Komatsu 107E-3 SERIES Series Engine Shop Manual SEN06502-20 – PDF DOWNLOAD

Komatsu 107E-3 SERIES Series Engine Shop Manual SEN06502-20 – PDF DOWNLOAD

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Komatsu 107E-3 SERIES Series Engine Shop Manual SEN06502-20 – PDF DOWNLOAD

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Komatsu 107E-3 SERIES Series Engine Shop Manual SEN06502-20 – PDF DOWNLOAD

The Komatsu 107E-3 SERIES engine is a diesel engine used in various heavy-duty equipment such as bulldozers, excavators, and other construction and mining equipment. The Komatsu 107E-3 SERIES engine Shop Manual, SEN06502-20, provides detailed information on the maintenance, repair, and overhaul of the engine.

• The manual includes comprehensive information on the engine’s mechanical and electrical systems, as well as instructions for maintenance tasks such as oil changes, air and fuel filter replacements, and more. It also includes troubleshooting information to help diagnose and repair any engine issues, as well as detailed schematics and diagrams to aid in the repair process.
• The manual also covers the removal and installation of engine components, including the cylinder head, pistons, crankshaft, and other internal engine parts. Additionally, it provides specifications and tolerances for each component, as well as procedures for engine overhaul and rebuilding.
• Overall, the Komatsu 107E-3 SERIES engine Shop Manual is an essential resource for anyone responsible for maintaining or repairing the engine. It provides detailed information to help ensure that the engine is running smoothly and efficiently, and can help to minimize downtime and reduce the costs associated with repairs.

TABLE OF CONTENTS:

Komatsu 107E-3 SERIES Series Engine Shop Manual SEN06502-20 – PDF DOWNLOAD

COVER…………………………………………………………………………………………………………. 1
00 INDEX AND FOREWORD………………………………………………………………………………………….. 3
INDEX…………………………………………………………………………………………………….. 4
ABBREVIATION LIST………………………………………………………………………………………….. 7
FOREWORD, SAFETY, BASIC INFORMATION………………………………………………………………………….. 13
HOW TO READ THE ENGINE SHOP MANUAL……………………………………………………………………….. 13
SAFETY NOTICE FOR OPERATION……………………………………………………………………………… 15
PRECAUTIONS TO PREVENT FIRE……………………………………………………………………………… 23
ACTIONS IF FIRE OCCURS………………………………………………………………………………….. 25
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS………………………………………………………………. 26
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS……………………………………………………………… 27
PRECAUTIONS FOR DEF…………………………………………………………………………………….. 28
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…………………………………………………………. 28
PRECAUTIONS FOR ADDING………………………………………………………………………………. 28
PRECAUTIONS FOR STORING……………………………………………………………………………… 28
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE……………………………………………………………….. 28
THE OTHER PRECAUTIONS……………………………………………………………………………….. 28
STORE AdBlue/DEF……………………………………………………………………………………….. 29
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT………………………………………………………………. 30
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…………………………………………………….. 33
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT……………………………………………………………… 40
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…………………………………………………………….. 42
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…………………………………………………………… 43
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER……………………………………………………………… 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…………………………………….. 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…………………………………….. 45
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…………………………………….. 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS………………………………………………….. 48
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…………………………………………………… 52
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR……………………………………………. 53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL………………………………………….. 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH………………………………………….. 56
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE……………………………………… 58
HOW TO READ ELECTRICAL WIRE CODE…………………………………………………………………………. 59
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD……………………………………………………………… 63
STANDARD TIGHTENING TORQUE TABLE…………………………………………………………………………. 66
CONVERSION TABLE……………………………………………………………………………………….. 73
01 SPECIFICATIONS……………………………………………………………………………………………… 79
CONTENTS………………………………………………………………………………………………….. 80
ABBREVIATION LIST………………………………………………………………………………………….. 82
SPECIFICATIONS…………………………………………………………………………………………….. 88
OUTLINE OF EXHAUST GAS REGULATION………………………………………………………………………… 88
