal: a 2 mm space from the tip). Such high-pressure piping must be replaced.

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50 Disassembly and assembly a

The boots are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. 6) Install fuel return hose (8). 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} <6D107E-1>

Temporarily install common rail (10) and high-pressure pipings (1) to (7). 3 Sleeve nut and mounting bolt (Temporary tighten): 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten high-pressure pipings (1) to (7) according to the following procedure. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 1] Head side of high-pressure pipings (6) and (1) 2] Rail side of high-pressure pipings (6) and (1) 3] Head side of high-pressure pipings (2) o (3) o (4) o (5) 4] Rail side of high-pressure pipings (2) o (3) o (4) o (5) 5] Pump side of high-pressure piping (7) and then its rail side Tighten clamp mounting bolts (12), (13) and (14) of high-pressure pipe (7). <WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC-8M0 only> 3 Mounting bolt (12): 24 ± 4 Nm [24 ± 0.4 kgm] <Other than WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC8M0 and PC240LC-8M0> 3 Mounting bolt (13): 24 ± 4 Nm {2.4 ± 0.4 kgm} 3 Mounting bolt (14): 10 ± 2 Nm {1.0 ± 0.2 kgm} Tighten common rail (10) with 4 bolts. a Apply sealant (LG-7) to the threaded part of 2 bolts inside the engine. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Install boots (9). a Set the slits of each boots out and down.

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC2208M0, PC220LC-8M0 and PC240LC-8M0 only>

107E-1 Series

50 Disassembly and assembly

SEN00259-10

28. Harness assembly < O t h e r t h a n WA 3 8 0 Z - 6 , P C 2 0 0 - 8 M 0 , PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC-8M0> Connect harness assembly (1) to the controller and sensor and then fix it to the engine. k Before connecting the harness connector, clean sands, dusts or water in the controller side connector.

29. Fuel filter assembly 1) Install filter bracket assembly (4). 2) Install drain hose (3) to the filter bracket. 3) Install filter inlet hose (1) and outlet hose (2). 4) Install fuel filter (5). a As the gasket touched the filter head, tighten the fuel filter 1/2 turn to install it.

<WA380Z-6, PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 and PC240LC8M0 only> Connect three connectors (2) of the injector harness. a Push in connector (2) in the direction of the arrow until it clicks.

30. Exhaust manifold 1) Fit a new gasket and then install exhaust manifold (4) to the cylinder head. Tighten the mounting bolts according to the numbers shown in the figure. 3 Mounting bolts tightening procedure: 1] Tighten every bolt with 24 ± 4 Nm {2.4 ± 0.4 kgm}. 2] Tighten every bolt with 53 ± 6 Nm {5.4 ± 0.6 kgm}. 3] Tighten [1] to [4] bolts alone in the figure in this order with 53 ± 6 Nm {5.4 ± 0.6 kgm}. <4D107E-1>

107E-1 Series

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50 Disassembly and assembly

<6D107E-1>

5) 31. Turbocharger assembly (4D107E-1) 1) Remove the head cover installed in the previous step. 2) Fit gasket (9) and place turbocharger assembly (4) temporarily on the exhaust manifold stud bolts. Then, fit gasket (8) to the turbocharger and install oil return tube (7). a Tighten oil return tube mounting bolt (6) with hexagonal wrench [1] under the condition shown in the figure. 3 Oil return tube mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}

3) 4)

Install turbocharger assembly (4) to the exhaust manifold with mounting nuts (3). Check that the oil return tube (7) does not interfere with the exhaust manifold and install head cover (5). 3 Turbocharger mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm} a Tighten the mounting nuts in the diagonal order. 3 Head cover mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

Install oil feed tube (2) to the turbocharger assembly and then install heat insulation cover (1). 3 Mounting nut on oil cooler side: 24 ± 4 Nm {2.4 ± 0.4 kgm} 3 Mounting nut on turbocharger side: 36 ± 5 Nm {3.6 ± 0.5 kgm} 3 Heat insulation cover mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

32. Turbocharger assembly (6D107E-1) 1) Fit the gasket and install turbocharger assembly (3) to exhaust manifold (4). 3 Mounting nut: 43 ± 6 Nm {4.4 ± 0.6 kgm} a Tighten the mounting nuts in the diagonal order.

