FD100~160E-8

Page 1/13
 The new engine adopts the latest technologies that
supports both reliable power and environment-
friendliness
EPA Tier 3/Euro IIIA compliant SAA6D107E-1
engine adopts KOMATSU’s latest engine
technologies and dramatically reduces NOx and
PM in exhaust.
Each system successfully interacts for better fuel
efficiency and lowered running noises. Reliable
fuel filters keep systems performance high and
protect components.
Rated Output : 122KW @ 2,200 rpm

Page 2/13
 Environment & Economy is the
world for the next generation.

Engine Technologies
Electronic Control System
Heavy Duty HPCR System
New Combustion System
Air to Air Charge Air Cooling System

Page 3/13
 Electronic Control System
The center control unit quickly processes signals from various
sensors on the vehicle in order to produce a maximum power in
any condition eliminating possible loss in engine performance.

Heavy Duty HPCR system

High pressure compressed fuel store in a
accumulator chamber so-called common
rail, is injected into each cylinder
sufficiently at a power timing by an
ECU(Electric Controlled Unit). This
HPCR(High Pressure Common Rail)
system promises optimized fuel burning
and reduced fuel consumption.

Page 4/13
 New Combustion System
A unique shape of the combustion chamber
on the top surface of each piston facilitates
complete fuel burning by optimizing
conditions, timings and amounts of fuel
injection, which helps reduce NOx and PM in
exhaust, as well as fuel consumption.

Air to Air Charge Air Cooling system

This system cools high temperature and
supplies it to cylinders.
As a result, the system maximizes
combustion efficiency and emission
performance, facilitating high output
while reducing NOx and fuel
consumption.

Page 5/13
Page 6/13
 Improvements from Current Model

1, New Komatsu SAA6D107 Engine

2, New Instrument Panel
3, Hydraulic Suspension cab
4, Wider Front View
5, New Operator Seat
6, Wet Disc Brake (Option)
7, Operator Presence System (Option)

Page 7/13
 １、New Komatsu SAA6D107 Engine

Tier 3 Engine

Page 8/13
 2, New Instrument Panel

Option

Page 9/13
 3, Hydraulic Suspension Cab

Komatsu’s original HSC (Hydraulic suspension cab) system allows the

operator’s cab to isolate the truck’s body to reduce running vibration
caused by a ground surface or the engine. This enhances comfortable
operating environment.

Page 10/13
 4, Wider Front View

Wide visibility has been achieved by positioning the chain mast outside.
Operatability and safety has been further enhance.

Page 11/13
 5, New Operator Seat

Page 12/13
 6, Wet Disc Brake (Option)

Page 13/13
 7, Operator Presence System (Option)

Page 14/13
 7-1 Operator Presence System (Option)
1,Controller ….24V (BX50 12V) Software and Size is same as BX50 Controller
2,Steering Wheel Synchronize System is not equipped

Page 15/13
 Tier 3 Engine

Emission Regulation

Page 16/13
 Table of Contents
1. Emission Regulation
1-1. Requirement
1-2. Emission Standard EPA / EU
1-3. Consent Decree
1-4. Regulation Contents
1-5. Emission Standard History
1-6. EPA Medium Range
1-7. 8-Mode Test Cycle – ISO 8178
1-8. Name Plate
1-9. Useful Life
２. Maintain or Rebuild Engines

Page 17/13
 1-1. Requirement
 Produce engine within the limit values of
gaseous emission

 Install engine which meets the limit values

 Affix engine plate so that the machine meets
the regulations

 Emission standard must be met over the entire

Useful Life
 Maintain or Rebuild engines certified to EPA
standard

Page 18/13
 1-2. Emission Standard EPA / EU
☆Gross power Limit values NOx/HC/PM (g/kw･h) * denotets NOx+NMHC
Region ☆Power range Usage Year
kw ,(PS) Purpose 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17
37<=kW<56 *7.5/0.40 *4.7/0.30(opt.1) *4.7/0.03(opt.1)
(50～76) *4.7/0.40(opt.2) *4.7/0.03(opt.2)
56<=kW<75 9.2/-/- *7.5/0.40 *4.7/0.40
(76～102) Tier 1 3.4/0.19/0.02 0.40/0.19/0.02
U 75<=kW<130 All *6.6/0.30 *4.0/0.30 Tier 4 Tier 4
(102～177) construction (transition period)
S 130<=kW<225 equipment *6.6/0.20
(177～306) and portable Tier 2 2.0/0.19/0.02
A 225<=kW<450 generators *4.0/0.20 Tier 3 Tier 4 0.40/0.19/0.02
(306～612) (transition period)
450<=kW<=560 *6.4/0.20 Tier 4
(612～761)
560<kW except portable *6.4/0.20 3.5/0.19/0.04
(761～) generators 9.2/1.3/0.54 Tier 2 3.5/0.4/0.1 Tier 4
560<kW<=900 Portable Tier 1 Tier 4
(761～1224) generators (transition period) 0.67/0.19/0.03
900<=kW 0.67/0.4/0.1
(1224～)
37<=kW<56 9.2/0.85 7.0/1.3/0.40 *4.7/0.40 *4.7/0.025
(50～76) All
E 56<=kW<75 construction *4.7/0.40
(76～102) equipment 3.3/0.19/0.025 0.40/0.19/0.025
75<=kW<130 (portable 9.2/0.70 6.0/1.0/0.30 *4.0/0.30 3rd stage B 4th stage
U (102～177) generators 1st stage 2nd stage 3rd stage A
130<=kW<560 shall be applied 9.2/1.3 6.0/1.0/0.20 *4.0/0.20 2.0/0.19/0.025 0.40/0.19/0.025
(177～761) from 2007) 0.54