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION…………………………………………………. 89
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION…………………………………………………. 90
LIST OF APPLICABLE MACHINES: 107E-3………………………………………………………………………. 91
SPECIFICATIONS…………………………………………………………………………………………. 92
SPECIFICATIONS: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)……………………………………. 92
SPECIFICATIONS: SAA4D107E-3 (HB215LC-3)……………………………………………………………….. 93
SPECIFICATIONS: SAA4D107E-3 (PC170LC-11)………………………………………………………………. 94
SPECIFICATIONS: SAA4D107E-3 (WA200-8)…………………………………………………………………. 95
SPECIFICATIONS: SAA6D107E-3 (BR380JG-3, BR380JG-3E0)……………………………………………………. 96
SPECIFICATIONS: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)……………………………………. 97
SPECIFICATIONS: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)…………………………….. 98
SPECIFICATIONS: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)……………………………………….. 99
SPECIFICATIONS: SAA6D107E-3 (PC210LC-11, PC210LCI-11, PC210LCI-11E0)………………………………………100
SPECIFICATIONS: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)…………………………………………………101
SPECIFICATIONS: SAA6D107E-3 (PC240LC-11)……………………………………………………………….102
SPECIFICATIONS: SAA6D107E-3 (PC290LC-11, PC290LCI-11)……………………………………………………103
SPECIFICATIONS: SAA6D107E-3 (WA270-8, WA270-8E0)………………………………………………………..104
SPECIFICATIONS: SAA6D107E-3 (WA320-8, WA320-8E0)………………………………………………………..105
SPECIFICATIONS: SAA6D107E-3 (WA380-8)………………………………………………………………….106
ENGINE GENERAL VIEW……………………………………………………………………………………..107
ENGINE GENERAL VIEW: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)………………………………..107
ENGINE GENERAL VIEW: SAA4D107E-3 (HB215LC-3)……………………………………………………………111
ENGINE GENERAL VIEW: SAA4D107E-3 (PC170LC-11)…………………………………………………………..115
ENGINE GENERAL VIEW: SAA4D107E-3 (WA200-8)……………………………………………………………..119
ENGINE GENERAL VIEW: SAA6D107E-3 (BR380JG-3, BR380JG-3E0)………………………………………………..123
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)………………………………..127
ENGINE GENERAL VIEW: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)…………………………131
ENGINE GENERAL VIEW: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)……………………………………135
ENGINE GENERAL VIEW: SAA6D107E-3 (PC210LC-11, PC210LCI-11, PC210LCI-11E0)………………………………….139
ENGINE GENERAL VIEW: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)…………………………………………….143
ENGINE GENERAL VIEW: SAA6D107E-3 (PC240LC-11, PC290LC-11, PC290LCI-11)…………………………………….147
ENGINE GENERAL VIEW: SAA6D107E-3 (WA270-8, WA270-8E0)……………………………………………………151
ENGINE GENERAL VIEW: SAA6D107E-3 (WA320-8, WA320-8E0)……………………………………………………155
ENGINE GENERAL VIEW: SAA6D107E-3 (WA380-8)……………………………………………………………..159
ENGINE PERFORMANCE CURVE…………………………………………………………………………………163
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)……………………………163
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (HB215LC-3)……………………………………………………….164
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (PC170LC-11)………………………………………………………165
ENGINE PERFORMANCE CURVE: SAA4D107E-3 (WA200-8)…………………………………………………………166
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (BR380JG-3, BR380JG-3E0)……………………………………………167
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)……………………………168
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)…………………….169
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)……………………………….170
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC210LC-11, PC210LCI-11, PC210LCI-11E0)……………………………..171
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)………………………………………..172
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC240LC-11)………………………………………………………173
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)…………………………………………..174
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA270-8, WA270-8E0)……………………………………………….175
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA320-8, WA320-8E0)……………………………………………….176
ENGINE PERFORMANCE CURVE: SAA6D107E-3 (WA380-8)…………………………………………………………177
10 STRUCTURE AND FUNCTION……………………………………………………………………………………….179
CONTENTS…………………………………………………………………………………………………..180
ABBREVIATION LIST…………………………………………………………………………………………..183
UREA SCR SYSTEM…………………………………………………………………………………………….189
LAYOUT DRAWING OF UREA SCR SYSTEM…………………………………………………………………………189
UREA SCR SYSTEM DIAGRAM………………………………………………………………………………….197
UREA SCR SYSTEM DIAGRAM………………………………………………………………………………….199
FUNCTION OF UREA SCR SYSTEM………………………………………………………………………………200
FUNCTION OF UREA SCR SYSTEM………………………………………………………………………………201
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM…………………………………………………………………..201
INDUCEMENT STRATEGY………………………………………………………………………………….204
COMPONENT PARTS OF UREA SCR SYSTEM………………………………………………………………………..223
