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KOMATSU 107E-5 SERIES ENGINE SHOP MANUAL SEN06896-03 – PDF DOWNLOAD
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Description
KOMATSU 107E-5 SERIES ENGINE SHOP MANUAL SEN06896-03 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 107E-5 SERIES ENGINE SHOP MANUAL SEN06896-03 – PDF DOWNLOAD
Language : English
Pages : 354
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 107E-5 SERIES ENGINE SHOP MANUAL SEN06896-03 – PDF DOWNLOAD
COVER.......................................................................................................................................................... 3 00 INDEX AND FOREWORD......................................................................................................................................... 3 INDEX..................................................................................................................................................... 4 FOREWORD, SAFETY, BASIC INFORMATION....................................................................................................................... 6 HOW TO READ THE ENGINE SHOP MANUAL.................................................................................................................... 6 SAFETY NOTICE FOR OPERATION........................................................................................................................... 8 PRECAUTIONS TO PREVENT FIRE........................................................................................................................... 16 ACTIONS IF FIRE OCCURS................................................................................................................................ 18 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.......................................................................................................... 19 ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION..................................................................................................... 20 PRECAUTIONS FOR DEF................................................................................................................................... 21 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.................................................................................................... 21 PRECAUTIONS FOR ADDING............................................................................................................................ 21 PRECAUTIONS FOR STORING........................................................................................................................... 21 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE........................................................................................................... 21 THE OTHER PRECAUTIONS............................................................................................................................. 21 STORE AdBlue/DEF...................................................................................................................................... 22 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.......................................................................................................... 23 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS............................................................................................... 26 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT......................................................................................................... 33 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT........................................................................................................ 35 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...................................................................................................... 36 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER......................................................................................................... 37 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER............................................................................. 37 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER............................................................................. 38 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER............................................................................. 39 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................................................................................ 41 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR............................................................................................. 45 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR..................................................................................... 46 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL................................................................................... 48 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH................................................................................... 49 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE.............................................................................. 51 HOW TO READ ELECTRICAL WIRE CODE...................................................................................................................... 52 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD......................................................................................................... 56 STANDARD TIGHTENING TORQUE TABLE...................................................................................................................... 59 CONVERSION TABLE...................................................................................................................................... 66 ABBREVIATION LIST..................................................................................................................................... 71 01 SPECIFICATIONS............................................................................................................................................. 75 CONTENTS.................................................................................................................................................. 76 SPECIFICATIONS............................................................................................................................................ 77 OUTLINE OF EXHAUST GAS REGULATION..................................................................................................................... 77 SYSTEM DIAGRAM OF ENGINE CONFORMED TO STAGE V REGULATION.......................................................................................... 79 LIST OF APPLICABLE MACHINES: 107E-5................................................................................................................... 80 SPECIFICATIONS........................................................................................................................................ 81 SPECIFICATIONS: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0).................................................................... 81 SPECIFICATIONS: SAA4D107E-5 (GD535-6)............................................................................................................. 82 SPECIFICATIONS: SAA4D107E-5 (WA200-8E0)........................................................................................................... 83 ENGINE GENERAL VIEW................................................................................................................................... 84 ENGINE GENERAL VIEW: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)............................................................... 84 ENGINE GENERAL VIEW: SAA4D107E-5 (GD535-6)........................................................................................................ 88 ENGINE GENERAL VIEW: SAA4D107E-5 (WA200-8E0)...................................................................................................... 92 ENGINE PERFORMANCE CURVE.............................................................................................................................. 96 ENGINE PERFORMANCE CURVE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0).......................................................... 96 ENGINE PERFORMANCE CURVE: SAA4D107E-5 (GD535-6)................................................................................................... 97 ENGINE PERFORMANCE CURVE: SAA4D107E-5 (WA200-8E0)................................................................................................. 98 10 STRUCTURE AND FUNCTION..................................................................................................................................... 99 CONTENTS..................................................................................................................................................100 UREA SCR SYSTEM...........................................................................................................................................102 LAYOUT DRAWING OF UREA SCR SYSTEM.....................................................................................................................102 UREA SCR SYSTEM DIAGRAM...............................................................................................................................104 FUNCTION OF UREA SCR SYSTEM...........................................................................................................................105 FUNCTION OF AdBlue/DEF SUPPLY SYSTEM..............................................................................................................105 INDUCEMENT STRATEGY...............................................................................................................................107 COMPONENT PARTS OF UREA SCR SYSTEM....................................................................................................................114 SCR ASSEMBLY......................................................................................................................................114 AdBlue/DEF TANK...................................................................................................................................116 AdBlue/DEF PUMP...................................................................................................................................118 AdBlue/DEF INJECTOR...............................................................................................................................119 AdBlue/DEF HOSE...................................................................................................................................120 AdBlue/DEF TANK HEATING