Page 19/13
 1-3. Consent Decree
Consent Decree and Komatsu Position
(1) Consent Decree
The engine manufactures listed below have to meet EPA non road Tier3 emission
regulation for the power between 300-750 HP from Jan. 1, 2005, instead of Jan. 1, 2006
which EPA stipulates due to the Consent Decree settled between these manufacturers
and EPA.
( The Consent Decree is the resolution for the claims of the United States against these
manufacturers for alleged violations of the Clean Air Act.)
Caterpillar, Navistar, DDC, Renault, Mack, Volvo, Cummins

(2) Komatsu Position

Jan. 1, 2005 is not the Tier3 deadline for Komatsu being different from these
manufacturers. So, Komatsu is not in the position to rush into Tier3 hastily.

Komatsu Tier3 machines will be introduced according to EPA regulation

with sufficient preparation for the maximum quality.

Page 20/13
 1-4. Regulation Contents
Contents of USA (EPA Tier3), EU (EU Stage3A), JAPAN Regulation (For: 130kW-560kW range)
2005 2006 2007 Details Certification

U CAT, Volvo, 1. Production regulation Certification

Cummins etc EPA Tier3 can be
S have to meet 1 2. Transitional measures obtained one
year earlier (by Nox+HC：4.0 Tier1,Tier2 engines may be produced after year before
A Consent Decree of
2006 up to the specified limit, but inventory enforcement
1998 with EPA) PM：0.2
（225～560ｋW） buildup (stockpiling) NOT allowed.
E 1. Sales regulation No timing
The non-compliant machine must be shipped limitation for
U EU Stage3A obtaining
out to the DBs by Dec 30, 2005, otherwise Certification.
Exhaust gas
Nox+HC：4.0 selling to the market is NOT allowed.
unit: g/kWh PM：0.2 2. Transitional measures
Engines produced by Dec 30 2005 can be
sold until Dec 30 2007; i.e. inventory
buildup (stockpiling) is possible.
1. Sales regulation No timing
EU Dynamic Noise Stage2 The non-compliant machine must be shipped limitation for
Output: 500kW and under obtaining
out and invoiced to the DBs by Jan 2, 2006, Certification.
3dB lower than the Stage1 otherwise selling to the market is NOT allowed.
2. Transitional measures NONE
J MLIT 1. Legislation to be established Apr 2005, Yet to be
(former Ministry Nox: 3.6 announced
A Enforcement to be Oct 2006.
of Transport) HC：0.4
P 2. Regulation values are virtually determined in
PM：0.17
A the 6th committee report.
FA Soot: 25%
N The world strictest emissions Regulation

Page 21/13
 1-5. Emission Standard History
82% reduction
Oxides of Nitrogen (g/bhp-hr)

of NOx
Unregulated level 54% (1996-2006)
15

10 35%
40%
Tier 1
5 ?
Tier 2 ?

Tier 3
0 Tier 4

1980 1985 1990 1995 2000 2005 2010 2015 2020

Page 22/13
 1-6. EPA Medium Range

Page 23/13
 1-7. 8-Mode Test Cycle - ISO
8178 Weighting 10%
Torque 100%
15%
10%
75%
15% Tier 3
10% Design Limits
50%
15% 3.0 gr/hp--hr
(NOx+NMHC)
Torque (%)
0.15 g/hp-hr PM
10%

15%
Engine
Speed
Idle Peak Torque Rated

Page 24/13
 1-8. Name Plate
Installing a view window for name plate

Engine hood
Nameplate view
Main nameplate window
or
supplementary
nameplate

Page 25/13
 1-9. Useful Life
Emission standards must be met over the entire useful life
of the engine

Page 26/13
 ２. Maintain or Rebuild Engines
1. Mechanic must have a reasonable technical basis
2. Don’t erase or reset emission-related codes without
diagnosing
3. Keep the following records for at least two years
a. SMR
b. Work performed
c. Components you worked on, including a list of
parts and components
d. Parameter adjustments
e. Emission-related codes
Page 27/13
 107 Engine
Common Rail