107E-1 Series

50 Disassembly and assembly

Install the turbocharger assembly oil feed tube. 3 Mounting nut on oil cooler side: 24 ± 4 Nm {2.4 ± 0.4 kgm} 3 Mounting nut on turbocharger side: 36 ± 5 Nm {3.6 ± 0.5 kgm} Fit the gasket to the turbocharger assembly and install oil return tube (2). 3 Oil return tube mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

SEN00259-10

34. Thermostat 1) Install thermostat (2).

Install coolant outlet connector (1).

33. Water pump 1) Attach the seal ring and then install water pump (2). 2) Attach the seal ring and then install coolant inlet connector (1). 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 35. Alternator 1) Install front side sling bracket (5) and alternator bracket (4). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

107E-1 Series

SEN00259-10

2) 3) 4)

Install alternator (3) temporarily using mounting bolt (2). Install plate (1). Tightening alternator mounting bolt (2).

36. Fan hub Install fan hub (2) with mounting bolt (1). 3 Mounting bolt: 32 ± 5 Nm {3.3 ± 0.5 kgm}

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

50 Disassembly and assembly

38. Fan pulley 1) Install fan pulley (4) with mounting bolt (3). 3 Mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 2) Install fan belt (1). q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (2), and rotate it to the opposite to the winding-up direction to decrease the fan belt (1) tension, then install. k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (2) is strong. If the wrench is loosely inserted, the wrench may accidentally come off w h i l e b e i n g r o ta t e d a n d i t i s extremely dangerous.) k After removing the fan belt (1), return the tensioner assembly (2) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (1) during work.

39. Engine sling bracket on rear side <All engine except for generator> Install engine sling bracket (1) to the cylinder bracket.

107E-1 Series

50 Disassembly and assembly

<Generator> Install engine sling bracket (1) to the fly wheel housing (FWH).

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41. Removal from engine repair stand 1) Lift engine assembly (1) temporarily and then separate it from tool A. 4 Engine assembly: Approx. 430 kg (4D107E-1) 4 Engine assembly: Approx. 520 kg (6D107E-1) (The weight depends on the applicable machines.) 2) Remove tool B.

40. Starting motor assembly Fit the gasket and then install starting motor assembly (2) with bolt (1). 2 Apply 1 mm wide gasket sealant (LG7) to the entire circumference of the front and back sides of the gasket. <4D107E-1>

<6D107E-1>

107E-1 Series

Set engine assembly (1) on stable engine stand [1] provided on both sides. 4) Install oil gauge assembly (2). <4D107E-1>

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50 Disassembly and assembly

<6D107E-1>

42. Refilling with oil 1) Check that the engine oil drain plug is tightened. 2) Add oil through the oil filler to the specified level. 5 5

Engine oil pan: Approx. 16 l (4D107E-1) Engine oil pan: Approx. 23 l (6D107E-1)

107E-1 Series

50 Disassembly and assembly

107E-1 Series

SEN00259-10

KOMATSU 107E-1 Series Diesel engine Form No. SEN00259-10

SEN05211-01 107-1 Series SEN05211-01

Engine Shop Manual

107E-1 Series

Machine model Serial number 107E-1 SERIES........................

90 Repair and replacement of parts Information related to repair and replacement Special tool table.........................................................................................................................................

107E-1 Series

SEN05211-01

90 Repair and replacement of parts

Special tool table Repair/ Replacement item

Symbol

Replacement of valve seat insert

Repair of cylinder block

Remarks

795-799-4500 Grooving kit

795-799-4700 Slide hammer

Intake and exhaust

795-799-6140 Remover (Collet)

Intake

795-799-6800 Valve seat cutter

795-799-6910 Guide (Arbor)

1 795-799-6920 Seat cutter 2 795-799-6930 Seat cutter

0.010 mm

0.020 mm (Oversize)

795-799-6150 Valve seat installer

795-790-2100 Spring tester

Camshaft bushing replacement 795-799-1360 kit

795-799-1500 Push tool kit

1 795-799-1530 Mandrel

2 795-799-1510 Anvil

3 795-799-1540 Ring

For locking bushing

4 795-799-1550 Ring

For removing/installing bushing

5 795-799-1520 Cap

Cotter pin

Operation and Maintenance Manual

7 795-799-1560

Repair of cylinder block

Q'ty

Replacement of connecting rod bushing

Part name

Grinding of valve

Part No.

795-799-9500 Sleeve driver

795-799-9600 Torque plate kit

790-331-1120 Wrench (angle)

107E-1 Series

90 Repair and replacement of parts

107E-1 Series

SEN05211-01

90 Repair and replacement of parts

KOMATSU 107E-1 Series Diesel engine Form No. SEN05211-01

SEN05212-00 107-1 Series SEN05212-00

Engine Shop Manual

107E-1 Series

Machine model Serial number 107E-1 SERIES........................

