Komatsu 107E-3 Series Engine Shop Manual SEN06502-17 – SAA4D107E-3 & SAA6D107E-3 PDF

Description

Komatsu 107E-3 Series Engine Shop Manual – SEN06502-17

This Komatsu 107E-3 Series Engine Shop Manual, document number SEN06502-17, is the complete engine-side service reference for the SAA4D107E-3 four-cylinder and SAA6D107E-3 six-cylinder common-rail diesel engines used across the 107E-3 machine range. It covers specifications, structure and function, standard value tables, full disassembly and assembly procedures, and maintenance standards for the engine, its intake and exhaust systems, fuel system, lubrication system, cooling system, electrical system, and the Tier 4 Final aftertreatment package (KDPF, KDOC, urea SCR, EGR, VGT, KCCV). If you are rebuilding, diagnosing, or adjusting a 107E-3 engine, this is the factory document you work from.

File Details

• Manual type: Engine Shop Manual
• Brand: Komatsu
• Series: 107E-3
• Engines covered: SAA4D107E-3 (4-cylinder), SAA6D107E-3 (6-cylinder)
• Language: English
• Page count: 686
• File format: PDF
• Document number: SEN06502-17
• Publication date: 11-2019

Chapters Covered

• 00 INDEX AND FOREWORD
• 01 SPECIFICATIONS
• 10 STRUCTURE AND FUNCTION
• 20 STANDARD VALUE TABLE
• 50 DISASSEMBLY AND ASSEMBLY
• 60 MAINTENANCE STANDARD

00 – Index and Foreword

The opening chapter explains how to read the manual, lists the abbreviations used in the text and in the circuit diagrams, and lays out the safety notices for operation, fire prevention and the actions to take if a fire occurs. It also covers waste-material disposal, exhaust gas regulation compliance, DEF (AdBlue) precautions and storage, and the handling precautions for hydraulic, electrical, fuel, and intake-system equipment. Rounding out the chapter are the push-pull coupler procedures, the connector disconnect/connect methods (Deutsch, slide-lock, lock-to-pull, lock-to-push, housing-to-rotate), how to read the electrical wire code, the maintenance-standard terminology, the standard tightening torque tables, and the conversion tables. Read this before you touch anything.

01 – Specifications

This chapter opens with an outline of the exhaust gas regulations that the 107E-3 engines are built to meet, then lists the applicable machines for each engine variant. Engine specifications follow for every machine covered – rated horsepower, maximum torque, high- and low-idle speeds, fuel consumption ratio, dry weight, fuel injection system type, lubricating oil and coolant capacities, alternator and starting motor ratings, and turbocharger model. Engine general views (left side, right side, front, rear) with principal dimensions are given for each applicable machine, followed by the engine performance curves (torque and flywheel horsepower against engine speed).

10 – Structure and Function

This is the theory chapter. It covers the urea SCR system layout and function, AdBlue/DEF supply and injection, purge, thawing and freeze prevention, the inducement strategy tables for North America and the European Union, and the SCR, DEF pump, DEF injector, DEF tank, DEF hose, and DEF tank heating valve. The engine system section describes the intake and exhaust system, engine main body parts (cylinder head, cylinder block, main moving parts, piston ring, vibration damper, timing gear, front cover, valve system, flywheel and housing), turbocharger system (VGT), EGR system, EGR valve, EGR cooler, KCCV system and ventilator, KDPF, KDOC, lubrication system, fuel system, cooling system, and electrical system with alternator, starting motor, engine wiring harness, engine controller pin-outs, and every sensor.

20 – Standard Value Table

Machine-specific standard value tables for every applicable machine, giving the new-machine standard and the repair limit or failure criterion for engine speed, air intake resistance, boost pressure, exhaust temperature, exhaust gas colour, valve clearance, compression pressure, blowby pressure, low-pressure circuit pressure, main filter differential pressure, return circuit pressure, supply pump discharge and return, injector return, pressure limiter leakage, engine oil pressure, engine oil temperature, oil consumption rate, fan speed, and alternator belt tension.

