Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 – PDF DOWNLOAD

Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 – PDF DOWNLOAD

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Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 – PDF DOWNLOAD

Language : English
Pages : 340
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Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 – PDF DOWNLOAD

The Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 is a technical reference guide that provides comprehensive information on the maintenance, repair, and overhaul of the Komatsu 107E-5 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-5 Series Engine Shop Manual SEN06896-02 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-5 series diesel engine continues to operate at peak performance, with maximum efficiency and reliability over its long service life.

TABLE OF CONTENTS:

Komatsu 107E-5 Series Engine Shop Manual SEN06896-02 – PDF DOWNLOAD

COVER………………………………………………………………………………………………………………………………………. 1
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
PECIFICATIONS: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)…………………………………………………………… 81
SPECIFICATIONS: SAA4D107E-5 (WA200-8E0)…………………………………………………………………………………………….. 82
ENGINE GENERAL VIEW………………………………………………………………………………………………………………….. 83
ENGINE GENERAL VIEW: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)……………………………………………………… 83
ENGINE GENERAL VIEW: SAA4D107E-5 (WA200-8E0)………………………………………………………………………………………… 87
ENGINE PERFORMANCE CURVE……………………………………………………………………………………………………………… 91
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)…………………………………………………. 91
ENGINE PERFORMANCE CURVE: SAA4D107E-5 (WA200-8E0)……………………………………………………………………………………. 92
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………………. 93
CONTENTS……………………………………………………………………………………………………………………………….. 94
UREA SCR SYSTEM…………………………………………………………………………………………………………………………. 96
LAYOUT DRAWING OF UREA SCR SYSTEM……………………………………………………………………………………………………… 96
UREA SCR SYSTEM DIAGRAM………………………………………………………………………………………………………………. 98
FUNCTION OF UREA SCR SYSTEM…………………………………………………………………………………………………………… 99
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM……………………………………………………………………………………………….. 99
INDUCEMENT STRATEGY……………………………………………………………………………………………………………….101
COMPONENT PARTS OF UREA SCR SYSTEM……………………………………………………………………………………………………..108
SCR ASSEMBLY……………………………………………………………………………………………………………………..108
AdBlue/DEF TANK…………………………………………………………………………………………………………………..110
AdBlue/DEF PUMP…………………………………………………………………………………………………………………..112
AdBlue/DEF INJECTOR……………………………………………………………………………………………………………….113
AdBlue/DEF HOSE…………………………………………………………………………………………………………………..114
AdBlue/DEF TANK HEATING VALVE………………………………………………………………………………………………………115
ENGINE SYSTEM……………………………………………………………………………………………………………………………116
LAYOUT OF ENGINE COMPONENTS……………………………………………………………………………………………………………116
LAYOUT DRAWING OF ENGINE COMPONENTS…………………………………………………………………………………………………116
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………………………………………………..117
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM………………………………………………………………………………………….117
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM……………………………………………………………………………………………118
FUNCTION OF INTAKE AND EXHAUST SYSTEM……………………………………………………………………………………………….118
AIR CLEANER………………………………………………………………………………………………………………………120
INTAKE AIR HEATER…………………………………………………………………………………………………………………121
ENGINE MAIN BODY PARTS………………………………………………………………………………………………………………..122
CYLINDER HEAD…………………………………………………………………………………………………………………….122
CYLINDER BLOCK……………………………………………………………………………………………………………………124
MAIN MOVING PARTS…………………………………………………………………………………………………………………126
CRANKSHAFT PULLEY…………………………………………………………………………………………………………………129
TIMING GEAR………………………………………………………………………………………………………………………130
FRONT COVER………………………………………………………………………………………………………………………131
VALVE SYSTEM……………………………………………………………………………………………………………………..132
FLYWHEEL AND FLYWHEEL HOUSING………………………………………………………………………………………………………134
TURBOCHARGER…………………………………………………………………………………………………………………………136
STRUCTURE OF TURBOCHARGER………………………………………………………………………………………………………….136
SPECIFICATIONS OF TURBOCHARGER……………………………………………………………………………………………………..137
FUNCTION OF TURBOCHARGER…………………………………………………………………………………………………………..137
CRANKCASE VENTILATION SYSTEM…………………………………………………………………………………………………………..139
SYSTEM DIAGRAM OF CRANKCASE VENTILATION SYSTEM……………………………………………………………………………………….139