Page 282828/13
 RED : For Poor Fuel Countries
Flow of fuel (3D)
Water Separator

Fuel main element 2U

Fuel air bleeder pump

Water sump
Extra 2U Fuel Filter

Fuel pre-element 10U

Page 29/13
 Flow of fuel
Injector

Pressure sensor
Common rail

Safety valve
Return block Supply pump

Fuel cooler
Not Used

Priming pump
Main filter
2U Pre-filter 10U
Crystal hole

Page 30/13
 Pre-filter

Filtering capacity: 10 microns

Maintenance: Every 500H
1

4
5

Page 31/13
 Fuel gear pump

Page 32/13
 Gear pump illustration

Page 33/13
 Fuel main filter

Filtering capacity: 2 microns

Maintenance: Every 1000H

Page 34/13
 Supply pump

Photo of pump upper view 6 4

1 5 Photo of pump front view

2 3

4 7

Page 35/13
 Supply pump illustration
Intake valve (3 in total)

Camshaft

Plunger (3 in total)

Page 36/13
 Common rail

Pressure sensor

Safety valve

Safety valve Pressure sensor

Page 37/13
 Injector

Fuel inlet port

Fuel return port

Injector installation hole

Page 38/13
 Sectional illustration of injector

2
3

4
Return fuel
1
Solenoid coil
5
Fuel inlet port
Nozzle needle

High pressure pipe

Page 39/13
 Measuring oil leakage from
safety valve

Page 40/13
 Measuring fuel pressure in the
low pressure fuel circuit

Adaptor: 6732-81-3170
O-ring: 6215-81-9710
Standard value
Low idling: 5.1 to 13.3 kg/cm2
Cranking: 3.1 to 11.3 kg/cm2

Page 41/13
 Measuring injector return
capacity (1)
1

Page 42/13
 Measuring injector return capacity by closing an
injector

Page 43/13
 Measuring injector return capacity (2)
Cummins Part No. 3164618
No hole provided
to this side

Cummins Part No. 4918354

Komatsu Part No.6754-71-5340

Standard value
Low idling: 180 cc/min

Page 44/13
 Replacement of Main filter

Remember to replace a small diameter

rubber seal to the thread portions when
replacing the main filter

Page 45/13
 Replacement of pre-fuel element

"First Try and Understand Advantages"

Reinforced type
cartridge removing wrench

Page 46/13
 Controller contour/connector
1/2 CM870 / CM850 ASSEMBLY
52.7
4-4-00 100.2

280.4 52.7

226.1

24.8

Connector type No. Back shell type No.

Power supply harness DTP06-4S New setting required
Engine harness DRC26-60S-05 0528-002-6005
Machine body harness DRC26-50S-04 0528-001-5005
Page 47/13
 Controller contour/connector 2/2
50-pin machine body
4-pin power 60-pin engine
supply

107 engine controller mounting bracket

(Protection from the heat by thermal insulation effect)

ECM : Electronic Control Module

Page 48/13
 Power supply connector 4-pin
(DTP06-4S)

1 Battery power supply (-)

2 Battery power supply (-) 4-pin power

supply
3 Battery power supply (+)

4 Battery power supply (+)

60-pin
engine
50-pin
machine
body

Page 49/13
 Engine connector 60-pin (DRC26-60S-05)
Pin No.1

Pin No.60

4-pin power
supply

60-pin
engine
50-pin
machine
body

Page 50/13
 Machine body connector 50-pin (DRC26-50S-04)
Pin No.1
Pin No.50

4-pin power
supply

60-pin
engine
50-pin
machine
body

Page 51/13
 Environment resistant specifications
<Principal environment resistant items>
Actuating temperature: Ambient -40 to +105C

Vertical

Horizontal
Front-rear

Page 52/13
SAA6D107 and 114 engine control system
Service connector Key switch
* Dark current prevention: Prevents
Engine speed and position
Idle validation SW1
ECM current consumption and self-
Main pulse
Idle validation SW2 discharge of battery
Backup pulse
Throttle (fuel dial)
Injection control
Power train relay

Fuel feed pump (114 Eng only)

Injector #1
Injector #2
Injector #3 Communications via KOMNET
Injector #4 Transmitted to engine controller
Injector #5 1. LSI control
Injector #6 2. HSI control
Machine monitor 3. AS control
Fuel rail pressure Engine (panel) Throttle command
controller Throttle limit
Machine controller
Emission control #1 (pump controller) Throttle adjustment
Charge pressure 4. Power mode selection
Charge temperature Machine controller #2
(example: transmission 5. Cylinder cut-out
Ambient pressure controller)
No-injection cranking
Theft prevention
Engine monitor
Oil pressure switch Received from engine controller
Coolant temperature Power supply 1 (+) 1. Engine operation information
Power supply 2 (+) speed and output torque
Power supply 1 (-) 2. Error code
WIF (Water detection) Power supply 2 (-) 3. Monitoring information

Page 53/13
 Engine Ne rotation sensor (crankshaft)
Major functions
 Senses the top dead center of cylinders
No. 1 to 6 of the engine
 Applies the Hall element effect

