This Komatsu SAA4D107E-5 Engine Shop Manual (SEN07009-03) is meant for the engine when it’s working hard in mid-size construction or quarry machines, not just idling in a yard. The people who usually reach for this book are shop mechanics, dealer techs, and serious owner-operators who actually tear into engines. They’re trying to sort no-starts, power loss, smoke issues, coolant/oil cross-contamination, and full rebuilds, not just change filters.
What this manual helps you do
- Trace fuel system faults on the Komatsu SAA4D107E-5 Engine using step-by-step diagnostic flow and test procedures.
- Check lubrication, cooling, and air systems for common failure modes like overheating, low oil pressure symptoms, and restricted air.
- Follow disassembly and assembly sequences for major components so you don’t crack housings or mis-time the engine.
- Diagnose electronic control and sensor problems with wiring references and logical checks instead of just throwing parts at it.
- Handle in-frame and out-of-frame overhaul work with the correct order of operations and inspection points for wear and damage.
Who this is for
This is a workshop-level manual for field techs, shop mechanics, and fleet maintenance leads who already know their way around diesel engines. If you just want basic maintenance intervals or how to operate the machine, you’re really looking for an Operation & Maintenance manual, not this shop manual.
FAQ
Q: Is this a searchable PDF I can print from?
A: Yes, this type of shop manual is normally supplied as a PDF you can search on-screen and print specific sections for the bench.
Q: Is it deep enough for a full rebuild?
A: The Komatsu SAA4D107E-5 Engine Shop Manual walks through diagnostic procedures, disassembly sequences, and reference torque tables used during workshop-level repairs.
Q: How do I know if it matches my machine variant?
A: You’ll want to match your engine’s exact model designation and book reference SEN07009-03; if your data plate doesn’t show SAA4D107E-5, this isn’t the right one.
Bottom line: if you’re planning to diagnose, strip, and rebuild a Komatsu SAA4D107E-5 in a real shop setting, this is what you want; if you just change oil and filters, keep looking.
📘 Show Index
Table of Contents:
- 00 Index and Foreword
- Index
- Foreword, Safety, Basic Information
- How to Read the Engine Shop Manual
- Safety Notice for Operation
- Precautions to Prevent Fire
- Procedures 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 Storage
- Precautions for Fire Hazard and Leakage
- Other Precautions
- Store DEF
- Precautions When You Handle Hydraulic Equipment
- Precautions When You Disconnect and Connect Pipings
- Precautions When You Handle Electrical Equipment
- Precautions When You Handle Fuel System Equipment
- Precautions When You Handle Intake System Equipment
- Disconnect and Connect Push-Pull Type Coupler
- How to Disconnect and Connect Type 1 Push-Pull Type Coupler
- How to Disconnect and Connect Type 2 Push-Pull Type Coupler
- How to Disconnect and Connect Type 3 Push-Pull Type Coupler
- Precautions for Disconnection and Connection of Connectors
- How to Disconnect and Connect Deutsch Connector
- How to Disconnect and Connect Slide Lock Type Connector
- How to Disconnect and Connect Connector with Lock to Pull
- How to Disconnect and Connect Connector with Lock to Push
- How to Disconnect and Connect Connector with Housing to Rotate
- How to Read the Codes for Electric Cable
- Explanation of Terms for Maintenance Standard
- Standard Tightening Torque Table
- Conversion Table
- Abbreviation List
- 01 Specifications
- Table of Contents
- Specifications
- Outline of Exhaust Gas Regulation
- System Diagram of Engine Conformed to Stage V Regulation
- List of Applicable Machines: 107E-5
- Specifications
- Specifications: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
- Specifications: SAA4D107E-5 (GD535-6)
- Specifications: SAA4D107E-5 (WA200-8E0)
- Specifications: SAA4D107E-5 (PC220LC-12, PC220LCI-12)
- Engine General View
- Engine General View: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
- Engine General View: SAA4D107E-5 (GD535-6)
- Engine General View: SAA4D107E-5 (WA200-8E0)
- Engine General View: SAA4D107E-5 (PC220LC-12, PC220LCI-12)
- Engine Performance Curve
- Engine Performance Curve: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