AdBlue/DEF MIXING TUBE……………………………………………………………………………….223
SCR ASSEMBLY………………………………………………………………………………………..225
AdBlue/DEF TANK……………………………………………………………………………………..229
AdBlue/DEF PUMP……………………………………………………………………………………..231
AdBlue/DEF INJECTOR………………………………………………………………………………….232
AdBlue/DEF HOSE……………………………………………………………………………………..233
AdBlue/DEF TANK HEATING VALVE…………………………………………………………………………234
ENGINE SYSTEM………………………………………………………………………………………………235
LAYOUT OF ENGINE COMPONENTS………………………………………………………………………………235
LAYOUT DRAWING OF ENGINE COMPONENTS……………………………………………………………………235
LAYOUT DRAWING OF ENGINE COMPONENTS……………………………………………………………………238
INTAKE AND EXHAUST SYSTEM PARTS…………………………………………………………………………..239
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM…………………………………………………………….239
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM…………………………………………………………….240
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM………………………………………………………………241
FUNCTION OF INTAKE AND EXHAUST SYSTEM………………………………………………………………….241
AIR CLEANER…………………………………………………………………………………………243
INTAKE AIR HEATER……………………………………………………………………………………245
ENGINE MAIN BODY PARTS…………………………………………………………………………………..246
CYLINDER HEAD……………………………………………………………………………………….246
CYLINDER BLOCK………………………………………………………………………………………248
MAIN MOVING PARTS……………………………………………………………………………………250
VIBRATION DAMPER…………………………………………………………………………………….254
TIMING GEAR…………………………………………………………………………………………255
FRONT COVER…………………………………………………………………………………………256
VALVE SYSTEM………………………………………………………………………………………..257
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………………………………260
TURBOCHARGER SYSTEM……………………………………………………………………………………..262
CIRCUIT DIAGRAM OF VGT SYSTEM…………………………………………………………………………262
FUNCTION OF VGT SYSTEM……………………………………………………………………………….263
VGT………………………………………………………………………………………………..265
EGR SYSTEM………………………………………………………………………………………….271
EGR VALVE…………………………………………………………………………………………..276
EGR COOLER………………………………………………………………………………………….280
KCCV SYSTEM…………………………………………………………………………………………283
KCCV VENTILATOR……………………………………………………………………………………..287
KDPF……………………………………………………………………………………………….289
KDOC……………………………………………………………………………………………….293
LUBRICATION SYSTEM………………………………………………………………………………………296
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS……………………………………………………………..296
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS……………………………………………………………..298
LUBRICATION SYSTEM CIRCUIT DIAGRAM…………………………………………………………………….299
LUBRICATION SYSTEM CIRCUIT DIAGRAM…………………………………………………………………….300
ENGINE OIL PUMP……………………………………………………………………………………..301
ENGINE BOOST OIL PUMP………………………………………………………………………………..302
ENGINE OIL FILTER……………………………………………………………………………………303
ENGINE OIL COOLER……………………………………………………………………………………304
ENGINE OIL REGULATOR VALVE……………………………………………………………………………305
SAFETY VALVE OF ENGINE OIL……………………………………………………………………………306
ENGINE OIL PAN………………………………………………………………………………………307
FUEL SYSTEM…………………………………………………………………………………………….308
LAYOUT DRAWING OF FUEL SYSTEM PARTS……………………………………………………………………308
FUEL SYSTEM CIRCUIT DIAGRAM…………………………………………………………………………..311
FUNCTION OF FUEL SYSTEM………………………………………………………………………………312
SUPPLY PUMP…………………………………………………………………………………………314
FUEL PREFILTER………………………………………………………………………………………315
FUEL MAIN FILTER…………………………………………………………………………………….316
COOLING SYSTEM………………………………………………………………………………………….317
LAYOUT DRAWING OF COOLING SYSTEM PARTS…………………………………………………………………317
COOLING SYSTEM CIRCUIT DIAGRAM………………………………………………………………………..318
COOLING SYSTEM CIRCUIT DIAGRAM………………………………………………………………………..319
DRIVE PULLEY………………………………………………………………………………………..320
WATER PUMP………………………………………………………………………………………….322
THERMOSTAT………………………………………………………………………………………….323
ELECTRICAL SYSTEM…………………………………………………………………………………………..324
COMPONENT PARTS OF ELECTRICAL SYSTEM………………………………………………………………………324
ALTERNATOR………………………………………………………………………………………….324
STARTING MOTOR………………………………………………………………………………………330
ENGINE WIRING HARNESS………………………………………………………………………………..332
ENGINE CONTROLLER……………………………………………………………………………………336
SENSOR…………………………………………………………………………………………………350
LAYOUT DRAWING OF ENGINE SENSOR……………………………………………………………………….350
LAYOUT DRAWING OF ENGINE SENSOR……………………………………………………………………….352
STRUCTURE OF AMBIENT PRESSURE SENSOR…………………………………………………………………..354
FUNCTION OF AMBIENT PRESSURE SENSOR……………………………………………………………………354
STRUCTURE OF ENGINE OIL PRESSURE SWITCH………………………………………………………………..355
FUNCTION OF ENGINE OIL PRESSURE SWITCH…………………………………………………………………355
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR………………………………………………356
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR……………………………………………….356
