Komatsu 107E-1 Diesel Series Engine Service Repair Shop Manual - SEN00161-08

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the 107E-1 Series Komatsu Diesel Engine and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.


APPLICABLE MODELS :

SAA6D107E-1
Komatsu PC200-8, PC200LC-8
Komatsu PC220-8, PC220LC-8 Hydraulic Excavator
Komatsu PC270-8
Komatsu PC228US-3E0, PC228USLC-3E0
Komatsu PC308USLC-3E0
Komatsu WA250-6
Komatsu WA320-6
Komatsu WA380-6
Komatsu BR380JG-1E0

SAA4D107E-1
Komatsu PC160LC-7E0
Komatsu WA200-6


TABLE OF CONTENTS :

00 Index and foreword SEN00162-08
-- Index SEN00163-08 q
Foreword and general information SEN00164-03
01 Specification SEN00165-05
-- Specification and technical data SEN00166-05 q
10 Structure, function and maintenance standard SEN00167-00
-- Structure, function and maintenance standard SEN00168-00
20 Standard value table SEN00247-05
-- Standard service value table SEN00248-05 q
30 Testing and adjusting SEN00249-01
-- Testing and adjusting SEN00250-01
40 Troubleshooting SEN00251-02
-- General information on troubleshooting SEN00252-01
-- Troubleshooting of electrical system (E-mode), Part 1 SEN00254-02
-- Troubleshooting of electrical system (E-mode), Part 2 SEN00255-01
-- Troubleshooting of mechanical system (S-mode) SEN00253-01
50 Disassembly and assembly SEN00256-02
General information on disassembly and assembly SEN00257-02
-- Disassembly and assembly, Part 1 SEN00258-01
-- Disassembly and assembly, Part 2 SEN00259-02


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00161-08
Total Pages : 361


This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.

TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Komatsu 107E-1 Diesel Series Engine Shop Manual PDF Download
Komatsu 107E-1 Diesel Series Engine Factory Service Manual PDF Download
Komatsu 107E-1 Diesel Series Engine FSM PDF Download
Komatsu 107E-1 Diesel Series Engine OEM Manual PDF Download

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COVER
00 INDEX AND FORWORD
INDEX
COMPOSITION OF SHOP MANUAL
TABLE OF CONTENTS
FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HANDLING OF CONNECTORS NEWLY USED OF ENGINES
HOW TO READ ELECTRIC WIRE CODE
PRECAUTIONS WHEN CARRYING OUT OPERATION
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

01 SPECIFICATION
SPECIFICATION AND TECHNICAL DATA
GENERAL
SPECIFICATIONS
GENERAL VIEW
DIMENSIONS TABLE
ENGINE PERFORMANCE CURVES

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STRUCTURE ,FUNCTION AND MAINTENANCE STANDARD
INTAKE, EXHAUST SYSTEM
INTAKE SYSTEM
EXHAUST SYSTEM
LUBRICATION OIL SYSTEM
COOLING SYSTEM
FUEL SYSTEM
MAINTENANCE STANDARD
TURBOCHARGER
CYLINDER HEAD
CYLINDER BLOCK
CRANKSHAFT
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
VIBRATION DAMPER
TIMING GEAR
CAMSHAFT
VALVE AND VALVE GUIDE
ROCKER ARM, SHAFT AND TAPPET
FLYWHEEL AND FLYWHEEL HOUSING
OIL PUMP

20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND TROUBLESHOOTING
RUN-IN STANDARD AND PERFORMANCE TEST CRITERIA

30 TESTING AND ADJUSTING
TESTING AND ADJUSTING
TESTING AND ADJUSTING TOOLS LIST
TESTING AIR BOOST PRESSURE
ADJUSTING OF VALVE CLEARANCE
TESTING COMPRESSION PRESSURE
TESTING BLOW-BY PRESSURE
TESTING ENGINE OIL PRESSURE
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM
TESTING FUEL PRESSURE
REDUCED CYLINDER MODE OPERATION
NO-INJECTION CRANKING
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURE RATE FROM INJECTOR
BLEEDING AIR FROM FUEL CIRCUIT
TESTING FUEL SYSTEM FOR LEAKAGE
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT

40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS ON TROUBLESHOOTING
ERROR AND FAILURE CODE TABLE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 1
E-1 CODE [111/CA111] ABNORMALITY IN ENGINE CONTROLLER
E-2 CODE [115/CA115] ABNORMALITY IN ENGINE NE, BKUP SPEED SENSOR
E-3 CODE [122/CA122] ABNORMALLY HIGH LEVEL IN CHARGE PRESSURE SENSOR
E-4 CODE [123/CA123] ABNORMALLY LOW LEVEL IN CHARGE PRESSURE SENSOR
E-5 CODE [131/CA131] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR POWER SUPPLY
E-6 CODE [132/CA132] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR POWER SUPPLY
E-7 CODE [144/CA144] ABNORMALLY HIGH LEVEL IN COOLANT TEMPERATURE SENSOR
E-8 CODE [145/CA145] ABNORMALLY LOW LEVEL IN COOLANT TEMPERATURE SENSOR
E-9 CODE [153/CA153] ABNORMALLY HIGH LEVEL IN CHARGE TEMPERATURE SENSOR
E-10 CODE [154/CA154] ABNORMALLY LOW LEVEL IN CHARGE TEMPERATURE SENSOR
E-11 CODE [155/CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE
E-12 CODE [187/CA187] ABNORMALLY LOW LEVEL IN SENSOR POWER SUPPLY 2
E-13 CODE [221/CA221] ABNORMALLY HIGH LEVEL IN ATOMPSPHERIC PRESSURE SENSOR
E-14 CODE [222/CA222] ABNORMALLY LOW LEVEL IN ATOMPSPHERIC PRESSURE SENSOR
E-15 CODE [227/CA227] ABNORMALLY HIGH LEVEL IN SENSOR POWER SUPPLY 2
E-16 CODE [234/CA234] ENGINE OVERSPEED
E-17 CODE [238/CA238] ABNORMALLY LEVEL IN NE SPEED SENSOR POWER SUPPLY
E-18 CODE [271/CA271] SHORT CIRCUIT IN IMV/PCV1
E-19 CODE [272/CA272] DISCONNECTION IN IMV/PCV1
E-20 CODE [322/CA322] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 1
E-21 CODE [323/CA323] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 5
E-22 CODE [324/CA324] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 3
E-23 CODE [325/CA325] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 6
E-24 CODE [331/CA331] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 2
E-25 CODE [332/CA332] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO. 4
E-26 CODE [342/CA342] MATCHING ERROR IN ENGINE CONTROLLER DATA
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE), PART 2
E-27 CODE [351/CA351] ABNORMALITY IN INJECTOR DRIVE CIRCUIT
E-28 CODE [352/CA352] ABNORMALLY LOW LEVEL IN SENSOR POWER SUPPLY 1
E-29 CODE [386/CA386] ABNORMALLY HIGH LEVEL IN SENSOR POWER SUPPLY 1
E-30 CODE [428/CA428] ABNORMALLY HIGH LEVEL IN WATER SENSOR
E-31 CODE [429/CA429] ABNORMALLY LOW LEVEL IN WATER SENSOR
E-32 CODE [431/CA431] ABNORMALITY IN IDLE VALIDATION SWITCH
E-33 CODE [432/CA432] ABNORMALITY IN IDLE VALIDATION PROCESSING
E-34 CODE [435/CA435] ABNORMALITY IN ENGINE OIL PRESSURE SWITCH
E-35 CODE [441/CA441] ABNORMALLY LOW POWER SUPPLY VOLTAGE
E-36 CODE [442/CA442] ABNORMALLY HIGH POWER SUPPLY VOLTAGE
E-37 CODE [449/CA449] ABNORMALLY HIGH COMMON RAIL PRESSURE 2
E-38 CODE [451/CA451] ABNORMALLY HIGH LEVEL IN COMMON RAIL PRESSURE SENSOR
E-39 CODE [452/CA452] ABNORMALLY LOW LEVEL IN COMMON RAIL PRESSURE SENSOR
E-40 CODE [488/CA488] DERATING OF TORQUE BY ABNORMALLY HIGH CHARGE TEMPERATURE
E-41 CODE [553/CA553] ABNORMALLY HIGH LEVEL IN COMMON RAIL PRESSURE SENSOR 1
E-42 CODE [559/CA559] NO-PRESSURE FEED BY SUPPLY PUMP 1
E-43 CODE [689/CA689] ABNORMALITY IN ENGINE NE SPEED SENSOR
E-44 CODE [731/CA731] ABNORMALITY IN ENGINE BKUP SPEED SENSOR PHASE
E-45 CODE [757/CA757] LOSS OF ALL DATA IN ENGINE CONTROLLER
E-46 CODE [778/CA778] ABNORMALITY IN ENGINE BKUP SPEED SENSOR
E-47 CODE [1633/CA1633] ABNORMALITY IN KOMNET
E-48 CODE [2185/CA2185] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR POWER SUPPLY
E-49 CODE [2186/CA2186] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR POWER SUPPLY
E-50 CODE [2249/CA2249] NO-PRESSURE FEED BY SUPPLY PUMP 2
E-51 CODE [2311/CA2311] ABNORMALITY IN IMV SOLENOID
E-52 CODE [2555/CA2555] DISCONNECTION IN INTAKE AIR HEATER RELAY
E-53 CODE [2556/CA2556] SHORT CIRCUIT IN INTAKE AIR HEATER RELAY
E-54 CODE [---/B@BAZG] DERATING OF SPEED BY ENGINE OIL PRESSURE REDUCTION
E-55 CODE [---/B@BAZG] DERATING OF TORQUE BY ENGINE OIL PRESSURE REDUCTION
E-56 CODE [---/B@BCNS] ENGINE OVERHEAT
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
S-12 OIL PRESSURE DROPS
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE

50 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
DISASSEMBLY AND ASSEMBLY, PART 1
GENERAL DISASSEMBLY OF ENGINE
DISASSEMBLY AND ASSEMBLY, PART 2
GENERAL ASSEMBLY OF ENGINE

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