Komatsu ENGINE 107E -1 SERIES Shop Manual SEN00161-29 – PDF

Description

Komatsu ENGINE 107E -1 SERIES Shop Manual SEN00161-29 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ENGINE 107E -1 SERIES Shop Manual SEN00161-29 – PDF DOWNLOAD

Language : English
Pages :604
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ENGINE 107E -1 SERIES Shop Manual SEN00161-29 – PDF DOWNLOAD

1. General precautions

TABLE OF CONTENTS:

Komatsu ENGINE 107E -1 SERIES Shop Manual SEN00161-29 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 3
Foreword and general information 11
Safety notice 12
How to read the shop manual 17
Explanation of terms for maintenance standard 19
Handling of electric equipment and hydraulic component 21
Handling of connectors newly used for engines 30
How to read electric wire code 33
Precautions when carrying out operation 36
Method of disassembling and connecting push-pull type coupler 39
Standard tightening torque table 42
Conversion table 46
01 Specification 53
Specification and technical data 53
General 54
Specifications 55
General view 80
Dimensions table128
Engine performance curves129
10 Structure, function and maintenance standard151
Intake system153
Exhaust system154
Lubricating oil system156
Cooling system160
Fuel system161
Fuel supply pump162
CRI system163
Turbocharger167
Cylinder head168
Cylinder block170
Crankshaft172
Piston, piston ring and piston pin174
Connecting rod176
Vibration damper178
Timing gear179
Camshaft180
Valve and valve guide182
Rocker arm, shaft and tappet184
Flywheel and flywheel housing186
Oil pump188
Water pump drive and fan drive189
Water pump191
Thermostat192
Alternator193
Starting motor198
Sensor202
Engine controller208
Control system211
20 Standard value table221
Standard service value table221
Standard value table for testing, adjusting and troubleshooting222
Running-in standard and performance test criteria245
30 Testing and adjusting269
Testing and adjusting269
Precautions Before Work270
Testing and adjusting tools list271
Sketches of special tools273
Testing boost pressure274
Adjustment of valve clearance275
Testing compression pressure278
Testing blowby pressure281
Testing engine oil pressure282
Handling fuel system parts283
Releasing remaining pressure in fuel system283
Testing fuel pressure284
Reduced cylinder mode operation290
No-injection cranking290
Testing fuel delivery, return and leak amount291
Bleeding air from fuel circuit302
Testing fuel system for leakage303
Handling controller high-voltage circuit304
Replacing the fan belt304
40 Troubleshooting307
General information on troubleshooting307
Precautions Before Work308
Points on troubleshooting309
Error and failure code table310
Troubleshooting method for open circuit in wiring harness of pressure sensor system312
Information in troubleshooting table314
Connection table for connector pin numbers316
T- branch box and T- branch adapter table352
Troubleshooting of electrical system (E-mode), Part 1357
E-1 Code [111/CA111] Abnormality in engine controller359
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor359
E-3 Code [122/CA122] Charge pressure sensor high error360
E-4 Code [123/CA123] Charge pressure sensor low error362
E-5 Code [131/CA131] Throttle sensor power supply high error364
E-6 Code [132/CA132] Throttle sensor power supply low error366
E-7 Code [144/CA144] Coolant temperature sensor high error368
E-8 Code [145/CA145] Coolant temperature sensor low error370
E-9 Code [153/CA153] Charge temperature sensor high error372
E-10 Code [154/CA154] Charge temperature sensor low error374
E-11 Code [155/CA155] Derating of speed by charge temperature high error376
E-12 Code [187/CA187] Sensor power supply 2 low error378
E-13 Code [221/CA221] Atompspheric pressure sensor high error380
E-14 Code [222/CA222] Atompspheric pressure sensor low error382
E-15 Code [227/CA227] Sensor power supply 2 high error384
E-16 Code [234/CA234] Engine overspeed384
E-17 Code [238/CA238] Abnormallity in Ne speed sensor power supply385
E-18 Code [271/CA271] Short circuit in IMV/PCV1386
E-19 Code [272/CA272] Disconnection in IMV/PCV1388
E-20 Code [322/CA322] Disconnection, short circuit in injector No 1390
E-21 Code [323/CA323] Disconnection, short circuit in injector No 5392
E-22 Code [324/CA324] Disconnection, short circuit in injector No 3394
E-23 Code [325/CA325] Disconnection, short circuit in injector No 6396