VALVE.....................................................................................................................121 ENGINE SYSTEM.............................................................................................................................................122 LAYOUT OF ENGINE COMPONENTS...........................................................................................................................122 LAYOUT DRAWING OF ENGINE COMPONENTS...............................................................................................................122 INTAKE AND EXHAUST SYSTEM PARTS.......................................................................................................................123 LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................................................................123 INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM.........................................................................................................124 FUNCTION OF INTAKE AND EXHAUST SYSTEM.............................................................................................................124 AIR CLEANER.......................................................................................................................................126 INTAKE AIR HEATER.................................................................................................................................127 ENGINE MAIN BODY PARTS................................................................................................................................128 CYLINDER HEAD.....................................................................................................................................128 CYLINDER BLOCK....................................................................................................................................130 MAIN MOVING PARTS.................................................................................................................................132 CRANKSHAFT PULLEY.................................................................................................................................135 TIMING GEAR.......................................................................................................................................136 FRONT COVER.......................................................................................................................................137 VALVE SYSTEM......................................................................................................................................138 FLYWHEEL AND FLYWHEEL HOUSING.....................................................................................................................140 TURBOCHARGER..........................................................................................................................................142 STRUCTURE OF TURBOCHARGER.........................................................................................................................142 SPECIFICATIONS OF TURBOCHARGER....................................................................................................................143 FUNCTION OF TURBOCHARGER..........................................................................................................................143 CRANKCASE VENTILATION SYSTEM..........................................................................................................................145 SYSTEM DIAGRAM OF CRANKCASE VENTILATION SYSTEM....................................................................................................145 FUNCTION OF CRANKCASE VENTILATION SYSTEM..........................................................................................................145 IMPACTOR (FILTERLESS).................................................................................................................................146 STRUCTURE OF IMPACTOR (FILTERLESS)................................................................................................................146 OPERATION OF IMPACTOR (FILTERLESS)................................................................................................................146 EXHAUST THROTTLE VALVE................................................................................................................................147 STRUCTURE OF EXHAUST THROTTLE VALVE...............................................................................................................147 FUNCTION OF EXHAUST THROTTLE VALVE................................................................................................................147 OPERATION OF EXHAUST THROTTLE VALVE...............................................................................................................147 KDPF..................................................................................................................................................148 STRUCTURE OF KDPF.................................................................................................................................148 FUNCTION OF KDPF..................................................................................................................................149 TYPES OF REGENERATION FUNCTION....................................................................................................................150 LUBRICATION SYSTEM....................................................................................................................................152 LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS........................................................................................................152 LUBRICATION SYSTEM CIRCUIT DIAGRAM................................................................................................................153 ENGINE OIL PUMP...................................................................................................................................154 ENGINE OIL FILTER.................................................................................................................................155 ENGINE OIL COOLER.................................................................................................................................156 ENGINE OIL REGULATOR VALVE........................................................................................................................158 SAFETY VALVE OF ENGINE OIL........................................................................................................................159 ENGINE OIL PAN....................................................................................................................................160 FUEL SYSTEM...........................................................................................................................................161 LAYOUT DRAWING OF FUEL SYSTEM PARTS...............................................................................................................161 FUEL SYSTEM CIRCUIT DIAGRAM.......................................................................................................................162 CRI SYSTEM........................................................................................................................................163 SUPPLY PUMP.......................................................................................................................................165 COMMON RAIL.......................................................................................................................................166 INJECTOR..........................................................................................................................................167 FUEL PREFILTER....................................................................................................................................169 FUEL MAIN FILTER..................................................................................................................................170 COOLING SYSTEM........................................................................................................................................171 LAYOUT DRAWING OF COOLING SYSTEM PARTS............................................................................................................171 COOLING SYSTEM CIRCUIT DIAGRAM....................................................................................................................172 DRIVE PULLEY......................................................................................................................................173 WATER PUMP........................................................................................................................................174 THERMOSTAT........................................................................................................................................175 ELECTRICAL SYSTEM.........................................................................................................................................176 COMPONENT PARTS OF ELECTRICAL SYSTEM..................................................................................................................176 ALTERNATOR........................................................................................................................................176 STARTING MOTOR....................................................................................................................................179 ENGINE WIRING HARNESS.............................................................................................................................180 ENGINE CONTROLLER.................................................................................................................................182 SENSOR................................................................................................................................................190 LAYOUT DRAWING OF ENGINE SENSOR...................................................................................................................190 STRUCTURE OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR......................................................................................193 FUNCTION OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR.......................................................................................193 STRUCTURE OF ENGINE OIL PRESSURE SWITCH...........................................................................................................194 FUNCTION OF ENGINE OIL PRESSURE SWITCH............................................................................................................194 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR.......................................................................................195 