Rotating ring TDC sensory notch

Ne rotation
sensor
Page 54/13
 About top dead center TDC
Directly
overhead
position

72 degrees to
the left

Position with TDC stamping and a

groove (on the circumference of the
damper)

1 to 6 reaches TDC when this groove and

Notch on the rotating ring stamped TDC are at position (P) overhead
matches Ne sensor
Rotate the position in the photo to the left 72
degrees to the right to attain TDC for 1 to 6

Page 55/13
 Engine G rotation sensor (camshaft)

Six (6) plus 1 grooves are

cut to the end of camshaft
Major functions
Senses a combusting cylinder
Applies the Hall element effect
G rotation sensor

Page 56/13
 Common rail pressure sensor
Major functions
Common rail internal pressure control

Common rail pressure sensor

Page 57/13
 Charge pressure and temperature
sensors

Major functions
Determining fuel for injection
Intake air preheating control

Charge pressure and

temperature sensors

Page 58/13
 Ambient pressure sensor

Major functions
Automatic altitude compensation and
fuel injection

Ambient
pressure sensor

Page 59/13
 Engine oil pressure switch
Major functions
Warning to hydraulic pressure drop
Protection of turbocharger

pressure switch

Page 60/13
EX50 Fuel system diagram
Pressure limiter

Common rail

* Return
check
Overflow valve
valve
Injector

Priming pump
Main filter

Fuel cooler
IMV valve
Gear pump
Supply pump Prefilter
Fuel tank

(1) Pressure limiter 1,850 bar (4) Return Check valve 0.48 bar * Zero-delivery choke (: dia. 0.4mm) Even if the valve
closes, little amount of fuel flows to the supply pump
plunger, this fuel is directed to the returning side via the
(2) Relief valve 105 bar to 13 bar (3) Bypass valve 0.1 bar choke to retain the state of zero-delivery
Normally no fuel flows

Page 61/13
Standard value for fuel return

Estimated causes of leakage and standard value

under normal condition
For checking leak from the pressure limiter, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
Defective pressure
limiter Pressure limiter At low idling time 0 cc (no leakage)
leakage
For checking leak capacity from the injector, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Defective pressure
(including high At cranking time (when
pressure piping starting disabled)
Injector return
inside the head) capacity At low idling time
(when starting
enabled) Measuring return
For checking return capacity from the supply pump, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
capacity from injector
Defective At cranking time (when
supply pump Return capacity from starting disabled)
supply pump
At low idling time (when
starting enabled)

Page 62/13
Removal and installation of injector
1. Apply engine oil to the O-ring on the injector and the
portion inserted to the head
(4) (3)
2. Temporarily install holder (2) to the injector, install
them in that state to the head tentatively, manually
fasten bolt (1) to attach to holder (2)
3. Tighten bolt (1) finely and alternately to press-fit the
injector and tighten by applying 10 Nm (10 Nm > torque
(1)
for temporary tightening)
(2)
4. Insert connection (3) and tighten with nut (4) with 15
Nm (apply oil to O-ring)
5. Loosen bolt (1) again
6. Tighten bolt (1) with 10 Nm.
7. Tighten connection nut (4) with 50 Nm

Removal and
installation of injector
Page 63/13
 Measuring fuel leakage from pressure limiter
(2) Injector return
Measure leakage as a means for judging
pressure limiter performance
Fuel cooler Tank
No leakage if normal
return connection

(1) Leak from

Pressure limiter pressure
limiter (3) Supply pump drain

Leakage
outlet port

Page 64/13
 Measuring fuel return from injector
Measure the return capacity as a means
for determining the injector performance (2) Injector return

Fuel cooler Tank

(2) return connection

(1) Leak from

(3) pressure
limiter (3) Supply pump drain

Reference value for measured return capacity: Engine Swing lock or arm relief time/30 sec.
in low idling/30 sec (2) Injector: 90 cc (3) Pump: 440 cc
(2) Injector: 40 cc (3) Pump: 400 cc
Page 65/13
 Measuring gear pump outlet port pressure

Engine in low idle revolution

Standard value: 5.1 kg/cm2 to 13.3 kg/cm2

At cranking time
Low
pressure (when starting disabled)
fuel circuit At low idling time
pressure
(when starting enabled)

Page 66/13
Page 67/13
 Contents
EX50 Engine Outline 3 Overflow valve 19
Means for Complying to the Next 5 Common Rail 20
Generation Emission Control Pressure Limiter Valve 21
DSA Piston (Deep Spray Angle) 6 Electronically controlled Injector 22
Engine L.H. side Appearance 7 Injector Wire Harness 23
Common Rail (High Pressure Common 8 Injector and High Pressure 24
Rail) Fuel System Connector
EX50 Fuel System Diagram 9 Injector Section Diagram 25
Supply Pump and Gear Pump 10 Injector Components 26
Supply Pump Pipe 11 Fuel Prefilter 27
IMV (Inlet Metering Valve) 12 Fuel Filter 28
Supply Pump Section Diagram 14 Fuel Low Pressure Line 29
(High pressure pump) Rear Gear Train 30
Supply Pump section diagram 15 Connecting Rod 31
Supply Pump and Gear Pump 17 Locker Arm 32
Gear Pump 18 Piston Cooling Nozzle 33
(Feed pump: Low pressure) Front Sea 34
Crank Case Breather 35

