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
FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE ENGINE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
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
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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