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Komatsu 107E-2 Series Diesel Engine Shop Manual – PDF DOWNLOAD
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Komatsu 107E-2 Series Diesel Engine Shop Manual
Book Code: SEN05623-06
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Description
Komatsu 107E-2 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 107E-2 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 107E-2 Series Engine
Book Code: SEN05623-06
Language: English
Pages: 406
File Format: Portable Document Format (PDF)
KOMATSU 107E-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 107E-2 Series Diesel Engine Shop Manual
How to read the shop manual:
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword:
• This section includes the index, foreword, safety and basic information.
01. Specification:
• This section explains the specifications of the machine.
10. Structure and function:
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table:
• The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
50. Disassembly and assembly:
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard:
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
TABLE OF CONTENTS:
Komatsu 107E-2 Series Diesel Engine Shop Manual
COVER........................................................................ 1 00 Index and foreword ....................................................... 3 Index ................................................................... 4 Foreword, safety and general information ................................ 7 Important safety notice ............................................. 7 How to read the shop manual ......................................... 14 Explanation of terms for maintenance standard ....................... 16 Handling equipment of fuel system devices ........................... 18 Handling of intake system parts ..................................... 19 Handling of hydraulic equipment ..................................... 20 Method of disconnecting and connecting of push-pull type coupler .... 22 Handling of electrical equipment .................................... 25 How to read electric wire code ...................................... 33 Precautions when performing operation ............................... 36 Standard tightening torque table .................................... 41 List of abbreviation ................................................ 47 Conversion table .................................................... 52 01 Specification ............................................................ 57 Table of contents ....................................................... 58 General information ..................................................... 59 Exhaust gas regulation .............................................. 59 Specifications .......................................................... 65 Applicable machines ................................................. 65 Specifications ...................................................... 66 General view ........................................................ 74 Engine performance curve ............................................ 99 10 Structure and function ...................................................107 Table of contents .......................................................108 Components layout .......................................................110 Components layout drawing (4D107) ...................................110 Components layout drawing (6D107) ...................................112 Intake and exhaust system parts .........................................114 Intake and exhaust system layout drawing (4D107) ....................114 Intake and exhaust system layout drawing (6D107) ....................115 Intake and exhaust system circuit diagram (4D107) ...................116 Intake and exhaust system circuit diagram (6D107) ...................118 Air cleaner (4D107) .................................................120 Air cleaner (6D107) .................................................121 VFT (4D107) .........................................................123 KVGT (6D107) ........................................................127 Aftercooler .........................................................135 EGR system piping drawing (4D107) ...................................136 EGR system piping drawing (6D107) ...................................138 EGR system circuit diagram (4D107) ..................................140 EGR system circuit diagram (6D107) ..................................142 EGR valve (4D107) ...................................................144 EGR valve (6D107) ...................................................146 EGR cooler ..........................................................148 Layout of KCCV (4D107) ..............................................149 Layout of KCCV (6D107) ..............................................152 KCCV ventilator .....................................................154 KDOC muffler (4D107) ................................................158 KDPF (6D107) ........................................................160 Engine main body parts ..................................................165 Cylinder head .......................................................165 Cylinder block ......................................................167 Main moving parts ...................................................169 Vibration damper (6D107) ............................................173 Timing gear .........................................................174 Front cover .........................................................175 Valve system ........................................................176 Flywheel ............................................................179 Lubrication system ......................................................181 Lubrication system parts layout drawing (4D107) .....................181 Lubrication system parts layout drawing (6D107) .....................183 Lubrication system circuit diagram (4D107) ..........................185 Lubrication system circuit diagram (6D107) ..........................186 Oil pump ............................................................187 Boost oil pump (6D107) ..............................................188 Oil filter ..........................................................189 Oil cooler ..........................................................190 Regulator valve .....................................................191 Safety valve ........................................................192 Oil pan .............................................................193 Fuel system .............................................................194 Fuel system parts layout drawing ....................................194 Fuel system circuit diagram .........................................197 Supply pump .........................................................201 Fuel cooler .........................................................202 Pre-filter ..........................................................203 Main filter .........................................................204 Cooling system ..........................................................205 Cooling system parts layout drawing .................................205 Cooling system circuit diagram (4D107) ..............................206 Cooling system circuit diagram (6D107) ..............................207 Drive pulley ........................................................208 Water pump ..........................................................213 Thermostat ..........................................................214 Electrical equipment ....................................................215 Alternator ..........................................................215 Starting motor ......................................................223 Intake air heater ...................................................227 Engine wiring harness (4D107) .......................................228 Engine wiring harness (6D107) .......................................230 Engine controller (4D107) ...........................................232 Engine controller (6D107) ...........................................238 Sensor ..............................................................244 20 Standard value tables ....................................................261 Table of contents .......................................................262 Standard service value table ............................................263 Standard value table for engine .....................................263 Running-in standard and performance test standard ...................287 50 Disassembly and assembly .................................................295 Table of contents .......................................................296 Related information on disassembly and assembly .........................297 How to read this manual .............................................297 Coating materials list ..............................................299 Special tool list ...................................................303 Sketch of special tool ..............................................305 Disassembly and assembly ................................................306 General disassembly of engine .......................................306 General assembly of engine ..........................................328 Removal and installation procedure of supply pump unit alone ........369 Engine front oil seal replacement procedure .........................373 Engine rear oil seal replacement procedure ..........................376 60 Maintenance standard .....................................................379 Table of contents .......................................................380 Intake and exhaust system parts .........................................381 VFT (4D107) .........................................................381 KVGT(6D107) .........................................................382 Engine main body parts ..................................................383 Cylinder head .......................................................383 Cylinder block ......................................................385 Crankshaft ..........................................................387 Piston ..............................................................389 Connecting rod ......................................................390 Vibration damper (6D107) ............................................392 Timing gear .........................................................393 Camshaft ............................................................394 Valve and valve guide ...............................................396 Rocker arm ..........................................................398 Tappet ..............................................................399 Flywheel ............................................................400 Lubrication system ......................................................402 Oil pump ............................................................402 INDEX........................................................................403
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