Komatsu 107E-1 Series Diesel Engine Shop Manual – PDF DOWNLOAD

Description

Komatsu 107E-1 Series Diesel Engine Shop Manual

FILE DETAILS:

Komatsu 107E-1 Series Diesel Engine Shop Manual 

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: SAA6D107E-1, SAA4D107E-1, 107E-1 Series Engine
Book Code: SEN00161-24
Language: English
Pages: 576

KOMATSU 107E-1 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 107E-1 Series Diesel Engine Shop Manual 

How to read the shop manual:

1. 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):

•  Chassis volume
  This section gives hydraulic circuit diagrams and electrical circuit diagrams.
•  Engine volume
  This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu 107E-1 Series Diesel Engine Shop Manual 

COVER
.........................................................................................  0
00 Index and foreword..........................................................................  0
	Index......................................................................................  3
		Composition of shop manual.............................................................  4
		Table of contents......................................................................  5
	Foreword and general information........................................................... 11
		Safety notice.......................................................................... 12
		How to read the shop manual............................................................ 17
		Explanation of terms for maintenance standard.......................................... 19
		Handling of electric equipment and hydraulic component................................. 21
		Handling of connectors newly used for engines.......................................... 30
		How to read electric wire code......................................................... 33
		Precautions when carrying out operation................................................ 36
		Method of disassembling and connecting push-pull type coupler.......................... 39
		Standard tightening torque table....................................................... 42
		Conversion table....................................................................... 46
01 Specification...............................................................................  0
	Specification and technical data........................................................... 53
		General................................................................................ 54
		Specifications......................................................................... 55
		General view........................................................................... 76
		Dimensions table.......................................................................116
		Engine performance curves..............................................................117
10 Structure, function and maintenance standard................................................  0
	Structure, function and maintenance standard...............................................135
		Intake system..........................................................................137
		Exhaust system.........................................................................138
		Lubricating oil system.................................................................140
		Cooling system.........................................................................144
		Fuel system............................................................................145
		Fuel supply pump.......................................................................146
		CRI system.............................................................................147
		Turbocharger...........................................................................151
		Cylinder head..........................................................................152
		Cylinder block.........................................................................154
		Crankshaft.............................................................................156
		Piston, piston ring and piston pin.....................................................158
		Connecting rod.........................................................................160
		Vibration damper.......................................................................162
		Timing gear............................................................................163
		Camshaft...............................................................................164
		Valve and valve guide..................................................................166
		Rocker arm, shaft and tappet...........................................................168
		Flywheel and flywheel housing..........................................................170
		Oil pump...............................................................................172
		Water pump drive and fan drive.........................................................173
		Water pump.............................................................................175
		Thermostat.............................................................................176
		Alternator.............................................................................177
		Starting motor.........................................................................182
		Sensor.................................................................................186
		Engine controller......................................................................192
		Control system.........................................................................195
20 Standard value table........................................................................  0
	Standard service value table...............................................................205
		Standard value table for testing, adjusting and troubleshooting........................206
		Running-in standard and performance test criteria......................................226
30 Testing and adjusting.......................................................................  0
	Testing and adjusting......................................................................247
		Testing and adjusting tools list.......................................................248
		Sketches of special tools..............................................................250
		Testing boost pressure.................................................................251
		Adjustment of valve clearance..........................................................252
		Testing compression pressure...........................................................255
		Testing blowby pressure................................................................258
		Testing engine oil pressure............................................................259
		Handling fuel system parts.............................................................260
		Releasing remaining pressure in fuel system............................................260
		Testing fuel pressure..................................................................261
		Reduced cylinder mode operation........................................................267
		No-injection cranking..................................................................267
		Testing fuel delivery, return and leak amount..........................................268
		Bleeding air from fuel circuit.........................................................279
		Testing fuel system for leakage........................................................280
		Handling controller high-voltage circuit...............................................281
		Replacing the fan belt.................................................................281
40 Troubleshooting.............................................................................  0
	General information on troubleshooting.....................................................283
		Points on troubleshooting..............................................................284
		Error and failure code table...........................................................285
		Troubleshooting method for open circuit in wiring harness of pressure
sensor system....287
		Information in troubleshooting table...................................................289
		Connection table for connector pin numbers.............................................291
		T- branch box and T- branch adapter table..............................................327
	Troubleshooting of electrical system (E-mode), Part 1......................................331
		Troubleshooting of electrical system (E-mode), Part 1..................................333
			E-1 Code [111/CA111] Abnormality in engine controller..............................333
			E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor...................333
			E-3 Code [122/CA122] Abnormally high level in charge pressure sensor...............334
			E-4 Code [123/CA123] Abnormally low level in charge pressure sensor................336
			E-5 Code [131/CA131] Abnormally high level in throttle sensor power supply.........338
			E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply..........340
			E-7 Code [144/CA144] Abnormally high level in coolant temperature sensor...........342