90 Repair and Replacement of parts Parts related to cylinder head Repair of cylinder head ...............................................................................................................................

Check of valve guide...................................................................................................................................

Replacement of valve seat insert................................................................................................................

Vacuum test of valve seat insert .................................................................................................................

Grinding of valve .........................................................................................................................................

107E-1 Series

SEN05212-00

90 Repair and Replacement of parts

Repair of cylinder head Check 1. Check the cylinder head mounting face for breakage and erosion. 2. Peel off the remaining gasket and clean the cylinder head mounting face.

If the sinking quantity of the valve and projection of the injector can be changed into the allowable range, the cylinder head can be repaired by grinding. a Cylinder head height (Reference): 105 ± 0.25 mm a If the sinking quantity of the valve and projection of the injector are out of the allowable range, replace the cylinder head.

3. Using a precision ruler and a feeler gauge, measure the flatness of the cylinder head mounting face. a Flatness of mounting face q End-to-End: Max. 0.305 mm q Side-to-Side: Max. 0.076 mm

a If the flatness is out of the specified range, repair the cylinder head by grinding or replace it according to the following criteria. 1) Measure the sinking quantity of the valves. a Valve sinking quantity q Intake side: 0.584 – 1.092 mm q Exhaust side: 0.965 – 1.473 mm 2) Measure the projection of injector nozzle. a Projection of injector nozzle: 2.45 – 3.15 mm

107E-1 Series

90 Repair and Replacement of parts

SEN05212-00

Check of valve guide 1. Check the valve guide for scuffing and seizure. 2. Measure the valve guide bore. a Valve guide bore: 7.027 â&#x20AC;&#x201C; 7.077 mm a If the valve guide bore is larger than the specified value or the inside wall of the valve guide is damaged, replace the cylinder head.

107E-1 Series

SEN05212-00

90 Repair and Replacement of parts

Replacement of valve seat insert a Valve seat insert replacement tools Symbol

Part No.

Part name

795-799-4500

Grooving kit

795-799-4700

Slide hammer

795-799-6140

Remover (Collet)

795-799-6800

Valve seat cutter

7. Tighten the T-handle firmly to bend tool C to under the valve seat insert or into the groove. 8. Hit the top nut of tool B until the valve seat insert comes off. 9. Rotate the T-handle counterclockwise to remove the valve seat insert from tool C.

a Judge if the valve seat insert needs to be replaced by the condition and sinking quantity of the valve and the contact condition of the valve seat insert. Removal 1. Check the contact faces of the valve seat insert and cylinder head and confirm that there is a sufficient groove on the valve seat. 2. If there is a sufficient groove on the valve seat insert, go to step 5. 3. If there is not a sufficient groove on the valve seat insert, make a sufficient groove with tool A.

Testing Measure the valve seat insert bore of the cylinder head. a Valve seat insert bore: 34.847 â&#x20AC;&#x201C; 34.863 mm

4. Using tools B and C, remove the valve seat insert. a When installing, be sure to set tool C perpendicular to the cylinder head. 5. Insert the tool C in valve seat insert and rotate the T-handle clockwise until tool C is meshed with the valve seat insert lightly. 6. Set tool C to the groove of the valve seat insert.

107E-1 Series

90 Repair and Replacement of parts

Installation a When installing the valve seat inserts, note that the ones for the exhaust valves are different from those for the intake valves. a Valve seat angle (Intake side): 30 degrees (Exhaust side): 45 degrees a Direct the chamfered periphery end (1) of the valve seat insert toward the bottom of the counterbore. 1. Using tool D, drive the intake and exhaust valve seat inserts into the counterbores.

SEN05212-00

3. If a new valve seat insert is installed or the leak through the valve is out of the allowable range, polish the valve seat and valve. a Before installing the valve, apply engine oil (EO15W-40) to its stem. 1) Apply fine lapping compound to the valve thinly and evenly. 2) Press an electric or hand polishing tool against the center of the valve and rotate the valve clockwise and counterclockwise alternately. 3) Continue to polish until the valve seat insert and valve are fitted to each other without clearance between them, judging from the sticking condition of the compound.

2. After installing the new valve seat insert, measure valve sinking quantity (A) and check for leak through the valve. a The lapping compound is abrasive. If all the dirt is not removed from the cylinder head, valve and valve seat, it affects the engine badly. 4) Wipe off the lapping compound from each part.