Page 68/13
 EX50 Engine Outline
Unit [High output]
Cylinder number x bore x stroke
* Increased emission
Engine displacement
* Output upgrading per projected area of
Aspiration
engine
Rated output/revolution
* Low speed torque upgrading with HPCR
C09 rated fuel consumption ratio

4 valves/cylinder

Low fuel consumption

* High injection pressure
* Multi-stage injection
* Injection timing control
ｺﾓﾝﾚｰﾙ
Common rail
Advanced combustion
technology
* Low NOx technology to
suppress deterioration of fuel
economy
ﾘﾔｷﾞﾔﾄﾚｰﾝ
Rear gear train

[Emission]
4 valves/cylinder Increased [Low noise]
intake air capacity * Supply pump drive torque
reduction
* Uniform fuel spray * Combustion noise reduction with
[Fuel air mix enhancement] pilot injection
* High injection pressure Rear gear train
* Multi-stage injection * Gear noise reduction
* Injection timing control Tappet cover discontinuation and
Advanced combustion ｴﾝｼﾞﾝﾏｳﾝﾄ
Engine mountECM
ECM integrated block structure
* Suppression of cover section
technology vibration with enhanced rigidity
* Low NOx technology High rigidity cylinder block
*Control compliance enabled * Vibration suppression with rib
without EGR layout, contour and change of skirt
contour

Page 69/13
 EX50 Engine Outline

High rigidity cylinder block

Standard large capacity F

sump oil pan

Page 70/13
 Means for complying to the next generation
emission control
Concept of fuel combustion

HPCR injector Optimized swirl

PM reduction with pilot Optimizes spray fuel and
and post injections air mixture -- PM reduction

Reduced protrusion at the center of the

fuel chamber
Promotes mixing of air with spray fuel

DSA (Deep Spray Angle) Chamfered combustion chamber rims

Suppresses fuel diffusion by having spray Prevents fuel spray flame from spreading
along the bottom of the combustion over the lower surface of the head -- PM
chamber -- NOx reduction reduction

Combustion flame area of spreading is

Protrusion at the center is lowered to controlled through optimized combustion Later combustion is induced to the chamfered portion
promote the mixing of air with spray chamber bottom-wall angle, subsequently to prevent the spreading of flame to the lower surface
to reduce PM suppressing NOx emission of the head ---PM reduction

Page 71/13
 DSA piston (Deep Spray Angle)
Head is ball-shaped

Page 72/13
 Common rail (High Pressure Common
Rail) fuel system
 Bosch HPCR pump (High
Pressure Common Rail)
 Common rail
 Electronically controlled
Injector

Page 74/13
EX50 Engine Fuel system diagram
Pressure limiter

Common rail

* Return
Overflow valve check
valve
Injector

Priming pump

Main filter

Fuel cooler
IMV valve
Gear pump
Supply pump
Prefilter

Fuel tank

* Even if Zero-delivery choke (: dia. 0.4mm) IMV valve is

(1) Pressure limiter 1,850 bar (3) Return check valve 0.48 bar closed, little amount of fuel flows to the supply pump plunger,
(2) Relief valve 105 bar to 13 bar (4) Bypass valve 0.1 bar this fuel is directed to the returning side via the choke to
retain the state of zero-delivery
Normally no fuel flows

Page 757575/13
 Supply Pump and Gear Pump

Gear pump
Supply pump

Page 76/13
 Supply Pump Pipe
IMV valve
(1) Gear pump inlet port (from prefilter)
(2) Gear pump outlet port (to main filter)
(3) Supply pump inlet port (from main filter)
(5)
(4) Supply pump outlet port (to common rail)
(5) Pump fuel return (to fuel cooler)

(1) (3)

(2)

(4)

Gear pump
Page 77/13
 IMV (Inlet Metering Valve)
Adjusts the amount of fuel from the gear pump to the
fuel pressure required by the engine and feed fuel to the
inlet port of the supply pump plunger
When the solenoid current is OFF, the piston is
pressed to the right by the force of spring. The triangle
slot connects to the fuel inlet port groove to maximize
the flow rate
When the current is ON, magnetic force of
proportional solenoid works on the armature to press
the piston to the left. The opening of the groove is
choked to reduce the flow rate.
Therefore, feed oil capacity is determined by the value
of the current to the solenoid
ピストン
Piston ママチュア
Armature