			E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor............344
			E-9 Code [153/CA153] Abnormally high level in charge temperature sensor............346
			E-10 Code [154/CA154] Abnormally low level in charge temperature sensor............348
			E-11 Code [155/CA155] Derating of speed by abnormally high charge temperature......350
			E-12 Code [187/CA187] Abnormally low level in sensor power supply 2................352
			E-13 Code [221/CA221] Abnormally high level in atompspheric pressure sensor........354
			E-14 Code [222/CA222] Abnormally low level in atompspheric pressure sensor.........356
			E-15 Code [227/CA227] Abnormally high level in sensor power supply 2...............358
			E-16 Code [234/CA234] Engine overspeed.............................................359
			E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply.............360
			E-18 Code [271/CA271] Short circuit in IMV/PCV1....................................361
			E-19 Code [272/CA272] Disconnection in IMV/PCV1....................................362
			E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1...............364
			E-21 Code [323/CA323] Disconnection, short circuit in injector No. 5...............366
			E-22 Code [324/CA324] Disconnection, short circuit in injector No. 3...............368
			E-23 Code [325/CA325] Disconnection, short circuit in injector No. 6...............370
			E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2...............372
			E-25 Code [332/CA332] Disconnection, short circuit in injector No. 4...............374
			E-26 Code [342/CA342] Matching error in engine controller data.....................376
			E-27 Code [351/CA351] Abnormality in injector drive circuit........................377
			E-28 Code [352/CA352] Sensor power supply 1 low error..............................378
			E-29 Code [386/CA386] Sensor power supply 1 high error.............................380
			E-30 Code [428/CA428] Water-in-fuel sensor high error..............................382
			E-31 Code [429/CA429] Water-in-fuel sensor low error...............................384
			E-32 Code [431/CA431] Abnormality in idle validation switch........................386
			E-33 Code [432/CA432] Abnormality in idle validation processing....................388
	Troubleshooting of electrical system (E-mode), Part 2......................................391
		E-34 Code [435/CA435] Abnormality in engine oil pressure switch........................393
		E-35 Code [441/CA441] Abnormally low power supply voltage..............................394
		E-36 Code [442/CA442] Abnormally high power supply voltage.............................396
		E-37 Code [449/CA449] Common rail pressure high error 2................................397
		E-38 Code [451/CA451] Common rail pressure sensor high error...........................398
		E-39 Code [452/CA452] Common rail pressure sensor low error............................400
		E-40 Code [488/CA488] Derating of torque by charge temperature high error..............402
		E-41 Code [553/CA553] Common rail pressure high error 1................................402
		E-42 Code [559/CA559] No-pressure feed 1 by supply pump................................403
		E-43 Code [689/CA689] Abnormality in engine Ne speed sensor............................405
		E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase....................407
		E-45 Code [757/CA757] Loss of all data in engine controller............................408
		E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor..........................409
		E-47 Code [1633/CA1633] Abnormality in KOMNET..........................................412
		E-48 Code [2185/CA2185] Throttle sensor power supply high error........................413
		E-49 Code [2186/CA2186] Throttle sensor power supply low error.........................414
		E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump..............................415
		E-51 Code [2311/CA2311] Abnormality in IMV solenoid....................................415
		E-52 Code [2555/CA2555] Disconnection in intake air heater relay.......................416
		E-53 Code [2556/CA2556] Short circuit in intake air heater relay.......................418
		E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction..............420
		E-55 Code [---/B@BAZK] Engine oil level low............................................420
		E-56 Code [---/B@BCNS] Engine overheat.................................................421
		E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error..................422
		E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error...................424
		E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error........................426
		E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error.........................428
		E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition).........................430
		E-62 Code [b6] Droop Rate Adjustment Volume High Error.................................434
		E-63 Code [b7] Droop Rate Adjustment Volume Low Error..................................436
		E-64 Code [b8] Low Idle Speed Adjustment Volume High Error.............................438
		E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error..............................440
		E-66 Code [bc] Rated Speed Median Adjustment Volume High Error.........................442
		E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error..........................444
		E-68 Code [bE] Ramp Time Adjustment Volume High Error..................................446
		E-69 Code [bF] Ramp Time Adjustment Volume Low Error...................................448
	Troubleshooting of mechanical system (S-mode)..............................................451
		Troubleshooting of mechanical system (S-mode)..........................................454
			Method of using troubleshooting charts.............................................454
			S-1 Starting performance is poor...................................................458
			S-2 Engine does not start..........................................................459
			S-3 Engine does not pick up smoothly...............................................462
			S-4 Engine stops during operations.................................................463
			S-5 Engine does not rotate smoothly................................................464
			S-6 Engine lacks output (or lacks power)...........................................465
			S-7 Exhaust smoke is black (incomplete combustion).................................466
			S-8 Oil consumption is excessive (or exhaust smoke is blue)........................467
			S-9 Oil becomes contaminated quickly...............................................468
			S-10 Fuel consumption is excessive.................................................469
			S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).........470
			S-12 Oil pressure drops............................................................471
			S-13 Oil level rises (Entry of coolant or fuel)....................................472
			S-14 Coolant temperature becomes too high (overheating)............................473
			S-15 Abnormal noise is made........................................................474
			S-16 Vibration is excessive........................................................475
50 Disassembly and assembly....................................................................  0
	General information on disassembly and assembly............................................477
		How to read this manual................................................................478
		Coating materials list.................................................................480
		Special tools list.....................................................................483
	Disassembly and assembly, Part 1...........................................................485
		General disassembly of engine..........................................................486
	Disassembly and assembly, Part 2...........................................................505
		General assembly of engine.............................................................506
90 Repair and Replacement of parts.............................................................  0
	Infomation related repair and replacement..................................................541
		Special tool table.....................................................................542
	Parts related to cylinder head.............................................................545
		Repair of cylinder head................................................................546
		Check of valve guide...................................................................547
		Replacement of valve seat insert.......................................................548
		Vacuum test of valve seat insert.......................................................550
		Grinding of valve......................................................................551
	Parts related to cylinder block............................................................555
		Repair of cylinder block...............................................................556
		Repair of crankshaft...................................................................568
		Replacement of connecting rod bushing..................................................571

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