107E-1 Series

SEN05212-00

90 Repair and Replacement of parts

Vacuum test of valve seat insert If the valve seems to be leaking, test the sealing performance between the valve and valve seat insert with the valve vacuum tester (Part No. 3824277) and cup (Part No. ST-1257-6). a The vacuum must not reduce more than 25.4 mmHg in 5 seconds. a Vacuum between valve and valve seat insert q Used parts: 51 kPa q New parts: 69 kPa

a If the valve vacuum tester is not available, test the valve seat contact surface by the following method. q Make marks on the valve seal face with a pencil as shown in the figure. q Install the valve in the valve guide. q While keeping the valve in contact with the valve seat insert, rotate it clockwise and counterclockwise 3 â&#x20AC;&#x201C; 4 turns. q If the valve is in contact with the valve seat insert normally, the pencil marks all around the valve seal are erased evenly.

a If the vacuum between the valve and valve seat insert or the valve seat contact face is out of the allowable range, disassemble the cylinder head and check the valve and valve seat insert for damage. Repair according to the following procedure, as necessary. 1. Clean the valve and valve seat insert, and then polish the valve again. 2. Replace any damaged valves and valve seat inserts. (If there are replacement parts) 3. Replace the cylinder head.

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Grinding of valve a Valve measuring tool Symbol

Part No.

795-790-2100

k k

Reuse of valve Part name Spring tester

When polishing the valve with an electric brush, put on safety glasses to avoid injury. When using cleaning liquid containing solvent or acid or alkaline substance, observe the items recommended by the manufacturer. Be sure to put on safety glasses and protective clothes to avoid injury.

When reusing a valve, check the following. q The valve head and valve stem are not worn excessively. q The valve stem end is not worn excessively. q The valve is not bent or distorted.

1. Clean the valve head with a soft rotary wire brush. a Keep each valve on a labeled rack etc. before measurement to avoid a mistake.

q q

Check the valve for damage and check the collet groove for wear. Measure the outside diameter of the valve stem. a Measure the outside diameter of each valve stem at 3 places of 40 mm, 90 mm and 140 mm from the end. a Outside diameter of valve stem: 6.96 â&#x20AC;&#x201C; 7.01 mm a If the valve is damaged or the outside diameter of its stem is out of the specified range, replace it with new one.

2. Polish the valve stem with Scotch-Brite 7448 (Part No. 3823258) and solvent.

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Measure the rim thickness and polish the valve only when the rim thickness can be secured sufficiently after polishing. a Allowable valve rim thickness: Min. 0.79 mm a If the valve rim thickness is out of the allowable value, replace the valve with new one.

90 Repair and Replacement of parts

Reuse of valve spring q

When reusing a valve spring, check the following.

1. Measure the free length of valve spring. a Free length of valve spring: Approximately 47.75 mm 2. Place a square by the valve spring and measure the inclination of the valve spring with a feeler gauge. a Inclination (max.) of valve spring: 1.5 mm

3. Using tool H, measure the tension of the valve spring. q If the load to compress the valve spring to a height of 35.33 mm is 320.8 â&#x20AC;&#x201C; 358.8 N (32.7 â&#x20AC;&#x201C; 36.6 kg), the valve spring is in the allowable range. a If the valve spring is out of the allowable range, replace it with new one.

107E-1 Series

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KOMATSU 107E-1 Series Diesel engine Form No. SEN05212-00

SEN05213-01 107-1 Series SEN05213-00

Engine Shop Manual

107E-1 Series

Machine model Serial number 107E-1 SERIES........................

90 Repair and replacement of parts Parts related to cylinder block Repair of cylinder block...............................................................................................................................

Repair of crankshaft.................................................................................................................................... 14 Replacement of connecting rod bushing..................................................................................................... 17

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90 Repair and replacement of parts

Repair of cylinder block Initial testing a Before removing the piston and connecting rod assembly, measure the projection of the piston. The projection of the piston measured before disassembly will be used for reference to judge if the cylinder block can be repaired by grinding.

