Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 – PDF DOWNLOAD

Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 – PDF DOWNLOAD

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Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 – PDF DOWNLOAD

Language : English
Pages : 374
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Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 – PDF DOWNLOAD

The Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 is a technical reference guide that provides comprehensive information on the maintenance, repair, and overhaul of the Komatsu 107E-3 series diesel engine. The engine is commonly used in heavy-duty equipment, such as construction machinery, mining equipment, and marine vessels.

The shop manual is organized into several sections, each covering specific aspects of the engine:

1. General Information: This section provides an overview of the engine, including specifications, maintenance intervals, and general operating guidelines.
2. Inspection and Adjustment: This section provides detailed instructions for inspecting and adjusting engine components, such as fuel injection systems, valves, and timing belts.
3. Engine Assembly: This section covers the removal and installation of major engine components, including the cylinder head, crankshaft, and pistons. The manual includes detailed illustrations and specifications to help technicians perform these tasks safely and efficiently.
4. Lubrication System: This section provides information on the engine’s lubrication system, including oil pump removal and installation, oil filter replacement, and oil pressure testing.
5. Cooling System: This section provides information on the engine’s cooling system, including water pump removal and installation, radiator removal and installation, and thermostat replacement.
6. Fuel System: This section covers the engine’s fuel system, including fuel pump removal and installation, fuel injector replacement, and fuel system troubleshooting.
7. Air Intake and Exhaust System: This section provides information on the engine’s air intake and exhaust system, including air filter replacement, turbocharger removal and installation, and exhaust manifold removal and installation.
8. Electrical System: This section provides information on the engine’s electrical system, including alternator and starter motor removal and installation, as well as troubleshooting procedures for electrical faults.
9. Special Tools: This section lists the special tools required for servicing the engine, including part numbers and illustrations.

The Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 is an essential reference guide for maintaining and repairing the engine. It provides detailed instructions, specifications, and illustrations to help technicians perform tasks accurately and safely. The manual is a valuable tool for ensuring that the Komatsu 107E-3 series diesel engine continues to operate at peak performance, with maximum efficiency and reliability over its long service life.

TABLE OF CONTENTS:

Komatsu 107E-3 Series Engine Shop Manual SEN06655-01 – 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……………………………………………………………118
AdBlue/DEF MIXING TUBE…………………………………………………………………..118
SCR ASSEMBLY……………………………………………………………………………119
AdBlue/DEF TANK…………………………………………………………………………121
AdBlue/DEF PUMP…………………………………………………………………………123
AdBlue/DEF INJECTOR……………………………………………………………………..124
AdBlue/DEF HOSE…………………………………………………………………………125
AdBlue/DEF TANK HEATING VALVE…………………………………………………………….126
ENGINE SYSTEM………………………………………………………………………………….127
LAYOUT OF ENGINE COMPONENTS………………………………………………………………….127
LAYOUT DRAWING OF ENGINE COMPONENTS……………………………………………………….127
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………128
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM………………………………………………..128
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM………………………………………………….129
FUNCTION OF INTAKE AND EXHAUST SYSTEM……………………………………………………..129
AIR CLEANER…………………………………………………………………………….131
INTAKE AIR HEATER……………………………………………………………………….133
ENGINE MAIN BODY PARTS………………………………………………………………………134
CYLINDER HEAD…………………………………………………………………………..134
CYLINDER BLOCK………………………………………………………………………….136
MAIN MOVING PARTS……………………………………………………………………….138
TIMING GEAR…………………………………………………………………………….142
FRONT COVER…………………………………………………………………………….143
VALVE SYSTEM……………………………………………………………………………144
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………………….147
TURBOCHARGER SYSTEM…………………………………………………………………………149
CIRCUIT DIAGRAM OF VGT SYSTEM…………………………………………………………….149
FUNCTION OF VGT SYSTEM…………………………………………………………………..149
VGT……………………………………………………………………………………150
EGR SYSTEM……………………………………………………………………………..153
EGR VALVE………………………………………………………………………………155
EGR COOLER……………………………………………………………………………..157
KCCV SYSTEM…………………………………………………………………………….159
KCCV VENTILATOR…………………………………………………………………………163
KDOC…………………………………………………………………………………..165
LUBRICATION SYSTEM………………………………………………………………………….168
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS…………………………………………………168
LUBRICATION SYSTEM CIRCUIT DIAGRAM………………………………………………………..169
ENGINE OIL PUMP…………………………………………………………………………170
ENGINE OIL FILTER……………………………………………………………………….171
ENGINE OIL COOLER……………………………………………………………………….172
ENGINE OIL REGULATOR VALVE……………………………………………………………….173
SAFETY VALVE OF ENGINE OIL……………………………………………………………….174
ENGINE OIL PAN………………………………………………………………………….175
FUEL SYSTEM………………………………………………………………………………..176
LAYOUT DRAWING OF FUEL SYSTEM PARTS……………………………………………………….176
FUEL SYSTEM CIRCUIT DIAGRAM………………………………………………………………177
FUNCTION OF FUEL SYSTEM………………………………………………………………….177
SUPPLY PUMP…………………………………………………………………………….180
FUEL PREFILTER………………………………………………………………………….181
FUEL MAIN FILTER………………………………………………………………………..182
COOLING SYSTEM……………………………………………………………………………..183
LAYOUT DRAWING OF COOLING SYSTEM PARTS…………………………………………………….183
COOLING SYSTEM CIRCUIT DIAGRAM……………………………………………………………184
DRIVE PULLEY……………………………………………………………………………185
WATER PUMP……………………………………………………………………………..186
THERMOSTAT……………………………………………………………………………..187
ELECTRICAL SYSTEM………………………………………………………………………………188
COMPONENT PARTS OF ELECTRICAL SYSTEM………………………………………………………….188
ALTERNATOR……………………………………………………………………………..188
STARTING MOTOR………………………………………………………………………….190
ENGINE WIRING HARNESS……………………………………………………………………191
ENGINE CONTROLLER……………………………………………………………………….193
SENSOR…………………………………………………………………………………….200
LAYOUT DRAWING OF ENGINE SENSOR…………………………………………………………..200
STRUCTURE OF AMBIENT PRESSURE SENSOR………………………………………………………204
FUNCTION OF AMBIENT PRESSURE SENSOR……………………………………………………….204
STRUCTURE OF ENGINE OIL PRESSURE SWITCH……………………………………………………205
FUNCTION OF ENGINE OIL PRESSURE SWITCH…………………………………………………….205
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR………………………………….206
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR…………………………………..206
STRUCTURE OF COOLANT TEMPERATURE SENSOR……………………………………………………207
FUNCTION OF COOLANT TEMPERATURE SENSOR…………………………………………………….207
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR………………………………………………….208
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR…………………………………………………..208
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR………………………………………………….209
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR…………………………………………………..209
STRUCTURE OF COMMON RAIL PRESSURE SENSOR…………………………………………………..210