STRUCTURE OF COOLANT TEMPERATURE SENSOR………………………………………………………………..357
FUNCTION OF COOLANT TEMPERATURE SENSOR…………………………………………………………………357
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR………………………………………………………………358
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………….358
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR………………………………………………………………359
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR……………………………………………………………….359
STRUCTURE OF COMMON RAIL PRESSURE SENSOR……………………………………………………………….360
FUNCTION OF COMMON RAIL PRESSURE SENSOR………………………………………………………………..360
STRUCTURE OF EGR VALVE LIFT SENSOR…………………………………………………………………….361
FUNCTION OF EGR VALVE LIFT SENSOR……………………………………………………………………..361
STRUCTURE OF VGT SPEED SENSOR…………………………………………………………………………362
FUNCTION OF VGT SPEED SENSOR………………………………………………………………………….362
STRUCTURE OF VGT POSITION SENSOR………………………………………………………………………363
FUNCTION OF VGT POSITION SENSOR……………………………………………………………………….363
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………….364
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………..364
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR………………………………………..365
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR…………………………………………365
STRUCTURE OF CRANKCASE PRESSURE SENSOR…………………………………………………………………366
FUNCTION OF CRANKCASE PRESSURE SENSOR………………………………………………………………….366
STRUCTURE OF ENGINE OIL LEVEL SENSOR…………………………………………………………………..367
FUNCTION OF ENGINE OIL LEVEL SENSOR……………………………………………………………………367
STRUCTURE OF AIR CLEANER CLOGGING SENSOR……………………………………………………………….368
FUNCTION OF AIR CLEANER CLOGGING SENSOR………………………………………………………………..368
STRUCTURE OF WATER-IN-FUEL SENSOR……………………………………………………………………..369
FUNCTION OF WATER-IN-FUEL SENSOR………………………………………………………………………369
STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)…………………………………………………..370
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)……………………………………………………370
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR…………………………………………………………..371
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR……………………………………………………………371
STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR…………………………………………………………….372
FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR……………………………………………………………..372
STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)………………………………………………..373
FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)…………………………………………………373
20 STANDARD VALUE TABLE…………………………………………………………………………………………375
CONTENTS…………………………………………………………………………………………………..376
ABBREVIATION LIST…………………………………………………………………………………………..377
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………………………383
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)…………………………383
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (HB215LC-3)…………………………………………………….386
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (PC170LC-11)……………………………………………………389
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (WA200-8)………………………………………………………392
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (BR380JG-3, BR380JG-3E0)…………………………………………395
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)…………………………398
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)………………….401
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)…………………………….404
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC210LC-11, PC210LCI-11, PC210LCI-11E0)…………………………..407
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)……………………………………..410
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC240LC-11)……………………………………………………413
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (PC290LC-11, PC290LCI-11)………………………………………..416
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA270-8, WA270-8E0)…………………………………………….419
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA320-8, WA320-8E0)…………………………………………….422
STANDARD VALUE TABLE FOR ENGINE: SAA6D107E-3 (WA380-8)………………………………………………………425
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD………………………………………………………………428
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (D51EX-24, D51EXI-24, D51PX-24, D51PXI-24)…………428
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (HB215LC-3)…………………………………….430
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (PC170LC-11)……………………………………431
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (WA200-8)………………………………………433
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (BR380JG-3, BR380JG-3E0)…………………………435
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24, D61EXI-24, D61PX-24, D61PXI-24)…………437
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (D61EX-24E0, D61EXI-24E0, D61PX-24E0, D61PXI-24E0)….439