Check 1. Measure the flatness of the cylinder block mounting face. a Flatness of mounting face q End-to-End: Max. 0.076 mm q Side-to-Side: Max. 0.051 mm

a A thicker head gasket to compensate for the ground part of the cylinder block mounting face is not prepared. If the projection of the piston is not to be within the specified value after the grinding work, replace the cylinder block. a Cylinder block height (New): 322.978 Âą 0.08 mm

a: Height b: Cylinder block top c: Crankshaft hole center

2. Check for a local dent and unevenness. a If there is any local dent or unevenness, grind the cylinder block mounting face. a The cylinder block mounting face can be ground only when the projection of the piston is to be within the specified value after the grinding work. a Projection of piston: 0.3180 Âą 0.167 mm

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Check of bore

Removal of camshaft bushing

a If the cylinder block is placed on the engine stand or the main bearing metal cap is not installed, measurement cannot be performed accurately because of distortion. Perform all measurement of the cylinder block after installing the main bearing metal cap and placing the cylinder block on a flat surface. (Cylinder bore, main bearing bore, camshaft bore, etc.)

a Camshaft bushing replacement tools Symbol

Part No.

Part name

795-799-1360

Camshaft bushing replacement kit

a The camshaft bushings are press fitted to the following journals. q 4D107E-1: No. 1, No. 5 (No bushings are press fitted to Nos. 2 â&#x20AC;&#x201C; 4) q 6D107E-1: No. 1, No. 7 (No bushings are press fitted to Nos. 2 â&#x20AC;&#x201C; 6) 1. Using tool J, remove the camshaft bushing. The following kit can be used to remove and install the camshaft bushing. q Camshaft bushing kit (Part No. 3165045) 2. Slide the drive bar from the centering guide. Insert the drive bar into the camshaft bore from the rear of the cylinder block. 3. Insert the camshaft bushing remover to push out the front and rear camshaft bushings from the cylinder block.

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Measurement of camshaft bore a Measure the camshaft bore with the camshaft bushing removed. a Camshaft bore q Portion where camshaft bushing has been fitted: Max. f 59.248 mm q Portion where camshaft bushing has not been fitted: Max. f 54.164 mm a If the bore at the portion where the camshaft bushing has been fitted is out of the specified value, replace the cylinder block. a If the bore at the portion where the camshaft bushing has not been fitted is out of the specified value, the camshaft bushing can be press fitted after the bore is so worked that the camshaft bushing of the standard size can be press fitted. q Bore to which camshaft bushing of standard size can be press fitted: f 59.235 Âą 0.013 mm q Bore after camshaft bushing is press fitted: f 54.083 â&#x20AC;&#x201C; 54.147 mm a After the camshaft bushing is press fitted, if the bore is out of the specified value, remove the camshaft bushing and check the camshaft bore of the cylinder block.

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Installation of camshaft bushing 1. Make match marks (1) at the larger oil hole of the camshaft bushing and the oil hole of the cylinder block with a marker. a Use the match marks to align the bushing and bore when installing.

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a Be sure to match the larger oil hole of the camshaft bushing to the larger oil hole on the lower side of the camshaft bore. a The oil hole must be of a size through which a rod 3.2 mm in diameter will go.

2. Slide and install the camshaft bushing to the camshaft bushing remover. 3. Align match marks (1) of the camshaft bushing and cylinder block and drive the front camshaft bushing to the correct installed depth. a At the correct installed depth of the front camshaft bushing, its end is 1.5 mm lower than the machined face of the cylinder block and its oil hole is matched to the oil hole of the cylinder block.

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Measurement of cylinder bore

Repair

a Do not measure the cylinder bore in the area of 50 mm from the cylinder block mounting face since it cannot be measured accurately in that area. a When measuring, polishing or boring the cylinder block, check that all the main bearing metal caps are positioned normally and tightened to proper torque. (See "Structure, function and maintenance standard")

a When repairing, take care that foreign matter will not enter the engine lubrication passage since it can damage the engine. a When repairing the cylinder bore, cover the lubricating oil holes and tappet holes on the cylinder block mounting face with water-resistant tapes.

1. Check the cylinder bore for a damage and excessive wear. 2. Using a dial bore gauge, measure the cylinder bore at 4 peripheral points equally spaced (90 degrees) at the top and bottom of the piston sliding surface of the cylinder. a Cylinder bore (New cylinder block): 106.990 â&#x20AC;&#x201C; 107.010 mm a Cylinder bore (Used cylinder block): 106.990 â&#x20AC;&#x201C; 107.030 mm a Roundness: Max. 0.038 mm a Taper: Max. 0.076 mm a The cylinder can be bored only once only when the piston and piston ring of the oversize (0.5 mm) are used. For the procedure, see "Overbore". a If the area to be repaired is more than 0.5 mm diameter, perform drilling again, and install repair sleeve.

