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
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-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
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