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR........................................................................................195 STRUCTURE OF COOLANT TEMPERATURE SENSOR...........................................................................................................196 FUNCTION OF COOLANT TEMPERATURE SENSOR............................................................................................................196 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR.........................................................................................................197 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR..........................................................................................................197 STRUCTURE OF Bkup (CAM) SPEED SENSOR..............................................................................................................198 FUNCTION OF Bkup (CAM) SPEED SENSOR...............................................................................................................198 STRUCTURE OF COMMON RAIL PRESSURE SENSOR..........................................................................................................199 FUNCTION OF COMMON RAIL PRESSURE SENSOR...........................................................................................................199 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR................................................................................200 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR.................................................................................200 STRUCTURE OF CRANKCASE PRESSURE SENSOR............................................................................................................201 FUNCTION OF CRANKCASE PRESSURE SENSOR.............................................................................................................201 STRUCTURE OF ENGINE OIL LEVEL SENSOR..............................................................................................................202 FUNCTION OF ENGINE OIL LEVEL SENSOR...............................................................................................................202 STRUCTURE OF AIR CLEANER CLOGGING SENSOR..........................................................................................................203 FUNCTION OF AIR CLEANER CLOGGING SENSOR...........................................................................................................203 STRUCTURE OF WATER-IN-FUEL SENSOR.................................................................................................................204 FUNCTION OF WATER-IN-FUEL SENSOR..................................................................................................................204 STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR.....................................................................................................205 FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR......................................................................................................205 STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)...............................................................................206 FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)................................................................................206 20 STANDARD VALUE TABLE.......................................................................................................................................207 CONTENTS..................................................................................................................................................208 STANDARD VALUE TABLE FOR ENGINE...........................................................................................................................209 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0).......................................................209 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (GD535-6)................................................................................................212 STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0)..............................................................................................215 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD.........................................................................................................218 PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)....218 PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (GD535-6).............................................220 PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (WA200-8E0)...........................................222 50 DISASSEMBLY AND ASSEMBLY...................................................................................................................................225 CONTENTS..................................................................................................................................................226 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................................................................................227 HOW TO READ THIS MANUAL...............................................................................................................................227 COATING MATERIALS LIST................................................................................................................................229 SPECIAL TOOLS LIST....................................................................................................................................234 SKETCHES OF SPECIAL TOOLS.............................................................................................................................236 ENGINE SYSTEM.............................................................................................................................................237 DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY.............................................................................................................237 DISASSEMBLE ENGINE GENERALLY......................................................................................................................238 ASSEMBLE ENGINE GENERALLY.........................................................................................................................265 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...............................................................................................................311 REMOVE SUPPLY PUMP ASSEMBLY.......................................................................................................................311 INSTALL SUPPLY PUMP ASSEMBLY......................................................................................................................314 REMOVE AND INSTALL ENGINE FRONT OIL SEAL..............................................................................................................317 REMOVE ENGINE FRONT OIL SEAL......................................................................................................................317 INSTALL ENGINE FRONT OIL SEAL.....................................................................................................................319 REMOVE AND INSTALL ENGINE REAR OIL SEAL...............................................................................................................322 REMOVE ENGINE REAR OIL SEAL.......................................................................................................................322 INSTALL ENGINE REAR OIL SEAL......................................................................................................................323 60 MAINTENANCE STANDARD.......................................................................................................................................327 CONTENTS..................................................................................................................................................328 ENGINE SYSTEM.............................................................................................................................................329 INTAKE AND EXHAUST SYSTEM PARTS.......................................................................................................................329 MAINTENANCE STANDARD OF TURBOCHARGER..............................................................................................................329 ENGINE MAIN BODY PARTS................................................................................................................................330 MAINTENANCE STANDARD OF CYLINDER HEAD.............................................................................................................330 MAINTENANCE STANDARD OF CYLINDER BLOCK............................................................................................................332 MAINTENANCE STANDARD OF CRANKSHAFT................................................................................................................334 MAINTENANCE STANDARD OF PISTON....................................................................................................................336 MAINTENANCE STANDARD OF CONROD....................................................................................................................337 MAINTENANCE STANDARD OF TIMING GEAR...............................................................................................................339 MAINTENANCE STANDARD OF CAMSHAFT..................................................................................................................340 MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE.....................................................................................................342 MAINTENANCE STANDARD OF ROCKER ARM................................................................................................................344 MAINTENANCE STANDARD OF TAPPET....................................................................................................................345 MAINTENANCE STANDARD OF FLYWHEEL..................................................................................................................346 LUBRICATION SYSTEM....................................................................................................................................348 MAINTENANCE STANDARD OF ENGINE OIL PUMP...........................................................................................................348 INDEX..........................................................................................................................................................349
DESCRIPTION:
KOMATSU 107E-5 SERIES ENGINE SHOP MANUAL SEN06896-03 – 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 21/12/24