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Honing work 1. The cylinder bore surface can be finished by honing work to accuracy required for installation of the piston rings. Honing can be performed only when the cylinder bore is within the specified value. a Do not use new piston rings for the cylinder bore after it is worn to mirror surface.

a Using ball-type grinding stones, hone the cylinder at a rotation speed of 300 â&#x20AC;&#x201C; 400 rpm and at a pitch of 1 vertical moving cycle per second. a Be sure to use mixture of 50% high-quality honing oil or engine oil (EO30W) and 50% diesel fuel as lubricating oil for honing. a Move the grinding stones vertically, smoothly and continuously along the cylinder bore length. 2. After honing 10 cycles, check the cylinder bore. a The cross hatch angle is decided by the rotation speed and the vertical moving speed of the grinding stones. A proper cross hatch angle cannot be obtained if the speed is too high or too low. a If the cylinder is honed correctly, cross hatch lines appear at angles of 25 â&#x20AC;&#x201C; 30 degrees to the cylinder block mounting face.

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Overbore 1. If the cylinder bore is out of the specified value or cylinder surface is damaged, the cylinder can be bored to the piston and piston rings of the oversize. a The boring work shall be performed with a proper boring machine by a skilled worker. a The cylinder must be perpendicular to the combustion chamber face of the cylinder block and the taper and roundness of the cylinder bore must be within the standard values.

90 Repair and replacement of parts

2. After boring, cut the inside edge at an angle of 15 degrees to about 1.25 mm with honing stones.

3. After boring the cylinder to the oversize, finish it by honing in 2 steps. a Use a honing machine for engine cylinder. a Use ball-type grinding stones only when the cylinder does not need to be bored again.

a The boring dimensions shown below are not the finished dimensions of the cylinder bore. The finished dimensions of the cylinder bore are obtained by the final honing work. a Boring dimensions: 107.45 mm a The cutting depth of each pass must not exceed 0.228 mm. a The cylinder can be bored only once. If the cylinder has been bored or a flaw on its surface cannot be removed, replace the cylinder block.

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a Hone the cylinder at a rotation speed of 300 – 400 rpm and at a pitch of 1 vertical moving cycle per second. a Be sure to use mixture of 50% high-quality honing oil or engine oil (EO30W) and 50% diesel fuel as lubricating oil for honing. 1) For the 1st honing pass or rough honing, use soft (high-speed cutting) silicone carbide grinding stones of 80 grits. Finish the cylinder to the final dimension by the honing work in this step. a Dimension after honing work: 107.490 – 107.510 mm

2) For the 2nd honing pass or finish honing, use medium-hard silicone carbide grinding stones of 285 grits. a Move the grinding stones at a pitch of 15 – 20 strokes to obtain proper cross hatch. a If the cylinder is honed accurately, cross hatch lines appear at angles of 25 – 30 degrees to the cylinder block top.

a : Cylinder block top b : Cross hatch angle

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Installation of repair sleeve Repair sleeve part number: 6754-29-2010

1) When installing the sleeve, coat each bore one at a time with Loctite 620.

Repair sleeve installation tools Symbol L M N

Part No. 795-799-9500 795-799-9600 790-331-1120

Part name Sleeve driver Torque plate kit Wrench (angle)

a If an oversize bore of more than diameter 0.5 mm is needed, the hole must be made in the block again and the repair sleeve installed. After installing, the sleeve bore must be finished again to a diameter of 107 ± 0.01 mm. Use the standard diameter piston and service piston ring set. 1. Remake a new hole in block for repair sleeve. A = 109.700 – 109.715 mm B = 6.35 mm a After completely making the hole, remove all metal chips, particles, and oil completely from the bore, and install the repair sleeve.

2) Using protective gloves, push the frozen sleeves as far as possible into the bore by hand.

3) Using too L, push the sleeve in until it contacts the step at the bottom of the bore. 2. Cool the repair sleeve at -12°C (+10°F) for at least one hour. Remove the sleeve one at a time and install them to the block as follows.

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3. Increase the inner bore of sleeve up to 106.880 mm.

