Komatsu 107E-2 Series Engine Shop Manual SEN05623-09 – PDF DOWNLOAD
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Komatsu 107E-2 Series Engine Shop Manual SEN05623-09 – PDF DOWNLOAD
How to read the shop manual (ALL-0320-010-A-03-A):
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
TABLE OF CONTENTS:
Komatsu 107E-2 Series Engine Shop Manual SEN05623-09 – PDF DOWNLOAD
Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 7
Important safety notice 7
How to read the shop manual 14
Explanation of terms for maintenance standard 16
Handling equipment of fuel system devices 18
Handling of intake system parts 19
Handling of hydraulic equipment 20
Method of disconnecting and connecting of push-pull type coupler 22
Handling of electrical equipment 25
How to read electric wire code 33
Precautions when performing operation 36
Standard tightening torque table 41
List of abbreviation 47
Conversion table 52
01 Specification 57
Table of contents 58
General information 59
Exhaust gas regulation 59
Specifications 65
Applicable machines 65
Specifications 66
General view 76
Engine performance curve 109
10 Structure and function 119
Table of contents 120
Components layout 122
Components layout drawing (4D107) 122
Components layout drawing (6D107) 124
Intake and exhaust system parts 126
Intake and exhaust system layout drawing (4D107) 126
Intake and exhaust system layout drawing (6D107) 127
Intake and exhaust system circuit diagram (4D107) 128
Intake and exhaust system circuit diagram (6D107) 130
Air cleaner (4D107) 132
Air cleaner (6D107) 133
VFT (4D107) 135
VGT(6D107) 139
Aftercooler 147
EGR system piping drawing (4D107) 148
EGR system piping drawing (6D107) 150
EGR system circuit diagram (4D107) 152
EGR system circuit diagram (6D107) 154
EGR valve (4D107) 156
EGR valve (6D107) 158
EGR cooler 160
Layout of KCCV (4D107) 161
Layout of KCCV (6D107) 164
KCCV ventilator 166
KDOC muffler (4D107) 170
KDPF (6D107) 172
Engine main body parts 177
Cylinder head 177
Cylinder block 179
Main moving parts 181
Vibration damper (6D107) 185
Timing gear 186
Front cover 187
Valve system 188
Flywheel 191
Lubrication system 193
Lubrication system parts layout drawing (4D107) 193
Lubrication system parts layout drawing (6D107) 195
Lubrication system circuit diagram (4D107) 197
Lubrication system circuit diagram (6D107) 198
Oil pump 199
Boost oil pump (6D107) 200
Oil filter 201
Oil cooler 202
Regulator valve 203
Safety valve 204
Oil pan 205
Fuel system 206
Fuel system parts layout drawing 206
Fuel system circuit diagram 209
Supply pump 213
Fuel cooler 214
Pre-filter 215
Main filter 216
Cooling system 217
Cooling system parts layout drawing 217
Cooling system circuit diagram (4D107) 218
Cooling system circuit diagram (6D107) 219
Drive pulley 220
Water pump 225
Thermostat 226
Electrical equipment 227
Alternator 227
Starting motor 235
Intake air heater 239
Engine wiring harness (4D107) 240
Engine wiring harness (6D107) 242
Engine controller (4D107) 244
Engine controller (6D107) 250
Sensor 256
20 Standard value tables 273
Table of contents 274
Standard service value table 275
Standard value table for engine 275
Running-in standard and performance test standard 305
50 Disassembly and assembly 315
Table of contents 316
Related information on disassembly and assembly 317
How to read this manual 317
Coating materials list 319
Special tool list 323
Sketch of special tool 325
Disassembly and assembly 326
General disassembly of engine 326
General assembly of engine 348
Removal and installation procedure of supply pump unit alone 389
Engine front oil seal replacement procedure 393
Engine rear oil seal replacement procedure 396
60 Maintenance standard 399
Table of contents 400
Intake and exhaust system parts 401
VFT (4D107) 401
VGT(6D107) 402
Engine main body parts 403
Cylinder head 403
Cylinder block 405
Crankshaft 407
Piston 409
Connecting rod 410
Vibration damper (6D107) 412
Timing gear 413
Camshaft 414
Valve and valve guide 416
Rocker arm 418
Tappet 419
Flywheel 420
Lubrication system 422
Oil pump 422
INDEX 423
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