FUNCTION OF CRANKCASE VENTILATION SYSTEM…………………………………………………………………………………………….139
IMPACTOR (FILTERLESS)…………………………………………………………………………………………………………………140
STRUCTURE OF IMPACTOR (FILTERLESS)………………………………………………………………………………………………….140
OPERATION OF IMPACTOR (FILTERLESS)………………………………………………………………………………………………….140
EXHAUST THROTTLE VALVE………………………………………………………………………………………………………………..141
STRUCTURE OF EXHAUST THROTTLE VALVE…………………………………………………………………………………………………141
FUNCTION OF EXHAUST THROTTLE VALVE………………………………………………………………………………………………….141
OPERATION OF EXHAUST THROTTLE VALVE…………………………………………………………………………………………………141
KDPF………………………………………………………………………………………………………………………………..142
STRUCTURE OF KDPF…………………………………………………………………………………………………………………142
FUNCTION OF KDPF………………………………………………………………………………………………………………….143
TYPES OF REGENERATION FUNCTION……………………………………………………………………………………………………..144
LUBRICATION SYSTEM……………………………………………………………………………………………………………………146
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS…………………………………………………………………………………………..146
LUBRICATION SYSTEM CIRCUIT DIAGRAM………………………………………………………………………………………………….147
ENGINE OIL PUMP…………………………………………………………………………………………………………………..148
ENGINE OIL FILTER…………………………………………………………………………………………………………………149
ENGINE OIL COOLER…………………………………………………………………………………………………………………150
ENGINE OIL REGULATOR VALVE…………………………………………………………………………………………………………152
SAFETY VALVE OF ENGINE OIL…………………………………………………………………………………………………………153
ENGINE OIL PAN……………………………………………………………………………………………………………………154
FUEL SYSTEM………………………………………………………………………………………………………………………….155
LAYOUT DRAWING OF FUEL SYSTEM PARTS…………………………………………………………………………………………………155
FUEL SYSTEM CIRCUIT DIAGRAM………………………………………………………………………………………………………..156
CRI SYSTEM……………………………………………………………………………………………………………………….157
SUPPLY PUMP………………………………………………………………………………………………………………………159
COMMON RAIL………………………………………………………………………………………………………………………160
INJECTOR…………………………………………………………………………………………………………………………161
FUEL PREFILTER……………………………………………………………………………………………………………………163
FUEL MAIN FILTER………………………………………………………………………………………………………………….164
COOLING SYSTEM……………………………………………………………………………………………………………………….165
LAYOUT DRAWING OF COOLING SYSTEM PARTS………………………………………………………………………………………………165
COOLING SYSTEM CIRCUIT DIAGRAM……………………………………………………………………………………………………..166
DRIVE PULLEY……………………………………………………………………………………………………………………..167
WATER PUMP……………………………………………………………………………………………………………………….168
THERMOSTAT……………………………………………………………………………………………………………………….169
ELECTRICAL SYSTEM………………………………………………………………………………………………………………………..170
COMPONENT PARTS OF ELECTRICAL SYSTEM……………………………………………………………………………………………………170
ALTERNATOR……………………………………………………………………………………………………………………….170
STARTING MOTOR……………………………………………………………………………………………………………………172
ENGINE WIRING HARNESS……………………………………………………………………………………………………………..173
ENGINE CONTROLLER…………………………………………………………………………………………………………………175
SENSOR………………………………………………………………………………………………………………………………183
LAYOUT DRAWING OF ENGINE SENSOR…………………………………………………………………………………………………….183
STRUCTURE OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR…………………………………………………………………………..186
FUNCTION OF INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR……………………………………………………………………………186
STRUCTURE OF ENGINE OIL PRESSURE SWITCH……………………………………………………………………………………………..187
FUNCTION OF ENGINE OIL PRESSURE SWITCH………………………………………………………………………………………………187
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR……………………………………………………………………………188
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR…………………………………………………………………………….188
STRUCTURE OF COOLANT TEMPERATURE SENSOR……………………………………………………………………………………………..189
FUNCTION OF COOLANT TEMPERATURE SENSOR………………………………………………………………………………………………189
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………………………………………190
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR…………………………………………………………………………………………….190
STRUCTURE OF Bkup (CAM) SPEED SENSOR………………………………………………………………………………………………..191
FUNCTION OF Bkup (CAM) SPEED SENSOR…………………………………………………………………………………………………191
STRUCTURE OF COMMON RAIL PRESSURE SENSOR…………………………………………………………………………………………….192
FUNCTION OF COMMON RAIL PRESSURE SENSOR……………………………………………………………………………………………..192
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR……………………………………………………………………..193
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR………………………………………………………………………193
STRUCTURE OF CRANKCASE PRESSURE SENSOR………………………………………………………………………………………………194
FUNCTION OF CRANKCASE PRESSURE SENSOR……………………………………………………………………………………………….194
