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KOMATSU 107E-3 SERIES ENGINE SHOP MANUAL SEN06655-03 – PDF DOWNLOAD
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Description
KOMATSU 107E-3 SERIES ENGINE SHOP MANUAL SEN06655-03 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 107E-3 SERIES ENGINE SHOP MANUAL SEN06655-03 – PDF DOWNLOAD
Language : English
Pages : 380
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 107E-3 SERIES ENGINE SHOP MANUAL SEN06655-03 – PDF DOWNLOAD
COVER........................................................................................................... 1 00 INDEX AND FOREWORD.......................................................................................... 3 INDEX...................................................................................................... 4 ABBREVIATION LIST.......................................................................................... 6 FOREWORD, SAFETY, BASIC INFORMATION........................................................................ 12 HOW TO READ THE ENGINE SHOP MANUAL..................................................................... 12 SAFETY NOTICE FOR OPERATION............................................................................ 14 PRECAUTIONS TO PREVENT FIRE............................................................................ 22 ACTIONS IF FIRE OCCURS................................................................................. 24 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS........................................................... 25 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS.......................................................... 26 PRECAUTIONS FOR DEF.................................................................................... 27 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING..................................................... 27 PRECAUTIONS FOR ADDING............................................................................. 27 PRECAUTIONS FOR STORING............................................................................ 27 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE............................................................ 27 THE OTHER PRECAUTIONS.............................................................................. 27 STORE AdBlue/DEF....................................................................................... 28 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT........................................................... 29 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................................ 32 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT.......................................................... 39 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT......................................................... 41 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT....................................................... 42 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.......................................................... 43 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER.............................. 43 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER.............................. 44 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER.............................. 45 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................................. 47 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR.............................................. 51 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...................................... 52 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.................................... 54 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.................................... 55 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE............................... 57 HOW TO READ ELECTRICAL WIRE CODE....................................................................... 58 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......................................................... 62 STANDARD TIGHTENING TORQUE TABLE....................................................................... 65 CONVERSION TABLE....................................................................................... 72 01 SPECIFICATIONS.............................................................................................. 77 CONTENTS................................................................................................... 78 ABBREVIATION LIST.......................................................................................... 79 SPECIFICATIONS............................................................................................. 85 OUTLINE OF EXHAUST GAS REGULATION...................................................................... 85 SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION............................................ 86 IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION............................................ 86 LIST OF APPLICABLE MACHINES: 107E-3.................................................................... 88 SPECIFICATIONS......................................................................................... 89 SPECIFICATIONS: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1)................................... 89 ENGINE GENERAL VIEW.................................................................................... 90 ENGINE GENERAL VIEW: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1).............................. 90 ENGINE PERFORMANCE CURVE............................................................................... 94 ENGINE PERFORMANCE CURVE: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1)......................... 94 10 STRUCTURE AND FUNCTION...................................................................................... 95 CONTENTS................................................................................................... 96 ABBREVIATION LIST.......................................................................................... 98 UREA SCR SYSTEM............................................................................................104 LAYOUT DRAWING OF UREA SCR SYSTEM......................................................................104 UREA SCR SYSTEM DIAGRAM................................................................................107 FUNCTION OF UREA SCR SYSTEM............................................................................108 FUNCTION OF AdBlue/DEF SUPPLY SYSTEM...............................................................108 INDUCEMENT STRATEGY................................................................................110 COMPONENT PARTS OF UREA SCR SYSTEM.....................................................................124 AdBlue/DEF MIXING TUBE.............................................................................124 SCR ASSEMBLY.......................................................................................125 AdBlue/DEF TANK....................................................................................127 AdBlue/DEF PUMP....................................................................................129 AdBlue/DEF INJECTOR................................................................................130 AdBlue/DEF HOSE....................................................................................131 AdBlue/DEF TANK HEATING VALVE......................................................................132 ENGINE SYSTEM..............................................................................................133 LAYOUT OF ENGINE COMPONENTS............................................................................133 LAYOUT DRAWING OF ENGINE COMPONENTS................................................................133 INTAKE AND EXHAUST SYSTEM PARTS........................................................................134 LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM........................................................134 INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM..........................................................135 FUNCTION OF INTAKE AND EXHAUST SYSTEM..............................................................135 AIR CLEANER........................................................................................137 INTAKE AIR HEATER..................................................................................139 ENGINE MAIN BODY PARTS.................................................................................140 CYLINDER HEAD......................................................................................140 CYLINDER BLOCK.....................................................................................142 MAIN MOVING PARTS..................................................................................144 TIMING GEAR........................................................................................148 FRONT COVER........................................................................................149 VALVE SYSTEM.......................................................................................150 FLYWHEEL AND FLYWHEEL HOUSING......................................................................153 TURBOCHARGER SYSTEM....................................................................................155 CIRCUIT DIAGRAM OF VGT SYSTEM......................................................................155 FUNCTION OF VGT SYSTEM.............................................................................155 VGT................................................................................................156 EGR SYSTEM.........................................................................................159 EGR VALVE..........................................................................................161 EGR COOLER.........................................................................................163 KCCV SYSTEM........................................................................................165 KCCV VENTILATOR....................................................................................169 KDOC...............................................................................................171 LUBRICATION SYSTEM.....................................................................................174 LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS.........................................................174 LUBRICATION SYSTEM CIRCUIT DIAGRAM.................................................................175 ENGINE OIL PUMP....................................................................................176 ENGINE OIL FILTER..................................................................................177 ENGINE OIL COOLER..................................................................................178 ENGINE OIL REGULATOR