マグネットコア
Magnet core

ピストンのスロット
Piston slot
Fuel inlet port from the gear pump
ギヤーポンプからの燃料入口

スプリング
Spring ソレノイドコイル
Solenoid coil

Page 78/13
 IMV (Inlet Metering Valve)
operation

Page 79/13
 Supply Pump section diagram
Inlet check valve
(3 sets)

Inlet check valve

Cam lobe

Plunger (3 sets)

Outlet check valve

Bosch CP3.3 Supply Pump
CP3.3 pump
Gear ratio 1.33
Plunger dia mm 7.5
Stroke mm 8.2
Displacement/rev mm3 1087
Peak torque Nm 50
@ 1600bar

Page 81/13
 Supply pump operation

Page 82/13
 Supply Pump and Gear Pump
St.140/150 St.50/60

MPROP (ZME) Plungers St.10.1 St.130 St.140/150 St.130

Housing High Pressure Plugs Gear Pump High Pressure Connector

Balls

St.190

KÜV (Overflow Valve)l

St.90

Seal Plug

St.180.1/100
St.70
Flange
Screw Plugs

St.20/180.2/200 St.180.3 St.100 St.80 St.80 St.60

Bushing Seal Ring Shim Eccentric Shaft Angular Ring Spring

= Manufactured in ChW

Page 83/13
 Gear Pump (Feed pump: Low
pressure)
Feeds fuel to the supply pump inlet port

O-ring Rivets
Coupling Lip seal

Bolts
Gears
O-rings
Housing

Driven by the supply pump

drive shaft

Page 84/13
 Overflow valve
 Overflow valve is installed to the supply
pump housing
 Returns oil to the gear pump inlet port
when the pressure of fuel fed from the gear
pump becomes constant
 Overflown fuel lubricates the supply pump Fuel inlet port from
drive shaft chamber the gear pump
IMV valve

Overflow valve

Supply pump housing

Page 85/13
Pressure limiter valve
Controls maximum pressure of
common rail
Pressure limiter set pressure
1850bar
Special equipment required to
replace the valve Because the tip
is tool edge machined

The tip is tool edged

Page 87/13
 Electronically controlled Injector
 Optimal injection timing and amount of
injection are determined by closing/opening
Notch
a 2-way valve with the solenoid of the head
 Solenoid operating voltage is 80 V
 Return fuel flows to the rear of the engine
via collecting passage in the cylinder head

Injector positioning pin

Injector concave ball and convex ball at the end of high

pressure connector make contact to seal high pressure
fuel with the thrust force

Page 88/13
Injector wire harness
Wire harnesses for two injectors run
through a connector

Wiring for injector

Page 89/13
 Injector and High Pressure
Connector
Solenoid seat surface
Causes for increased injector fuel return
Defective solenoid seat surface
Defective high pressure fuel connector
seat surface
Increased clearance between the valve
piston and injector body, etc.

Clearance between the valve

piston and injector body

High pressure fuel connector seat surface

Edge filter

Page 90/13
Injector Section Diagram
16 32 22 31
1. Nozzle Body
2. Nozzle Needle
12. Spacer Disc
18 20 24
13. Spacer Disc
3. Nozzle Nut
4. Injector Body
14. Spacer Disc 14
5. Interm. Pin
15. Armature Plate
28 25
16. Armature Spring
6. Nozzle Spring
7. Valve Body
17. Shim Washer 12
8. Valve Piston 26
9. Seal Ring
10. Valve Ball
10 23
11. Retaining Screw (nut)

7 21

6 8 30 19
4 27 13 15 17
9 29 11
2
1
18. Lock Ring 26. Armature Bolt
19. Magnet Core 27. Ball Holder
20. Tube 28. Armature Guide
5 21. O-Ring 29. Support Washer
22. Interm. Piece 30. O-Ring
23. Seal Ball 31. Support Plate
24. Valve Spring 32. Tension Nut
25. Connector Base Ass.

Page 91/13
Injector Components
Magnet Nut Armature Spring Residual Air Gap Injector Body Armature Lift Shim Valve Retaining Ball Holder
Shim Nut

Magnetspannmutter Ankerfeder Einstellscheibe Hub- Einstellring Ventilspannmutter Kugelführung

Injektorkörper
Seal Ball Valve Ball

Dichtkugel Ventilkugel

Magnet Group Nozzle Spring

Düsenfeder

Nozzle Needle

Düsennadel
Magnetgruppe

Lock Ring Nozzle Body

Sicherungsscheibe Düsenkörper
Valve Group
Armature Plate Armature Bolt Armature Guide Valve Body and Piston Nozzle Spring Shim Thrust washer with Nozzle Nut
Bushing

Brac
Ventilgruppe Einstellscheibe mit
Ankerplatte Ankerbolzen Ankerscheibe Ventilstück und Ventilkolben Ausgleichsscheibe Hülse 92/1
Düsenspannmutter

Page 92/13
 Fuel pre-filter
 With water separator, 10U
 With water detector sensor (WIF)
 Manual priming pump