STRUCTURE OF ENGINE OIL LEVEL SENSOR………………………………………………………………………………………………..195
FUNCTION OF ENGINE OIL LEVEL SENSOR…………………………………………………………………………………………………195
STRUCTURE OF AIR CLEANER CLOGGING SENSOR…………………………………………………………………………………………….196
FUNCTION OF AIR CLEANER CLOGGING SENSOR……………………………………………………………………………………………..196
STRUCTURE OF WATER-IN-FUEL SENSOR…………………………………………………………………………………………………..197
FUNCTION OF WATER-IN-FUEL SENSOR……………………………………………………………………………………………………197
STRUCTURE OF EXHAUST MANIFOLD PRESSURE SENSOR………………………………………………………………………………………..198
FUNCTION OF EXHAUST MANIFOLD PRESSURE SENSOR…………………………………………………………………………………………198
STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)…………………………………………………………………….199
FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)……………………………………………………………………..199
20 STANDARD VALUE TABLE………………………………………………………………………………………………………………………201
CONTENTS………………………………………………………………………………………………………………………………..202
STANDARD VALUE TABLE FOR ENGINE……………………………………………………………………………………………………………203
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)……………………………………………….203
STANDARD VALUE TABLE FOR ENGINE: SAA4D107E-5 (WA200-8E0)………………………………………………………………………………….206
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD……………………………………………………………………………………………209
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (D51EX-24E0, D51EXI-24E0, D51PX-24E0, D51PXI-24E0)….209
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA4D107E-5 (WA200-8E0)…………………………………….211
50 DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………………………………..213
CONTENTS………………………………………………………………………………………………………………………………..214
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY……………………………………………………………………………………………..215
HOW TO READ THIS MANUAL……………………………………………………………………………………………………………….215
COATING MATERIALS LIST………………………………………………………………………………………………………………..217
SPECIAL TOOLS LIST……………………………………………………………………………………………………………………221
SKETCHES OF SPECIAL TOOLS……………………………………………………………………………………………………………..223
ENGINE SYSTEM……………………………………………………………………………………………………………………………224
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY……………………………………………………………………………………………….224
DISASSEMBLE ENGINE GENERALLY……………………………………………………………………………………………………….225
ASSEMBLE ENGINE GENERALLY………………………………………………………………………………………………………….252
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…………………………………………………………………………………………………298
REMOVE SUPPLY PUMP ASSEMBLY………………………………………………………………………………………………………..298
INSTALL SUPPLY PUMP ASSEMBLY……………………………………………………………………………………………………….301
REMOVE AND INSTALL ENGINE FRONT OIL SEAL………………………………………………………………………………………………..304
REMOVE ENGINE FRONT OIL SEAL……………………………………………………………………………………………………….304
INSTALL ENGINE FRONT OIL SEAL………………………………………………………………………………………………………306
REMOVE AND INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………………309
REMOVE ENGINE REAR OIL SEAL………………………………………………………………………………………………………..309
INSTALL ENGINE REAR OIL SEAL……………………………………………………………………………………………………….310
60 MAINTENANCE STANDARD………………………………………………………………………………………………………………………313
CONTENTS………………………………………………………………………………………………………………………………..314
ENGINE SYSTEM……………………………………………………………………………………………………………………………315
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………………………………………………..315
MAINTENANCE STANDARD OF TURBOCHARGER………………………………………………………………………………………………..315
ENGINE MAIN BODY PARTS………………………………………………………………………………………………………………..316
MAINTENANCE STANDARD OF CYLINDER HEAD……………………………………………………………………………………………….316
MAINTENANCE STANDARD OF CYLINDER BLOCK………………………………………………………………………………………………318
MAINTENANCE STANDARD OF CRANKSHAFT………………………………………………………………………………………………….320
MAINTENANCE STANDARD OF PISTON……………………………………………………………………………………………………..322
MAINTENANCE STANDARD OF CONROD……………………………………………………………………………………………………..323
MAINTENANCE STANDARD OF TIMING GEAR…………………………………………………………………………………………………325
MAINTENANCE STANDARD OF CAMSHAFT……………………………………………………………………………………………………326
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE………………………………………………………………………………………..328
MAINTENANCE STANDARD OF ROCKER ARM………………………………………………………………………………………………….330
MAINTENANCE STANDARD OF TAPPET……………………………………………………………………………………………………..331
MAINTENANCE STANDARD OF FLYWHEEL……………………………………………………………………………………………………332
LUBRICATION SYSTEM……………………………………………………………………………………………………………………334
MAINTENANCE STANDARD OF ENGINE OIL PUMP……………………………………………………………………………………………..334
INDEX……………………………………………………………………………………………………………………………………….335