6. Install the tool M to cylinder block. 1) Place the head gasket on to top surface of cylinder block. 2) Set the torque plate to the dowel pin, place it on the cylinder block, and tighten it with mounting bolt. a

4. Cut off the top end of the sleeve so that extrusion is less than 0.050 mm from the top surface of block.

First, tighten the mounting bolts by 2 – 3 turns or more by hand, and then tighten them according to the following procedure. 2 Apply engine oil (EO15W-40) to the threaded portion and head seat of each bolt. 3 Mounting bolt: a Tighten the bolts in the order shown in the figure. 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] Loosen all the bolts by returning them 360 deg. 3] 90 ± 3 Nm {9.2 ± 0.3 kgm} 4] 90 ± 5 deg. (When tightened with angle tightening tool N)

5. Chamfer the edge of the sleeve by using hone so that it becomes approximately 1.25 mm x 15 deg.

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7. Use diamond hone of 160 grit for level 1 honing process (coarse honing process). a Dimension after honing work: less than 106.9873 mm a Hone the cylinder at a rotation speed of 300 – 400 rpm and at a pitch of 1 vertical moving cycle per second. a Be sure to use mixture of 50% high-quality honing oil or engine oil (EO30W) and 50% diesel fuel as lubricating oil for honing.

90 Repair and replacement of parts

8. Use silicon carbide hone of 280 grit for level 2 honing process (finishing honing process). a Dimension after honing work: 106.990 – 107.010 mm a Perform plateau honing by 10 to 12 strokes. a If the cylinder is honed accurately, cross hatch lines appear at angles of 25 – 30 degrees to the cylinder block top.

a : Cylinder block top b : Cross hatch angle 9. Remove torque plate from the cylinder block.

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Cleaning q

After the polishing or finish-honing work, clean the cylinder bore with high-concentration detergent solution and warm water.

When using compressed air, put on proper personal protective item to protect your eyes and face from chips and dirt that will be blown off. k When using cleaning liquid containing solvent or acid or alkaline substance, observe the items recommended by the manufacturer. Be sure to put on safety glasses and protective clothes to avoid injury. a Clean the cylinder bore immediately after the polishing and finish-honing work since chips and dirt can damage the engine. a After finishing the cleaning work, be sure to remove the tapes which are covering the tappet holes since they can damage the engine. 1. Rinse the cylinder bore until all the detergent is washed away. 2. Dry the cylinder bore with compressed air.

If any dust is left, repeat the cleaning work until it is removed. 1) Clean the cylinder bore with solvent. 2) Dry the cylinder bore with compressed air.

4. If the cylinder block is not used right away, apply rust preventive to all the machined surfaces. Cover the cylinder block to protect its inside and outside from dust and chips.

a Before using a new cylinder block or a cylinder block which has been kept, be sure to remove oil and rust preventive from its cylinder bore, gasket seal and main bearing bore.

3. Check the cleanliness of the cylinder bore with a white lint-free cloth impregnated with oil lightly. If any grits are left, repeat the cleaning work until they are removed.

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Repair of crankshaft Regrinding of crankpin journal fillet radius Recommended procedure q Smoothly connect the radius of 4.00 Âą 0.20 mm to the reground diameter and side.

Regrinding of main journal fillet radius Recommended procedure - Journal q Smoothly connect the radius of 4.2 Âą 0.2 mm to the reground diameter.

Finishing of surface

(A): The fillet connected to the journal surface must be 0.8 Ra or less in the range of at least 45 degrees. (B): The other parts of the fillet must be 1.6 Ra or less. (C): Max. 0.3 Ra (Journal surface) (D): New undercut dimension (E): Original dimension a Perform grinding in the opposite direction to the engine rotation and perform polishing in the same direction as the engine rotation.

(A): The fillet connected to the journal surface must be 0.8 Ra or less in the range of at least 45 degrees. (B): The other parts of the fillet must be 1.6 Ra or less. (C): Max. 0.3 Ra (Journal surface) (D): Original dimension (E): New undercut dimension a Perform grinding in the opposite direction to the engine rotation and perform polishing in the same direction as the engine rotation.

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Measurement Measure the crankshaft main journal and crankpin journal. a Roundness: Max. 0.050 mm a Taper: Max. 0.013 mm a If any journal is out of the specified value, polish the crankshaft again. Even if only one journal is out of the specified value, be sure to polish all the journals.

a If the crankpin journal of the crankshaft is out of the specified value, polish the crankshaft again. 1] Machine the crankshaft to the specified maximum value of the objective undersize bearing metal. 2] Finish the crankshaft to the standard value of the objective undersize bearing metal. a Even if the diameter of only one journal is out of the specified value, be sure to polish all the journals. 2. Measure the outside diameter of the main journal. a Outside diameter of main journal (Standard): 82.962 â&#x20AC;&#x201C; 83.013 mm

1. Measure the outside diameter of the crankpin journal. a Outside diameter of crankpin journal (Standard): 68.962 â&#x20AC;&#x201C; 69.013 mm a Outside diameter of undersize main journal Unit: mm Undersize

Min.