VALVE.........................................................................179 SAFETY VALVE OF ENGINE OIL.........................................................................180 ENGINE OIL PAN.....................................................................................181 FUEL SYSTEM............................................................................................182 LAYOUT DRAWING OF FUEL SYSTEM PARTS................................................................182 FUEL SYSTEM CIRCUIT DIAGRAM........................................................................183 FUNCTION OF FUEL SYSTEM............................................................................183 SUPPLY PUMP........................................................................................186 FUEL PREFILTER.....................................................................................187 FUEL MAIN FILTER...................................................................................188 COOLING SYSTEM.........................................................................................189 LAYOUT DRAWING OF COOLING SYSTEM PARTS.............................................................189 COOLING SYSTEM CIRCUIT DIAGRAM.....................................................................190 DRIVE PULLEY.......................................................................................191 WATER PUMP.........................................................................................192 THERMOSTAT.........................................................................................193 ELECTRICAL SYSTEM..........................................................................................194 COMPONENT PARTS OF ELECTRICAL SYSTEM...................................................................194 ALTERNATOR.........................................................................................194 STARTING MOTOR.....................................................................................196 ENGINE WIRING HARNESS..............................................................................197 ENGINE CONTROLLER..................................................................................199 SENSOR.................................................................................................206 LAYOUT DRAWING OF ENGINE SENSOR....................................................................206 STRUCTURE OF AMBIENT PRESSURE SENSOR...............................................................210 FUNCTION OF AMBIENT PRESSURE SENSOR................................................................210 STRUCTURE OF ENGINE OIL PRESSURE SWITCH............................................................211 FUNCTION OF ENGINE OIL PRESSURE SWITCH.............................................................211 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR........................................212 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR.........................................212 STRUCTURE OF COOLANT TEMPERATURE SENSOR............................................................213 FUNCTION OF COOLANT TEMPERATURE SENSOR.............................................................213 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR..........................................................214 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR...........................................................214 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR..........................................................215 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR...........................................................215 STRUCTURE OF COMMON RAIL PRESSURE SENSOR...........................................................216 FUNCTION OF COMMON RAIL PRESSURE SENSOR............................................................216 STRUCTURE OF VGT SPEED SENSOR......................................................................217 FUNCTION OF VGT SPEED SENSOR.......................................................................217 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR..................................................218 FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR...................................................218 STRUCTURE OF CRANKCASE PRESSURE SENSOR.............................................................219 FUNCTION OF CRANKCASE PRESSURE SENSOR..............................................................219 STRUCTURE OF AIR CLEANER CLOGGING SENSOR...........................................................220 FUNCTION OF AIR CLEANER CLOGGING SENSOR............................................................220 STRUCTURE OF WATER-IN-FUEL SENSOR..................................................................221 FUNCTION OF WATER-IN-FUEL SENSOR...................................................................221 STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR).............................................222 FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)..............................................222 STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR......................................................223 FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR.......................................................223 STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR........................................................224 FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR.........................................................224 STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)..........................................225 FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)...........................................225 20 STANDARD VALUE TABLE........................................................................................227 CONTENTS...................................................................................................228 ABBREVIATION LIST..........................................................................................229 STANDARD VALUE TABLE FOR ENGINE............................................................................235 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1)......................235 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD..........................................................238 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1)....238 50 DISASSEMBLY AND ASSEMBLY....................................................................................241 CONTENTS...................................................................................................242 ABBREVIATION LIST..........................................................................................243 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY............................................................249 HOW TO READ THIS MANUAL................................................................................249 COATING MATERIALS LIST.................................................................................251 SPECIAL TOOLS LIST.....................................................................................255 SKETCHES OF SPECIAL TOOLS..............................................................................257 ENGINE SYSTEM..............................................................................................258 DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)...................................................258 METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)................................................258 METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3)...................................................285 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3).....................................................332 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3)................................................332 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)..............................................335 REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3)....................................................338 METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3)...............................................338 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3).............................................340 REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3).....................................................343 METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3)................................................343 METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3)..............................................344 60 MAINTENANCE STANDARD........................................................................................347 CONTENTS...................................................................................................348 ABBREVIATION LIST..........................................................................................349 ENGINE SYSTEM..............................................................................................355 INTAKE AND EXHAUST SYSTEM PARTS........................................................................355 MAINTENANCE STANDARD OF VGT........................................................................355 ENGINE MAIN BODY PARTS.................................................................................356 MAINTENANCE STANDARD OF CYLINDER HEAD..............................................................356 MAINTENANCE STANDARD OF CYLINDER BLOCK.............................................................358 MAINTENANCE STANDARD OF CRANKSHAFT.................................................................360 MAINTENANCE STANDARD OF PISTON.....................................................................362 MAINTENANCE STANDARD OF CONROD.....................................................................363 MAINTENANCE STANDARD OF TIMING GEAR................................................................365 MAINTENANCE STANDARD OF CAMSHAFT...................................................................366 MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE......................................................368 MAINTENANCE STANDARD OF ROCKER ARM.................................................................370 MAINTENANCE STANDARD OF TAPPET.....................................................................371 MAINTENANCE STANDARD OF FLYWHEEL...................................................................372 LUBRICATION SYSTEM.....................................................................................374 MAINTENANCE STANDARD OF ENGINE OIL PUMP............................................................374 INDEX...........................................................................................................375
DESCRIPTION:
KOMATSU 107E-3 SERIES ENGINE SHOP MANUAL SEN06655-03 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
S.S 22/12/24
