Komatsu SAA6D107E-1-A Engine Shop Manual 6D107E-BE1 (00) PDF

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Komatsu SAA6D107E-1-A Engine Shop Manual 6D107E-BE1 (00) – PDF DOWNLOAD

FILE DETAILS:

Komatsu SAA6D107E-1-A Engine Shop Manual 6D107E-BE1 (00) – PDF DOWNLOAD

 Language : English
Pages : 316
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu SAA6D107E-1-A Engine Shop Manual 6D107E-BE1 (00) – PDF DOWNLOAD 

FD100-8 M246-7001 and up
FD115-8 M246-7001 and up
FD135-8 M247-7001 and up
FD150E-8 M247-7001 and up
FD160E-8 M247-7001 and up

How to read the shop manual :
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.

TABLE OF CONTENTS:

Komatsu SAA6D107E-1-A Engine Shop Manual 6D107E-BE1 (00) – PDF DOWNLOAD

FD100-8 M246-7001 and up
FD115-8 M246-7001 and up
FD135-8 M247-7001 and up
FD150E-8 M247-7001 and up
FD160E-8 M247-7001 and up

00 Index and foreword 6D107E-BE1 (00)
Composition of shop manual 00-2
Table of contents 00-3
Safety notice 00-6
How to read the shop manual 00-11
Explanation of terms for maintenance standard 00-13
Handling of electric equipment and hydraulic component 00-15
Handling of connectors newly used for engines 00-24
How to read electric wire code 00-27
Precautions when carrying out operation 00-30
Method of disassembling and connecting push-pull type coupler 00-33
Standard tightening torque table 00-36
Conversion table 00-40
01 Specification 6D107E-BE1 (01)
General 01-2
Specifications 01-3
General view 01-4
Engine performance curve 01-9
10 Structure, function and maintenance standard 6D107E-BE1 (10)
Air intake and exhaust units 10-4
Intake system 10-6
Exhaust system 10-7
Turbocharger 10-10
Cooling system 10-17
Fuel system 10-18
Cylinder head 10-22
Cylinder block 10-26
Crankshaft 10-28
Piston, piston ring and piston pin 10-30
Connecting rod 10-31
Vibration damper 10-32
Timing gear 10-33
Camshaft 10-34
Valve and valve guide 10-36
Rocker arm, shaft and tappet 10-38
Oil pump 10-42
Oil pan 10-43
Flywheel and flywheel housing 10-44
Oil filter 10-46
Oil cooler 10-47
Fuel supply pump 10-48
Water pump drive and fan drive 10-49
20 Standard value table 6D107E-BE1 (20)
Standard value table for testing, adjusting and troubleshooting 20-2
Run-in standard and performance test criteria 20-3
6D107E-BE1 (00) 00 Index and foreword
00-4 SAA6D107E-1-A
30 Testing and adjusting 6D107E-BE1 (30)
Testing and adjusting tools list 30-2
Testing air boost pressure 30-4
Adjustment of valve clearance 30-5
Testing compression pressure 30-7
Testing blow-by pressure 30-10
Testing engine oil pressure 30-11
Handling fuel system parts 30-12
Releasing residual pressure in fuel system 30-12
Testing fuel pressure 30-13
Reduced cylinder mode operation 30-15
No-injection cranking 30-15
Testing leakage from pressure limiter and return rate from injector 30-16
Bleeding air from fuel circuit 30-20
Testing fuel system for leakage 30-21
Replacing the fan belt 30-22
Handling controller high-voltage circuit 30-22
Functions of troubleshooting tool and check of failure code 30-24
40 Troubleshooting 6D107E-BE1 (40)
General information on troubleshooting 40-4
Failure code table 40-5
Information in troubleshooting table 40-7
Method of using troubleshooting charts 40-9
Troubleshooting for mechanical system (S mode) 40-12
S-1 Starting performance is poor 40-12
S-2 Engine does not start 40-13
S-3 Engine does not pick up smoothly 40-16
S-4 Engine stops during operations 40-17
S-5 Engine does not rotate smoothly 40-18
S-6 Engine lacks output (or lacks power) 40-19
S-7 Exhaust smoke is black (incomplete combustion) 40-20
S-8 Oil consumption is excessive (or exhaust smoke is blue) 40-21
S-9 Oil becomes contaminated quickly 40-22
S-10 Fuel consumption is excessive 40-23
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 40-24
S-12 Oil pressure drops 40-25
S-13 Oil level rises (Entry of coolant or fuel) 40-26
S-14 Coolant temperature becomes too high (overheating) 40-27
S-15 Abnormal noise is made 40-28
S-16 Vibration is excessive 40-29
Troubleshooting for electrical system (E mode) 40-30
E-1 Failure code [111] Abnormality in engine controller 40-30
