Komatsu 107E-1 Series Diesel Engine Shop Manual SEN00161-18 – SAA6D107E-1 & SAA4D107E-1 Repair, Troubleshooting & Rebuild PDF

Description

Komatsu 107E-1 Series Engine Shop Manual – SEN00161-18

This is the complete Komatsu 107E-1 Series Diesel Engine Shop Manual, form number SEN00161-18, published under the 2010 KOMATSU copyright. It is the workshop-level reference for the SAA6D107E-1 and SAA4D107E-1 diesel engines fitted across the Komatsu hydraulic excavator, wheel loader, motor grader, bulldozer, mobile crusher and portable generator ranges. Everything a technician needs to test, adjust, strip, repair and reassemble these engines is held in a single 530-page PDF that can be opened on a laptop in the workshop or printed page by page on the bench.

File Details

• Manual type: Engine Shop Manual
• Brand: Komatsu
• Engine series: 107E-1 Series
• Engines covered: SAA6D107E-1, SAA4D107E-1
• Language: English
• Page count: 530 pages
• File format: PDF
• Document number: SEN00161-18
• Publication date: 07-10 (July 2010)

Chapters Covered

• 00 Index and foreword
• 01 Specification
• 10 Structure, function and maintenance standard
• 20 Standard value table
• 30 Testing and adjusting
• 40 Troubleshooting
• 50 Disassembly and assembly
• 90 Repair and replacement of parts

01 Specification

Applicable machine tables, cylinder count, bore and stroke, total piston displacement, firing order, overall dimensions, flywheel horsepower, maximum torque, high and low idle speeds, minimum fuel consumption ratio, dry weight, lubricating oil and coolant refill quantities, alternator and starting motor ratings. Engine performance curves for every listed machine model are reproduced as full-page graphs showing torque and flywheel horsepower against engine speed.

10 Structure, Function and Maintenance Standard

Air intake and exhaust paths, turbocharger construction and lubrication, the gerotor oil pump circuit, the pressure regulating valve, the full-flow oil filter and bypass, coolant circulation through the block and head, and the high-pressure common rail fuel system from the gear pump through the fuel supply pump, common rail, pressure sensor and pressure relief valve to the injectors. Individual sections cover the cylinder head, cylinder block, crankshaft, piston, piston rings, piston pin, connecting rod, vibration damper, timing gears, camshaft, valves and valve guides, rocker arms, flywheel and housing, oil pump and sensors. Maintenance standard tables give the measurement criteria and the remedy for every wear point.

20 Standard Value Table

Standard values for new machines and permissible field limits, arranged model by model. High idle and low idle speeds, intake resistance, intake pressure at the aftercooler inlet, exhaust temperature, exhaust gas colour, quick acceleration smoke limits, valve clearance (intake 0.25 mm, exhaust 0.51 mm), compression pressure, blow-by pressure, oil pressure at rated and low idle, oil temperature, oil consumption ratio, radiator pressure valve opening pressure and fan speed are all listed with their measurement conditions and units.

30 Testing and Adjusting

Special tool lists and sketches, boost pressure testing, valve clearance adjustment with the barring tool and wide-slit alignment, compression pressure testing through the injector mount, blow-by pressure testing, engine oil pressure testing, releasing residual fuel pressure, low-pressure circuit and return circuit fuel pressure testing, fuel delivery, return and leak amount measurement, reduced cylinder mode operation and no-injection cranking, bleeding air from the fuel circuit, fuel system leak testing and fan belt replacement.

40 Troubleshooting

Three full troubleshooting sections. The electrical (E-mode) chapters step through every failure code with the INSITE error code and the matching machine monitor code — injector drive faults, rail pressure sensor errors, sensor power supply faults, water-in-fuel sensor, idle validation, KOMNET communication and the generator controller adjustment volume codes. Each entry lists the contents of the trouble, the controller action, the symptom on the machine, and cause-by-cause checks with resistance and voltage limits. The mechanical (S-mode) charts use questions, check items, causes and remedies to work through poor starting, no-start, rough running, engine stops, low output, black smoke, oil consumption, coolant contamination and abnormal noise.

50 Disassembly and Assembly

General disassembly of the engine and general assembly, part by part, with the coating material list, the full special tool list and the tightening torque for every fastener. The sequence covers mounting the engine on the repair stand, the starting motor, fan pulley, vibration damper, belt tensioner, thermostat, water pump, turbocharger and exhaust manifold, fuel filter, harness, high-pressure piping and common rail, air intake manifold cover, head cover, rocker housing, rocker arms, push rods, injectors, cylinder head, oil cooler, engine controller, fuel supply pump and gear, flywheel, rear and front oil seals, flywheel housing, oil pan, front cover, oil pump, camshaft, gear housing, pistons and connecting rods, crankshaft, piston cooling nozzles and tappets. Assembly reverses the process with the correct torque, angle-tightening steps, sealant application widths and runout limits.

90 Repair and Replacement of Parts

Cylinder head repair and flatness limits, valve guide checking, valve seat insert removal and installation with the grooving kit and slide hammer, the vacuum test on the valve seat, valve grinding and valve stem measurement, valve spring testing, cylinder block repair, camshaft bushing removal and installation, cylinder bore measurement, honing and the one-time oversize bore to 0.5 mm pistons, crankshaft journal regrinding and undersize bearing tables, and connecting rod bushing replacement with the push tool kit and final bore machining.

What This Komatsu 107E-1 Shop Manual Lets You Do

With the SEN00161-18 manual open, a technician can diagnose an E-mode fault on the machine monitor and trace it to the exact connector pin, measure rail pressure, compression pressure, blow-by, boost pressure or oil pressure against the factory standard, adjust valve clearance to 0.25 mm intake and 0.51 mm exhaust, torque the cylinder head through its three-stage 90 Nm / 90 Nm / 90° sequence, rebuild the common rail high-pressure circuit, replace a cylinder head or valve seat insert, re-bore a worn cylinder block to oversize pistons, or regrind a crankshaft to an undersize journal. It is the same information used when these engines are stripped on the bench, and it removes the guesswork from every measurement, clearance and torque value.

The SAA6D107E-1 and SAA4D107E-1 are the engines behind the PC200-8, PC220-8, PC270-8, WA250-6, WA320-6, WA380-6, GD555-5, GD655-5 and D39EX-22, so this single PDF replaces the need to hunt down separate procedures for each machine. Because every value is printed with its measurement condition and unit, there is no need to cross-reference outside charts — the manual carries the high idle speed, the torque figure, the clearance and the test method on the same page as the procedure.

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Delivered as an instant PDF download, the Komatsu 107E-1 Series engine shop manual opens on any laptop, tablet or phone and prints cleanly for the workshop. No shipping, no waiting, and the full 530 pages are available the moment payment clears.