E-24 Code [331/CA331] Disconnection, short circuit in injector No 2398
E-25 Code [332/CA332] Disconnection, short circuit in injector No 4400
E-26 Code [342/CA342] Calibration error in engine controller data402
E-27 Code [351/CA351] Abnormality in injector drive circuit403
E-28 Code [352/CA352] Sensor power supply 1 low error404
E-29 Code [386/CA386] Sensor power supply 1 high error406
E-30 Code [428/CA428] Water-in-fuel sensor high error408
E-31 Code [429/CA429] Water-in-fuel sensor low error410
E-32 Code [431/CA431] Abnormality in idle validation switch412
E-33 Code [432/CA432] Abnormality in idle validation processing414
Troubleshooting of electrical system (E-mode), Part 2417
E-34 Code [435/CA435] Abnormality in engine oil pressure switch419
E-35 Code [441/CA441] Abnormally low power supply voltage420
E-36 Code [442/CA442] Abnormally high power supply voltage422
E-37 Code [449/CA449] Common rail pressure high error 2423
E-38 Code [451/CA451] Common rail pressure sensor high error424
E-39 Code [452/CA452] Common rail pressure sensor low error426
E-40 Code [488/CA488] Derating of torque by charge temperature high error428
E-41 Code [553/CA553] Common rail pressure high error 1428
E-42 Code [559/CA559] No-pressure feed 1 by supply pump429
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor431
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase433
E-45 Code [757/CA757] Loss of all data in engine controller434
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor435
E-47 Code [1633/CA1633] Abnormality in KOMNET438
E-48 Code [2185/CA2185] Throttle sensor power supply high error439
E-49 Code [2186/CA2186] Throttle sensor power supply low error440
E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump441
E-51 Code [2311/CA2311] Abnormality in IMV solenoid441
E-52 Code [2555/CA2555] Disconnection in intake air heater relay442
E-53 Code [2556/CA2556] Short circuit in intake air heater relay444
E-54 Code [—/B@BAZG] Derating of speed by engine oil pressure reduction446
E-55 Code [—/B@BAZK] Engine oil level low446
E-56 Code [—/B@BCNS] Engine overheat447
E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error448
E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error450
E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error452
E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error454
E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition)456
E-62 Code [b6] Droop Rate Adjustment Volume High Error460
E-63 Code [b7] Droop Rate Adjustment Volume Low Error462
E-64 Code [b8] Low Idle Speed Adjustment Volume High Error464
E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error466
E-66 Code [bc] Rated Speed Median Adjustment Volume High Error468
E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error470
E-68 Code [bE] Ramp Time Adjustment Volume High Error472
E-69 Code [bF] Ramp Time Adjustment Volume Low Error474
Troubleshooting of mechanical system (S-mode)477
Method of using troubleshooting charts480
S-1 Starting performance is poor484
S-2 Engine does not start485
S-3 Engine does not pick up smoothly488
S-4 Engine stops during operations489
S-5 Engine does not rotate smoothly490
S-6 Engine lacks output (or lacks power)491
S-7 Exhaust smoke is black (incomplete combustion)492
S-8 Oil consumption is excessive (or exhaust smoke is blue)493
S-9 Oil becomes contaminated quickly494
S-10 Fuel consumption is excessive495
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)496
S-12 Oil pressure drops497
S-13 Oil level rises (Entry of coolant or fuel)498
S-14 Coolant temperature becomes too high (overheating)499
S-15 Abnormal noise is made500
S-16 Vibration is excessive501
50 Disassembly and assembly503
General information on disassembly and assembly503
Precautions Before Work504
How to read this manual505
Coating materials list507
Special tools list510
Disassembly and assembly, Part 1513
General disassembly of engine514
Disassembly and assembly, Part 2533
General assembly of engine534
90 Repair and replacement of parts569
Information related to repair and replacement569
Special tool table570
Parts related to cylinder head573
Repair of cylinder head574
Check of valve guide575
Replacement of valve seat insert576
Vacuum test of valve seat insert578
Grinding of valve579
Parts related to cylinder block583
Repair of cylinder block584
Repair of crankshaft596
Replacement of connecting rod bushing599

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24