FUNCTION OF COMMON RAIL PRESSURE SENSOR……………………………………………………210
STRUCTURE OF VGT SPEED SENSOR…………………………………………………………….211
FUNCTION OF VGT SPEED SENSOR……………………………………………………………..211
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR…………………………………………..212
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………212
STRUCTURE OF CRANKCASE PRESSURE SENSOR…………………………………………………….213
FUNCTION OF CRANKCASE PRESSURE SENSOR……………………………………………………..213
STRUCTURE OF AIR CLEANER CLOGGING SENSOR…………………………………………………..214
FUNCTION OF AIR CLEANER CLOGGING SENSOR……………………………………………………214
STRUCTURE OF WATER-IN-FUEL SENSOR…………………………………………………………215
FUNCTION OF WATER-IN-FUEL SENSOR………………………………………………………….215
STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)………………………………………216
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)……………………………………….216
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR………………………………………………217
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR……………………………………………….217
STRUCTURE OF EGR ORIFICE TEMPERATURE SENSOR………………………………………………..218
FUNCTION OF EGR ORIFICE TEMPERATURE SENSOR…………………………………………………218
STRUCTURE OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)……………………………………219
FUNCTION OF VGT ACTUATOR (WITH BUILT-IN POSITION SENSOR)…………………………………….219
20 STANDARD VALUE TABLE…………………………………………………………………………….221
CONTENTS………………………………………………………………………………………222
ABBREVIATION LIST………………………………………………………………………………223
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………….229
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-3(FH100-1, FH120-1, FH135-1, FH160-1)…………………..229
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD………………………………………………….232
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D107E-3 (FH100-1, FH120-1, FH135-1, FH160-1)….232
50 DISASSEMBLY AND ASSEMBLY…………………………………………………………………………235
CONTENTS………………………………………………………………………………………236
ABBREVIATION LIST………………………………………………………………………………237
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY……………………………………………………243
HOW TO READ THIS MANUAL……………………………………………………………………..243
COATING MATERIALS LIST………………………………………………………………………245
SPECIAL TOOLS LIST………………………………………………………………………….249
SKETCHES OF SPECIAL TOOLS……………………………………………………………………251
ENGINE SYSTEM………………………………………………………………………………….252
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY (4D107E-3)……………………………………………252
METHOD FOR DISASEMBLING ENGINE GENERALLY (4D107E-3)…………………………………………252
METHOD FOR ASEMBLING ENGINE GENERALLY (4D107E-3)……………………………………………279
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (4D107E-3)……………………………………………..326
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (4D107E-3)…………………………………………326
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (4D107E-3)……………………………………….329
REMOVE AND INSTALL ENGINE FRONT OIL SEAL (4D107E-3)…………………………………………….332
METHOD FOR REMOVING ENGINE FRONT OIL SEAL (4D107E-3)………………………………………..332
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL (4D107E-3)………………………………………334
REMOVE AND INSTALL ENGINE REAR OIL SEAL (4D107E-3)……………………………………………..337
METHOD FOR REMOVING ENGINE REAR OIL SEAL (4D107E-3)…………………………………………337
METHOD FOR INSTALLING ENGINE REAR OIL SEAL (4D107E-3)……………………………………….338
60 MAINTENANCE STANDARD…………………………………………………………………………….341
CONTENTS………………………………………………………………………………………342
ABBREVIATION LIST………………………………………………………………………………343
ENGINE SYSTEM………………………………………………………………………………….349
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………349
MAINTENANCE STANDARD OF VGT………………………………………………………………349
ENGINE MAIN BODY PARTS………………………………………………………………………350
MAINTENANCE STANDARD OF CYLINDER HEAD……………………………………………………..350
MAINTENANCE STANDARD OF CYLINDER BLOCK…………………………………………………….352
MAINTENANCE STANDARD OF CRANKSHAFT………………………………………………………..354
MAINTENANCE STANDARD OF PISTON……………………………………………………………356
MAINTENANCE STANDARD OF CONROD……………………………………………………………357
MAINTENANCE STANDARD OF TIMING GEAR……………………………………………………….359
MAINTENANCE STANDARD OF CAMSHAFT………………………………………………………….360
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE………………………………………………362
MAINTENANCE STANDARD OF ROCKER ARM………………………………………………………..364
MAINTENANCE STANDARD OF TAPPET……………………………………………………………365
MAINTENANCE STANDARD OF FLYWHEEL………………………………………………………….366
LUBRICATION SYSTEM………………………………………………………………………….368
MAINTENANCE STANDARD OF ENGINE OIL PUMP……………………………………………………368
INDEX……………………………………………………………………………………………..369