Priming pump

WIF：water in fuel
Page 93/13
 Fuel filter
Main filter 2U
Cautions at replacement
To replace, install filter without filling fuel to
the element
Fill the fuel by operating priming pump

Page 94/13
 Fuel Low Pressure Line
Nylon tube on low
pressure side Tube is
used (60 C to 130 C)

Quick coupler is used

for connection (press the
knob to disconnect)
Moving images of quick coupler

Quick coupler

Moving
image
operation
panel

Page 95/13
 Rear gear train
Timing gear
With rear gear train
Flywheel housing is aluminum made

Supply pump gear Cam gear Rear crank gear

Reference: The photo shows D61 bulldozer specifications

Page 96/13
 Connecting rod
1.Cautions at assembly 2. Destructive machining (laser
The longer portion to the exhaust side machining)
(If reversed, it leads to earlier burning-out Eliminates error combination
accident) of the connecting rod caps

Exhaust
side

Machined broken-out section

Page 97/13
 Locker arm
4 valves/cylinder
Valve clearance adjustment
Locker arm, crosshead (guideless)

Crosshead

Locker arm end

Page 98/13
 Piston cooling nozzle
Piston cooling nozzle

Piston is attached with cooling

gallery

Oil pump

Page 99/13
 Front seal
Cassette seal type
Insert both the outer and inner seal cylinders
simultaneously

Encircled
portion is the
rotary sealing
portion

Crankshaft Seal insertion tool

Page 100/13
 Crankcase breather
Located in the rear of the
engine, it separates oil mists in
the blow-by with the baffle on
the lower surface of the head Breather
cover
Two circuits for blow-by and oil
are provided

Blow-by outlet
port

Oil return circuit

Page 101/13
 Contents

1. Injector Removal and Installation [No.1] Removal of Head Cover and Harness Page 3

Injector Removal and Installation [No.2] High-pressure Pipe and Connection Page 4

Injector Removal and Installation [No.3] Removal of Harness and Locker Arm Page 5

Injector Removal and Installation [No.4] Removal of Injector Page 6

Injector Removal and Installation [No.5] Installation of Injector Page 7

Injector Removal and Installation [No.5] Locker Arm Installation and Engine Turning Page 8

Injector Removal and Installation [No.2] Engine Top Check and Valve Adjustment Page 9

Injector Removal and Installation [No.8] Valve Adjustment Page 10

Injector Removal and Installation [No.9] Installation of High-pressure Pipe, Harness and Head Cover Page 11

2. Tools used for Valve Clearance Adjustment Page 12

3. Types and Shapes of Harness Couplers Pages 13 and 14

4. Removal and Installation of Wire Harness Page 15

5. Removal of Supply Pump Page 16

6. Installation of Supply Pump [Tightening torque 24 +-4Nm] Page 17

7. Removal and Installation of Engine Controller Page 18

Page 103/13
 Injector Removal and Installation [No.1]
Removal of Head Cover and Harness
Removal of head cover

Injector coupler

Removal of main harness

Fuel pressure Harness bracket

sensor coupler

Page 104/13
 Injector Removal and Installation [No.2]
High-pressure Pipe and Connection

Removal of high-
pressure pipe

High pressure
injection pipe
Removal of connection sleeve nut

Positioning key

Intended for
preventing
damages as
well as
contaminatio
n with
foreign
Injector substances

Injector
sleeve nut

Page 105/13
 Injector Removal and Installation [No.3] Removal of Harness and Locker Arm

Removal of harness Removal of locker arm assembly

Loosen the nut and adjustment screw
somewhat prior to the operation

Crosshead is
integrated with
the harness Locker arm
assembly

Page 106/13
 Injector Removal and Installation [No.4] Removal of Injector

Removal of injector

Holder mounting bolt

Holder

Specialized injector
pull-out jig

Protection of injector ntended for

preventing
damages as
well as
contamination
with foreign
substances

Page 107/13
 Injector Removal and Installation [No.5] Installation of Injector

Temporary
installation of injector

Installation of injector

Apply oil to
O-ring

(1) Injector 10Nm

(2) Connection 15Nm
(3) Injector 10Nm
(4) Connection 50Nm

Page 108/13
 Injector Removal and Installation [No.6]
Locker Arm Installation and Engine Turning

 Installation of the crosshead

 Installation of the locker arm
assembly
Crosshead that does not
 Turning of the engine require adjustment
 Check of TDC

Slot

Page 109/13
 Injector Removal and Installation [No.7]
Engine Top Check and Valve Adjustment
Air intake Exhaust valve
valve is open Overlap is closed

1.6TDC

2.5TDC 3.4TDC
Crosshead

 Valve clearance adjustment Locker arm

Tip is movable

Cap is a fitted type

and slides vertically.