Max.

0.25 US

82.712

82.763

0.50 US

82.462

82.513

0.75 US

82.212

82.263

1.00 US

81.962

82.013

a US: Undersize

a Outside diameter of undersize crankpin journal Unit: mm Size

Min.

Max.

0.25 US

68.712

68.763

0.50 US

68.462

68.513

0.75 US

68.212

68.263

1.00 US

67.962

68.013

a If the main journal of the crankshaft is out of the specified value, polish the crankshaft again. 1] Machine the crankshaft to the specified maximum value of the objective undersize bearing. 2] Finish the crankshaft to the standard value of the objective undersize bearing. a Even if the diameter of only one journal is out of the specified value, be sure to polish all the journals.

a US: Undersize

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3. Check the thrust faces for a damage and excessive wear. a A slight scratch is allowed. Polish the worked surface with polish cloth of fine mesh. a The thrust bearing surfaces are in the following positions. q 4D107E-1: 4th main journal q 6D107E-1: 6th main journal 4. Measure the dimension of the thrust surface. a End play of thrust surface: 0.065 â&#x20AC;&#x201C; 0.432 mm a If the end play of the thrust surface is out of the specified value, a thrust bearing of 0.25 mm or 0.50 mm oversize can be used.

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Replacement of connecting rod bushing a Connecting rod bushing replacement tools Symbol

Part No.

795-799-1500

Part name Push tool (KIT)

4. Install mandrel (3) to anvil (4). Match the angle of the connecting rod to that of anvil (4) so that the connecting rod will be horizontal.

Removal 1. Insert mandrel (3) in the connecting rod pin hole.

5. Apply pressure over cap (5) to push out the connecting rod bushing to the bore bottom.

2. Install removal ring (thin) (2) over mandrel (3). Align the angled face accurately.

6. Remove cotter pin (6) and then remove cap (5) and removal ring (thin) (2).

3. Put cap (5) over mandrel (3) and fix it with cotter pin (6).

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7. With the bushing removed, measure the connecting rod pin hole diameter. a Connecting rod pin hole diameter (when bushing is removed): 42.987 â&#x20AC;&#x201C; 43.013 mm

90 Repair and replacement of parts

Press fitting 1. Before installing the connecting rod bushing, soak it and the pin end of the connecting rod in clean engine oil (EO15W-40).

2. Insert the connecting rod bushing in mandrel (3).

3. Install removal ring (thin) (2) and then install stop ring (1). 4. Match the angles of removal ring (thin) (2) and stop ring (1) to each other, set their angled ends down, match the notch of the removal ring to the pin in the stop ring, and install them over mandrel (3).

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90 Repair and replacement of parts

5. Put cap (5) and fix it with cotter pin (6).

6. Insert the assembly of mandrel (3) in the chamfered side of the connecting rod and align the angles of the bushing, connecting rod and stop ring.

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8. Place the connecting rod and mandrel on anvil (4). (Match the angle of the connecting rod to that of anvil (4) so that the connecting rod will be horizontal.)

9. Using a hydraulic press, press fit the bushing to the connecting rod from above the cap. Press fit until the stop ring touches the connecting rod. 10. Check the clearance between the connecting rod bushing and connecting rod. a Using a feeler gauge of 0.025 mm, check that the bushing is fitted to the rod hole normally. a The feeler gauge of 0.025 mm must not go between the bushing and connecting rod.

7. Press fit the assembly of mandrel (3) until it touches the pin hole of the connecting rod.

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Machining q

a a

The inside of a new connecting rod bushing must be finished. Machine the bushing with a rod boring machine or equivalent. If SUNNEN PM-300 or equivalent connecting rod boring machine is adjusted correctly, it can be used to adjust the tolerance of bend, torsion, etc. Do not use a honing machine of "floating rod" type. Finished bushing bore: 40.019 â&#x20AC;&#x201C; 40.033 mm

Check for bend and torsion Check the connecting rod for bend and torsion. a Distance between centers of holes (large and small): 191.975 â&#x20AC;&#x201C; 192.025 mm a Parallelism of bushing bore with large end hole q In bend direction: 0.02 mm q In torsion direction: 0.03 mm

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KOMATSU 107E-1 Series Diesel engine Form No. SEN05213-01