E-2 Failure code [115] Engine Ne or Bkup speed sensor error 40-31
E-3 Failure code [122] Abnormally high level in charge pressure sensor 40-32
E-4 Failure code [123] Abnormally low level in charge pressure sensor 40-34
E-5 Failure code [131] Throttle sensor high error 40-36
E-6 Failure code [132] Throttle sensor low error 40-38
E-7 Failure code [143] (Torque derating by low engine oil pressure) 40-40
E-8 Failure code [144] Abnormally high level in coolant temperature sensor 40-42
E-9 Failure code [145] Abnormally low level in coolant temperature sensor 40-44
E-10 Failure code [146] (Engine overheating) 40-46
E-11 Failure code [153] Abnormally high level in charge temperature sensor 40-48
E-12 Failure code [154] Abnormally low level in charge temperature sensor 40-50
E-13 Failure code [187] Abnormally low level in sensor power supply 2 40-52
E-14 Failure code [221] Abnormally high level in atmospheric pressure sensor 40-54
E-15 Failure code [222] Abnormally low level in atmospheric pressure sensor 40-56
00 Index and foreword 6D107E-BE1 (00)
SAA6D107E-1-A 00-5
E-16 Failure code [227] Abnormally high level in sensor power supply 2 40-58
E-17 Failure code [234] Engine overspeed 40-59
E-18 Failure code [238] Abnormally level in Ne speed sensor power supply 40-60
E-19 Failure code [271] Short circuit in IMV 40-61
E-20 Failure code [272] Disconnection in IMV 40-62
E-21 Failure code [322] Disconnection, short circuit in injector No 1 (L/B No 1) 40-64
E-22 Failure code [323] Disconnection, short circuit in injector No 5 (L/B No 5) 40-66
E-23 Failure code [324] Disconnection, short circuit in injector No 3 (L/B No 3) 40-68
E-24 Failure code [325] Disconnection, short circuit in injector No 6 (L/B No 6) 40-70
E-25 Failure code [331] Disconnection, short circuit in injector No 2 (L/B No 2) 40-72
E-26 Failure code [332] Disconnection, short circuit in injector No 4 (L/B No 4) 40-74
E-27 Failure code [342] Matching error in engine controller data 40-76
E-28 Failure code [351] Abnormality in injector drive circuit 40-78
E-29 Failure code [352] Abnormally low level in sensor power supply 1 40-80
E-30 Failure code [386] Abnormally high level in sensor power supply 1 40-82
E-31 Failure code [415] (Rotation derating by low engine oil pressure) 40-83
E-32 Failure code [418] Water mixed in fuel 40-84
E-33 Failure code [428] Abnormally high level in water sensor 40-86
E-34 Failure code [429] Abnormally low level in water sensor 40-88
E-35 Failure code [431] Idle validation switch error 40-90
E-36 Failure code [432] Idle validation action error 40-92
E-37 Failure code [435] Abnormality in engine oil pressure switch 40-94
E-38 Failure code [441] Abnormally low power supply voltage 40-96
E-39 Failure code [442] Abnormally high power supply voltage 40-98
E-40 Failure code [449] Abnormally high common rail pressure 2 40-100
E-41 Failure code [451] Abnormally high level in common rail pressure sensor 40-102
E-42 Failure code [452] Abnormally low level in common rail pressure sensor 40-104
E-43 Failure code [488] Derating of torque by abnormally high charge temperature 40-106
E-44 Failure code [553] Abnormally high common rail pressure 1 40-107
E-45 Failure code [559] No-pressure feed by supply pump 1 40-108
E-46 Failure code [689] Abnormality in engine Ne speed sensor 40-110
E-47 Failure code [731] Abnormality in engine Bkup speed sensor phase 40-112
E-48 Failure code [757] Loss of all data in engine controller 40-114
E-49 Failure code [778] Abnormality in engine Bkup speed sensor 40-116
E-50 Failure code [2185] Throttle sensor supply voltage high error 40-118
E-51 Failure code [2186] Throttle sensor power supply low error 40-119
E-52 Failure code [2249] No-pressure feed by supply pump 2 40-120
E-53 Failure code [2311] Abnormality in IMV solenoid 40-122
E-54 Failure code [2555] Disconnection in intake air heater relay 40-124
E-55 Failure code [2556] Short circuit in intake air heater relay 40-126
50 Disassembly and assembly 6D107E-BE1 (50)
How to read this manual 50-2
Coating materials list 50-4
Special tools list 50-7
General disassembly of engine 50-8
General assembly of engine 50-22

S.V 13/12/24