Page 110/13
 Injector Removal and Installation [No.9] Installation of High-
pressure Pipe, Harness and Head Cover
 Installation of high-
pressure pipe
 Installation of the
harness coupler
 Installation of head
cover
High-pressure
injection pipe
sleeve nut

O-ring
Coating with oil
Check for flaws

Check
for flaws

Page 111/13
 Tools used for Valve Clearance Adjustment
Valve clearance adjustment
Head cover mounting nut Socket 1.3mm Set
Ratchet handle 3/8 mm sq. Set
Extension 100mm Set
Cranking Ratchet handle 1/2 mm sq. Classroom set
Extension 250mm Classroom set
Burning tool (102) Practical training
Socket 15mm 1/2 mm sq. Practical training
Pulling out breather Flat head screwdriver Set for practical training
Valve clearance adjustment Thickness gauge (102) Practical training
Hex screwdriver 5mm Purchase
Offset wrench 9/16 Classroom
Breather is to be purchased Engine oil Practical training
Plastics hammer Classroom
Removal and installation of injector
Main harness clamp (Check required) Offset wrench Set for practical training
Injection pipe sleeve nut Special goggles [Brake pipe] 19mm Purchase
Connection nut Socket 24mm Practical training
Injector harness nut Socket (Long) 10mm Purchase
Ratchet handle 3/8 mm sq. Set
Locker arm assembly Socket 10mm Set
Ratchet handle 3/8 mm sq. Set
Injector holder Socket 10mm Set
Extension 100mm Set
Ratchet handle 3/8 mm sq. Set
Injector puller Pulling jig Specialized Purchase
Practical training
Engine oil Practical training
Installation of holder Bow torque wrench 5-45N Purchase
Connection nut Bow torque wrench 10-90N Purchase
Injection pipe sleeve nut Limiter wrench (Mouth piece replaceable) 24Nm Practical training
Wrench (For limiter) 19mm Purchase
Removal and installation of ECM
Main harness Hex wrench 4mm Classroom set
Harness clamp and mounting bolt Socket 13mm Set
Extension 100mm Set
Ratchet handle 3/8 mm sq. Set
Supply pump
High-pressure pipe nut Wrench
Pump mounting nut Socket 13mm Set
Extension 100mm Set
Ratchet handle 3/8 mm sq. Set
Engine oil

Page 112/13
 Types and Shapes of Harness Couplers [No.1]

(1) Coupler for atmospheric (2) Coupler for injector (3) Fuel rail pressure sensor
pressure sensor

(5) Coupler for water (4) Coupler for boost pressure

temperature sensor sensor

Page 113/13
 Types and Shapes of Harness Couplers [No.2]

(10) Coupler for supply metering

sensor

(6) Coupler for G rotation

sensor

(9) Coupler for hydraulic switch

(8) Coupler for ECM

(7) Coupler for Ne rotation

sensor

Page 114/13
 Removal and Installation of Wire Harness
Applicable coupler Removal and installation procedure
2
(1) Atmospheric pressure sensor (1) Slide the protective rubber cover.
Type (1)

1 (6) G rotation sensor (2) Slide the coupler clip-on.

3
(7) Ne rotation sensor (3) Pull out the coupler while pushing the clip.
(9) Hydraulic switch

Applicable coupler Removal and installation procedure

1 2
(2) Injector coupler (1) Push the clip to release the stopper.
Type (2)

(3) Fuel rail pressure sensor (2) Pull out the coupler while pushing the clip.
(4) Boost pressure sensor
(10) Supply pump

Applicable coupler Removal and installation procedure

(5) Water temperature sensor (1) Expand the clip outward to pull out the
coupler.
Type (3)

Applicable coupler Removal and installation procedure

(8) ECM harness (1) Loosen the center bolt of the cassette.
Type (4)

The cassette will allow pulling out gradually.

(2) Hold the cassette body to pull it out.

Page 115/13
 Removal of Supply Pump
• High-pressure pipe [Between supply
pump and common rail] [Width
across flat: 19 mm]
• Removal of high-pressure pipe
clamps at two locations [Width
across flat: 10 mm]
• Low-pressure pipe [Between fuel
filter inlet and outlet/fuel return and
supply pump]
• Removal of quick coupler [Pull out
the coupler while pressing the
stopper.]
* Use care so that the nipple may not be
damaged after the coupler has been
removed.
• Removal of supply pump metering
harness coupler
• [See the section of Removal and
Installation of Coupler.]
• Remove the supply pump mounting
nut and then remove the supply
pump body. [Pull it out] [Width across
flat: 13 mm]
Page 116/13
 Installation of Supply Pump
[Tightening torque 24 +- 4Nm]

*Gear counter mark/No positioning is

done
• Coat the O-ring with engine oil.
*When inserting, prevent the stud bolt
from interfering with the O-ring.
• Installation of the pipe and harness
[Tightening torque 35 +- 3.5Nm]

Page 117/13
 Removal and Installation of Engine Controller
 Removal of harness

Install the
clamp
together

Install the
grounding
wire
together

 Removal of ECM
 Installation of ECM

Page 118/13
 THE END

Page 119/13
Page 120/13