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Komatsu Engine 107E-1 Series workshop repair service manual download

Komatsu Engine 107E-1 Series shop service manual  Foreword and general information

Important safety notice:Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

Intake, exhaust system

Intake, exhaust system

To prevent injury to workers, the symbol ♠ is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

General precautions

♠Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

8) Before starting work, warm up your body thoroughly to start work under good condition.

This is Manual Covers: 

00 Index and foreword
Index

  • Composition of shop manual
  • Table of contents

Foreword and general information

  • Safety notice
  • How to read the shop manual
  • Explanation of terms for maintenance standard
  • Handling of electric equipment and hydraulic component
  • Handling of connectors newly used for engines
  • How to read electric wire code
  • Precautions when carrying out operation
  • Method of disassembling and connecting push-pull type coupler
  • Standard tightening torque table
  • Conversion table

01 Specification
Specification and technical data SEN00166-05

  • General
  • Specifications
  • General view
  • Dimensions table
  • Engine performance curves

10 Structure, function and maintenance standard
Structure, function and maintenance standard SEN00168-00
Intake, exhaust system
Intake system
Exhaust system
Lubricating oil system
Cooling system
Fuel system
Maintenance standard

  • Turbocharger
  • Cylinder head
  • Cylinder block
  • Crankshaft
  • Piston, piston ring and piston pin
  • Connecting rod
  • Vibration damper
  • Timing gear
  • Camshaft
  • Valve and valve guide
  • Rocker arm, shaft and tappet
  • Flywheel and flywheel housing
  • Oil pump

20 Standard value table
Standard service value table SEN00248-05

  • Standard value table for testing, adjusting and troubleshooting
  • Run-in standard and performance test criteria

30 Testing and adjusting
Testing and adjusting SEN00250-01
Testing and adjusting

  • Testing and adjusting tools list
  • Testing air boost pressure
  • Adjustment of valve clearance
  • Testing compression pressure
  • Testing blow-by pressure
  • Testing engine oil pressure
  • Handling fuel system parts
  • Releasing residual pressure in fuel system
  • Testing fuel pressure
  • Reduced cylinder mode operation
  • No-injection cranking
  • Testing leakage from pressure limiter and return rate from injector
  • Bleeding air from fuel circuit
  • Testing fuel system for leakag
  • Handling controller high-voltage circuit

40 Troubleshooting
General information on troubleshooting SEN00252-01
General information on troubleshooting

  • Points on troubleshooting
  • Error and failure code table

Troubleshooting of electrical system (E-mode), Part 1 SEN00254-02
Troubleshooting of electrical system (E-mode), Part 1

  • E-1 Code [111/CA111] Abnormality in engine controller
  • E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor
  • E-3 Code [122/CA122] Abnormally high level in charge pressure sensor
  • E-4 Code [123/CA123] Abnormally low level in charge pressure sensor
  • E-5 Code [131/CA131] Abnormally high level in throttle sensor power supply
  • E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply
  • E-7 Code [144/CA144] Abnormally high level in coolant temperature sensor
  • E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor
  • E-9 Code [153/CA153] Abnormally high level in charge temperature sensor
  • E-10 Code [154/CA154] Abnormally low level in charge temperature sensor
  • E-11 Code [155/CA155] Derating of speed by abnormally high charge temperature
  • E-12 Code [187/CA187] Abnormally low level in sensor power supply 2
  • E-13 Code [221/CA221] Abnormally high level in atompspheric pressure sensor
  • E-14 Code [222/CA222] Abnormally low level in atompspheric pressure sensor
  • E-15 Code [227/CA227] Abnormally high level in sensor power supply 2
  • E-16 Code [234/CA234] Engine overspeed
  • E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply
  • E-18 Code [271/CA271] Short circuit in IMV/PCV1
  • E-19 Code [272/CA272] Disconnection in IMV/PCV1
  • E-20 Code [322/CA322] Disconnection, short circuit in injector No 1
  • E-21 Code [323/CA323] Disconnection, short circuit in injector No 5
  • E-22 Code [324/CA324] Disconnection, short circuit in injector No 3
  • E-23 Code [325/CA325] Disconnection, short circuit in injector No 6
  • E-24 Code [331/CA331] Disconnection, short circuit in injector No 2
  • E-25 Code [332/CA332] Disconnection, short circuit in injector No 4
  • E-26 Code [342/CA342] Matching error in engine controller data
  • and more

50 Disassembly and assembly
General information on disassembly and assembly SEN00 57-0
General information on disassembly and assembly
How to read this manual
Coating materials list 4
Special tools list 7
Disassembly and assembly, Part 1 SEN00 58-01
Disassembly and assembly
General disassembly of engine
Disassembly and assembly, Part SEN00 59-0
Disassembly and assembly, Part
General assembly of engine

♦ Komatsu-107E-1-Shop-Manual.pdf (Size: 13.2 MB )

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