50 – Disassembly and Assembly

Full step-by-step disassembly and assembly for the 4D107E-3 and the 6D107E-3, plus dedicated procedures for removing and installing the supply pump assembly, the engine front oil seal, and the engine rear oil seal. This chapter is where the special tools are listed and sketched, the coating materials table is given, and every tightening torque, liquid gasket application, angle-tightening sequence, and measurement step is spelled out. Fuel leakage check procedures after supply pump, common rail, or high-pressure pipe work are included.

60 – Maintenance Standard

Wear limits and service criteria for VGT radial and end play, cylinder head and block strain, main bearing bore and thickness, cylinder bore and roundness, crankshaft journal and pin dimensions, piston and piston ring clearances, connecting rod bushing and bearing dimensions, vibration damper, timing gear backlash, camshaft end play and lobe height, valve and valve guide, rocker arm, tappet, flywheel runout, and engine oil pump rotor clearance.

Engines and Machines Covered

The 4-cylinder SAA4D107E-3 section covers the D51EX-24, D51EXI-24, D51PX-24 and D51PXI-24 bulldozers; the HB215LC-3 and PC170LC-11 hydraulic excavators; and the WA200-8 wheel loader. The 6-cylinder SAA6D107E-3 section covers the BR380JG-3 mobile crusher; the D61EX-24, D61EX-24E0, D61EXI-24, D61EXI-24E0, D61PX-24, D61PX-24E0, D61PXI-24 and D61PXI-24E0 bulldozers; the GD655-6, GD655-7, GD675-6 and GD675-7E0 motor graders; the PC210LC-11, PC210LCI-11, PC228USLC-11, PC238USLC-11, PC240LC-11, PC290LC-11 and PC290LCI-11 hydraulic excavators; and the WA270-8, WA270-8E0, WA320-8, WA320-8E0 and WA380-8 wheel loaders. Because this is an engine shop manual rather than a machine manual, the content is organised around the two engine variants – the same engine data applies to every machine listed that uses it.

Aftertreatment and Emissions Systems

Tier 4 Final / Stage IV / Stage V emissions hardware is covered in depth: the Komatsu Diesel Particulate Filter (KDPF) with its KDOC oxidation catalyst and KCSF soot filter, passive and active regeneration (automatic, manual stationary, and active regeneration for service), the urea SCR system with AdBlue/DEF injection and the ammonia oxidation catalyst, the cooled EGR circuit with EGR valve and EGR cooler, the Variable Geometry Turbocharger (VGT) with its hydraulic actuator and position sensor, and the Komatsu Closed Crankcase Ventilation (KCCV) system with CDR valve and crankcase pressure sensor. Sensor locations, controller input/output signal tables, and the inducement strategy steps are documented for both North American and European Union markets.

What This Manual Lets You Do

With this Komatsu 107E-3 Series Engine Shop Manual on hand you can set valve clearance to the exact cold specification, measure and judge crankshaft end play and main bearing clearance, disassemble and reassemble the cylinder head and piston and connecting rod assemblies to the correct torque-plus-angle sequence, remove and refit the supply pump assembly without disturbing timing, service the front and rear oil seals, diagnose VGT, EGR, KCCV, KDPF and SCR faults using the standard value tables, and check fuel pressure at every point in the common-rail circuit. Every procedure is presented with the tool required, the tightening torque, the angle-tightening step where the torque-plus-angle method applies, and the measurement limit that tells you whether a part can be reused or must be replaced.

IMAGES PREVIEW

Instant PDF Delivery

The manual is delivered as an instant PDF download – no shipping, no waiting, no physical book to keep track of in the workshop. Open it on a laptop, tablet or phone, print the pages you need for the job, and keep the rest on file. Whether you are a Komatsu dealer technician, an independent heavy-equipment shop, a fleet maintenance operation, or an owner doing your own engine work, this is the reference that keeps the job inside the factory specification.