Komatsu SAA4D107E-3, SAA6D107E-3, 107E-3 Series SEN06502-17 (Preview)
COVER
00 INDEX AND FOREWORD
INDEX
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE ENGINE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
PRECAUTIONS FOR ADDING
PRECAUTIONS FOR STORING
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
THE OTHER PRECAUTIONS
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
01 SPECIFICATIONS
CONTENTS
ABBREVIATION LIST
SPECIFICATIONS
OUTLINE OF EXHAUST GAS REGULATION
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION
LIST OF APPLICABLE MACHINES: 107E-3
SPECIFICATIONS
SPECIFICATIONS: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
SPECIFICATIONS: SAA4D107E-3 (HB215LC-3)
SPECIFICATIONS: SAA4D107E-3 (PC170LC-11)
SPECIFICATIONS: SAA4D107E-3 (WA200-8)
SPECIFICATIONS: SAA6D107E-3 (BR380JG-3)
SPECIFICATIONS: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
SPECIFICATIONS: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
SPECIFICATIONS: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
SPECIFICATIONS: SAA6D107E-3 (PC210LC-11,PC210LCI-11)
SPECIFICATIONS: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
SPECIFICATIONS: SAA6D107E-3 (PC240LC-11)
SPECIFICATIONS: SAA6D107E-3 (PC290LC-11, PC290LCI-11)
SPECIFICATIONS: SAA6D107E-3 (WA270-8, WA270-8E0)
SPECIFICATIONS: SAA6D107E-3 (WA320-8, WA320-8E0)
SPECIFICATIONS: SAA6D107E-3 (WA380-8)
ENGINE GENERAL VIEW
ENGINE GENERAL VIEW: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
ENGINE GENERAL VIEW: SAA4D107E-3 (HB215LC-3)
ENGINE GENERAL VIEW: SAA4D107E-3 (PC170LC-11)
ENGINE GENERAL VIEW: SAA4D107E-3 (WA200-8)
ENGINE GENERAL VIEW: SAA6D107E-3 (BR380JG-3)
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
ENGINE GENERAL VIEW: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
ENGINE GENERAL VIEW: SAA6D107E-3 (PC210LC-11,PC210LCI-11)
ENGINE GENERAL VIEW: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
ENGINE GENERAL VIEW: SAA6D107E-3 (PC240LC-11, PC290LC-11, PC290LCI-11)
ENGINE GENERAL VIEW: SAA6D107E-3 (WA270-8, WA270-8E0)
ENGINE GENERAL VIEW: SAA6D107E-3 (WA320-8, WA320-8E0)
ENGINE GENERAL VIEW: SAA6D107E-3 (WA380-8)
ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (HB215LC-3)
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (PC170LC-11)
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (WA200-8)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (BR380JG-3)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC210LC-11, PC210LCI-11)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC240LC-11)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA270-8, WA270-8E0)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA320-8, WA320-8E0)
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA380-8)
10 STRUCTURE AND FUNCTION
CONTENTS
ABBREVIATION LIST
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
FUNCTION OF UREA SCR SYSTEM
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM
INDUCEMENT STRATEGY
COMPONENT PARTS OF UREA SCR SYSTEM
AdBlue/DEF MIXING TUBE
SCR ASSEMBLY
AdBlue/DEF TANK
AdBlue/DEF PUMP
AdBlue/DEF INJECTOR
AdBlue/DEF HOSE
AdBlue/DEF TANK HEATING VALVE
ENGINE SYSTEM
LAYOUT OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
INTAKE AND EXHAUST SYSTEM PARTS
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM
FUNCTION OF INTAKE AND EXHAUST SYSTEM
AIR CLEANER
INTAKE AIR HEATER
ENGINE MAIN BODY PARTS
CYLINDER HEAD
CYLINDER BLOCK
MAIN MOVING PARTS
VIBRATION DAMPER
TIMING GEAR
FRONT COVER
VALVE SYSTEM
FLYWHEEL AND FLYWHEEL HOUSING
TURBOCHARGER SYSTEM
CIRCUIT DIAGRAM OF VGT SYSTEM
FUNCTION OF VGT SYSTEM
VGT
EGR SYSTEM
EGR VALVE
EGR COOLER
KCCV SYSTEM
KCCV VENTILATOR
KDPF
KDOC
LUBRICATION SYSTEM
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
LUBRICATION SYSTEM CIRCUIT DIAGRAM
LUBRICATION SYSTEM CIRCUIT DIAGRAM
ENGINE OIL PUMP
ENGINE BOOST OIL PUMP
ENGINE OIL FILTER
ENGINE OIL COOLER
ENGINE OIL REGULATOR VALVE
SAFETY VALVE OF ENGINE OIL
ENGINE OIL PAN
FUEL SYSTEM
LAYOUT DRAWING OF FUEL SYSTEM PARTS
FUEL SYSTEM CIRCUIT DIAGRAM
FUNCTION OF FUEL SYSTEM
SUPPLY PUMP
FUEL PREFILTER
FUEL MAIN FILTER
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
COOLING SYSTEM CIRCUIT DIAGRAM
COOLING SYSTEM CIRCUIT DIAGRAM
DRIVE PULLEY
WATER PUMP
THERMOSTAT
ELECTRICAL SYSTEM
COMPONENT PARTS OF ELECTRICAL SYSTEM
ALTERNATOR
STARTING MOTOR
ENGINE WIRING HARNESS
ENGINE CONTROLLER
SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
STRUCTURE OF AMBIENT PRESSURE SENSOR