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (GD655-6, GD655-7, GD675-6, GD675-7E0)…………….441
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC210LC-11, PC210LCI-11, PC210LCI-11E0)…………..443
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC228USLC-11, PC238USLC-11)……………………..445
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC240LC-11)……………………………………447
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (PC290LC-11, PC290LCI-11)………………………..449
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA270-8, WA270-8E0)…………………………….451
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA320-8, WA320-8E0)…………………………….453
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D107E-3 (WA380-8)………………………………………455
50 DISASSEMBLY AND ASSEMBLY……………………………………………………………………………………..457
CONTENTS…………………………………………………………………………………………………..458
ABBREVIATION LIST…………………………………………………………………………………………..459
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY………………………………………………………………..465
HOW TO READ THIS MANUAL………………………………………………………………………………….465
COATING MATERIALS LIST…………………………………………………………………………………..467
SPECIAL TOOLS LIST………………………………………………………………………………………471
SKETCHES OF SPECIAL TOOLS………………………………………………………………………………..473
ENGINE SYSTEM………………………………………………………………………………………………474
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)………………………………………………………..474
METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)……………………………………………………..474
METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3)………………………………………………………..501
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (6D107E-3)………………………………………………………..548
METHOD FOR DISASEMBLING ENGINE GENERALLY (6D107E-3)……………………………………………………..549
METHOD FOR ASEMBLING ENGINE GENERALLY (6D107E-3)………………………………………………………..574
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3)………………………………………………………….617
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3)……………………………………………………..617
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)……………………………………………………620
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (6D107E-3)………………………………………………………….623
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (6D107E-3)……………………………………………………..623
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (6D107E-3)……………………………………………………625
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3)…………………………………………………………628
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3)…………………………………………………….628
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3)…………………………………………………..630
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (6D107E-3)…………………………………………………………633
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (6D107E-3)…………………………………………………….633
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (6D107E-3)…………………………………………………..635
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)………………………………………………………….637
METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3)……………………………………………………..637
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3)……………………………………………………638
REMOVE AND INSTALL ENGINE REAR OIL SEAL (6D107E-3)………………………………………………………….641
METHOD FOR REMOVING ENGINE REAR OIL SEAL (6D107E-3)……………………………………………………..641
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (6D107E-3)……………………………………………………641
60 MAINTENANCE STANDARD…………………………………………………………………………………………645
CONTENTS…………………………………………………………………………………………………..646
ABBREVIATION LIST…………………………………………………………………………………………..647
ENGINE SYSTEM………………………………………………………………………………………………653
INTAKE AND EXHAUST SYSTEM PARTS…………………………………………………………………………..653
MAINTENANCE STANDARD OF VGT…………………………………………………………………………..653
MAINTENANCE STANDARD OF VGT…………………………………………………………………………..654
ENGINE MAIN BODY PARTS…………………………………………………………………………………..655
MAINTENANCE STANDARD OF CYLINDER HEAD………………………………………………………………….655
MAINTENANCE STANDARD OF CYLINDER BLOCK…………………………………………………………………657
MAINTENANCE STANDARD OF CRANKSHAFT…………………………………………………………………….660
MAINTENANCE STANDARD OF PISTON………………………………………………………………………..662
MAINTENANCE STANDARD OF CONROD………………………………………………………………………..663
MAINTENANCE STANDARD OF VIBRATION DAMPER……………………………………………………………….665
MAINTENANCE STANDARD OF TIMING GEAR……………………………………………………………………666
MAINTENANCE STANDARD OF CAMSHAFT………………………………………………………………………667
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE…………………………………………………………..669
MAINTENANCE STANDARD OF ROCKER ARM…………………………………………………………………….671
MAINTENANCE STANDARD OF TAPPET………………………………………………………………………..672
MAINTENANCE STANDARD OF FLYWHEEL………………………………………………………………………673
LUBRICATION SYSTEM………………………………………………………………………………………675
MAINTENANCE STANDARD OF ENGINE OIL PUMP………………………………………………………………..675
INDEX………………………………………………………………………………………………………….677