- Engine Performance Curve: SAA4D107E-5 (GD535-6)
- Engine Performance Curve: SAA4D107E-5 (WA200-8E0)
- Engine Performance Curve: SAA4D107E-5 (PC220LC-12, PC220LCI-12)
- 10 Structure and Function
- Table of Contents
- Engine System
- Layout of Engine Components
- Layout Drawing of Urea SCR System (Split Aftertreatment Device)
- Layout Drawing of Urea SCR System (Integrated Aftertreatment Device)
- Layout Drawing of Engine Components (Split Aftertreatment Device)
- Layout Drawing of Engine Components (Integrated Aftertreatment Device)
- Intake and Exhaust System Parts
- Layout Drawing of Intake and Exhaust System
- Intake and Exhaust System Circuit Diagram
- Function of Intake and Exhaust System
- Air Cleaner
- Intake Air Heater
- Turbocharger
- Crankcase Ventilation System
- Impactor (Filterless)
- Exhaust Throttle Valve
- KDPF
- SCR Assembly
- Urea SCR System
- Types of Regeneration Function
- Engine Main Body Parts
- Cylinder Head
- Cylinder Block
- Main Drive Parts
- Crankshaft Pulley
- Timing Gear
- Front Cover
- Valve System
- Flywheel and Flywheel Housing
- Lubrication System
- Layout Drawing of Lubrication System Parts
- Lubrication System Circuit Diagram
- Engine 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
- CRI System
- Supply Pump
- Common Rail
- Injector
- Fuel Prefilter
- Fuel Main Filter
- Cooling System
- Layout Drawing of Cooling System Parts
- 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 (Split Aftertreatment Device)
- Layout Drawing of Engine Sensor (Integrated Aftertreatment Device)
- Structure of Intake Manifold Pressure and Temperature Sensor
- Function of Intake Manifold Pressure and Temperature 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 (Cam) Speed Sensor
- Structure of Common Rail Pressure Sensor
- Function of Common Rail Pressure 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 Exhaust Manifold Pressure Sensor
- Function of Exhaust Manifold Pressure Sensor
- Structure of Exhaust Throttle Valve (with Built-in Position Sensor)
- Function of Exhaust Throttle Valve (with Built-in Position Sensor)
- 20 Standard Value Table
- Table of Contents
- Standard Value Table for Engine
- Standard Value Table for Engine: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
- Standard Value Table for Engine: SAA4D107E-5 (GD535-6)
- Standard Value Table for Engine: SAA4D107E-5 (WA200-8E0)
- Standard Value Table for Engine: SAA4D107E-5 (PC220LC-12, PC220LCI-12)
- Running-in Standard and Performance Test Standard
- Performance Test Standard and Standard for Operation of Engine for Break in Period: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)
- Running-in Standard and Performance Test Standard: SAA4D107E-5 (GD535-6)
- Running-in Standard and Performance Test Standard: SAA4D107E-5 (WA200-8E0)
- Running-in Standard and Performance Test Standard: SAA4D107E-5 (PC220LC-12, PC220LCI-12)
- 50 Disassembly and Assembly
- Table of Contents
- Precautions Before Work
- Related Information on Disassembly and Assembly
- How to Read This Manual
- Coating Materials List
- Special Tool List
- Sketches of Special Tools
- Engine System
- Disassemble and Assemble Engine Generally
- How to Disassemble Engine Generally
- How to Assemble Engine Generally
- Remove and Install Supply Pump Assembly
- How to Remove Supply Pump Assembly
- How to Install Supply Pump Assembly
- Remove and Install Engine Front Oil Seal
- How to Remove Engine Front Oil Seal
- How to Install Engine Front Oil Seal
- Remove and Install Engine Rear Oil Seal
- How to Remove Engine Rear Oil Seal
- How to Install Engine Rear Oil Seal
- 60 Maintenance Standard
- Table of Contents
- Engine System
- Intake and Exhaust System Parts
- Maintenance Standard for Turbocharger
- Engine Main Body Parts
- Maintenance Standard for Cylinder Head
- Maintenance Standard for Cylinder Block
- Maintenance Standard for Crankshaft
- Maintenance Standard for Piston
- Maintenance Standard for Connecting Rod
- Maintenance Standard for Timing Gear
- Maintenance Standard for Camshaft
- Maintenance Standard for Valve and Valve Guide
- Maintenance Standard for Rocker Arm
- Maintenance Standard for Tappet
- Maintenance Standard for Flywheel
- Lubrication System
- Maintenance Standard for Engine Oil Pump
- Index
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