FUNCTION OF AMBIENT PRESSURE SENSOR
STRUCTURE OF ENGINE OIL PRESSURE SWITCH
FUNCTION OF ENGINE OIL PRESSURE SWITCH
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR
STRUCTURE OF COOLANT TEMPERATURE SENSOR
FUNCTION OF COOLANT TEMPERATURE SENSOR
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR
STRUCTURE OF COMMON RAIL PRESSURE SENSOR
FUNCTION OF COMMON RAIL PRESSURE SENSOR
STRUCTURE OF EGR VALVE LIFT SENSOR
FUNCTION OF EGR VALVE LIFT SENSOR
STRUCTURE OF VGT SPEED SENSOR
FUNCTION OF VGT SPEED SENSOR
STRUCTURE OF VGT POSITION SENSOR
FUNCTION OF VGT POSITION SENSOR
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR
STRUCTURE OF CRANKCASE PRESSURE SENSOR
FUNCTION OF CRANKCASE PRESSURE SENSOR
STRUCTURE OF ENGINE OIL LEVEL SENSOR
FUNCTION OF ENGINE OIL LEVEL SENSOR
STRUCTURE OF AIR CLEANER CLOGGING SENSOR
FUNCTION OF AIR CLEANER CLOGGING SENSOR
STRUCTURE OF WATER-IN-FUEL SENSOR
FUNCTION OF WATER-IN-FUEL SENSOR
STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR
STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR
FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR
STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)
FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)
20 STANDARD VALUE TABLE
CONTENTS
ABBREVIATION LIST
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (PC170LC-11)
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC210LC-11, PC210LCI-11)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC240LC-11)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8, WA270-8E0)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8, WA320-8E0)
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (HB215LC-3)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (PC170LC-11)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (WA200-8)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (BR380JG-3)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC210LC-11, PC210LCI-11)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC240LC-11)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC290LC-11, PC290LCI-11)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA270-8, WA270-8E0)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA320-8, WA320-8E0)
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA380-8)
50 DISASSEMBLY AND ASSEMBLY
CONTENTS
ABBREVIATION LIST
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
ENGINE SYSTEM
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)
METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)
METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3)
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)
METHOD FOR DISASEMBLING ENGINE GENERALLY (6D107E-3)
METHOD FOR ASEMBLING ENGINE GENERALLY (6D107E-3)
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3)
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3)
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3)
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (6D107E-3)
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (6D107E-3)
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3)
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3)
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3)
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3)
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (6D107E-3)
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (6D107E-3)
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)
METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3)
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3)
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3)
METHOD FOR REMOVING ENGINE REAR OIL SEAL (6D107E-3)
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (6D107E-3)
60 MAINTENANCE STANDARD
CONTENTS
ABBREVIATION LIST
ENGINE SYSTEM
INTAKE AND EXHAUST SYSTEM PARTS
MAINTENANCE STANDARD OF VGT
MAINTENANCE STANDARD OF VGT
ENGINE MAIN BODY PARTS
MAINTENANCE STANDARD OF CYLINDER HEAD
MAINTENANCE STANDARD OF CYLINDER BLOCK
MAINTENANCE STANDARD OF CRANKSHAFT
MAINTENANCE STANDARD OF PISTON
MAINTENANCE STANDARD OF CONROD
MAINTENANCE STANDARD OF VIBRATION DAMPER
MAINTENANCE STANDARD OF TIMING GEAR
MAINTENANCE STANDARD OF CAMSHAFT
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE
MAINTENANCE STANDARD OF ROCKER ARM
MAINTENANCE STANDARD OF TAPPET
MAINTENANCE STANDARD OF FLYWHEEL
LUBRICATION SYSTEM
MAINTENANCE STANDARD OF ENGINE OIL PUMP
INDEX
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