Komatsu SAA4D107E-1 and SAA6D107E-1 engine shop manual
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SEN00161-12
ENGINE
107E-1 SERIES
107E-1 Series 1
SEN00163-12
Engine
1SHOP MANUAL
107E-1 Series
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
SEN00163-12 00 Index and foreword
2 107E-1 Series
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00161-12
00 Index and foreword SEN00162-12
Index SEN00163-12 q
Foreword and general information SEN00164-05 q
01 Specification SEN00165-09
Specification and technical data SEN00166-09 q
10 Structure, function and maintenance standard SEN00167-00
Structure, function and maintenance standard SEN00168-00
20 Standard value table SEN00247-09
Standard service value table SEN00248-09 q
30 Testing and adjusting SEN00249-02
Testing and adjusting SEN00250-02
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
00 Index and foreword SEN00163-12
107E-1 Series 3
Table of contents 1
00 Index and foreword
Index SEN00163-12
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00164-05
Safety notice ............................................................................................................................ 2
How to read the shop manual .................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00166-09
General .................................................................................................................................... 2
Specifications........................................................................................................................... 3
General view............................................................................................................................ 16
Dimensions table ..................................................................................................................... 36
Engine performance curves..................................................................................................... 37
10 Structure, function and maintenance standard
Structure, function and maintenance standard SEN00168-00
Intake, exhaust system ............................................................................................................... 2
Intake system .......................................................................................................................... 2
Exhaust system ....................................................................................................................... 3
Lubricating oil system.................................................................................................................. 5
Cooling system............................................................................................................................ 9
Fuel system................................................................................................................................. 10
Maintenance standard................................................................................................................. 15
Turbocharger ........................................................................................................................... 15
Cylinder head .......................................................................................................................... 16
Cylinder block .......................................................................................................................... 18
Crankshaft ............................................................................................................................... 20
Piston, piston ring and piston pin............................................................................................. 22
Connecting rod ........................................................................................................................ 23
Vibration damper ..................................................................................................................... 24
Timing gear .............................................................................................................................. 25
Camshaft ................................................................................................................................. 26
Valve and valve guide.............................................................................................................. 28
Rocker arm, shaft and tappet .................................................................................................. 30
Flywheel and flywheel housing ................................................................................................ 32
Oil pump .................................................................................................................................. 34
20 Standard value table
Standard service value table SEN00248-09
Standard value table for testing, adjusting and troubleshooting .............................................. 2
Run-in standard and performance test criteria ........................................................................ 14
SEN00163-12 00 Index and foreword
4 107E-1 Series
30 Testing and adjusting
Testing and adjusting SEN00250-02
Testing and adjusting................................................................................................................... 2
Testing and adjusting tools list ................................................................................................. 2
Testing air boost pressure........................................................................................................ 4
Adjustment of valve clearance ................................................................................................. 5
Testing compression pressure ................................................................................................. 7
Testing blow-by pressure ......................................................................................................... 10
Testing engine oil pressure ...................................................................................................... 11
Handling fuel system parts ...................................................................................................... 12
Releasing residual pressure in fuel system ............................................................................. 12
Testing fuel pressure................................................................................................................ 13
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector......................................... 17
Bleeding air from fuel circuit .................................................................................................... 24
Testing fuel system for leakage ............................................................................................... 25
Handling controller high-voltage circuit .................................................................................... 26
40 Troubleshooting
General information on troubleshooting SEN00252-01
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error and failure code table ..................................................................................................... 3
Troubleshooting of electrical system (E-mode), Part 1 SEN00254-02
Troubleshooting of electrical system (E-mode), Part 1................................................................ 3
E-1 Code [111/CA111] Abnormality in engine controller .......................................................... 3
E-2 Code [115/CA115] Abnormality in engine Ne, Bkup speed sensor ................................... 3
E-3 Code [122/CA122] Abnormally high level in charge pressure sensor ............................... 4
E-4 Code [123/CA123] Abnormally low level in charge pressure sensor ................................ 6
E-5 Code [131/CA131] Abnormally high level in throttle sensor power supply........................ 8
E-6 Code [132/CA132] Abnormally low level in throttle sensor power supply ......................... 10
E-7 Code [144/CA144] Abnormally high level in coolant temperature sensor ......................... 12
E-8 Code [145/CA145] Abnormally low level in coolant temperature sensor .......................... 14
E-9 Code [153/CA153] Abnormally high level in charge temperature sensor ......................... 16
E-10 Code [154/CA154] Abnormally low level in charge temperature sensor ......................... 18
E-11 Code [155/CA155] Derating of speed by abnormally high charge temperature .............. 20
E-12 Code [187/CA187] Abnormally low level in sensor power supply 2 ................................ 22
E-13 Code [221/CA221] Abnormally high level in atompspheric pressure sensor .................. 24
E-14 Code [222/CA222] Abnormally low level in atompspheric pressure sensor .................... 26
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2............................... 28
E-16 Code [234/CA234] Engine overspeed............................................................................. 29
E-17 Code [238/CA238] Abnormally level in Ne speed sensor power supply ......................... 30
E-18 Code [271/CA271] Short circuit in IMV/PCV1 ................................................................. 31
E-19 Code [272/CA272] Disconnection in IMV/PCV1 ............................................................. 32
E-20 Code [322/CA322] Disconnection, short circuit in injector No. 1..................................... 34
E-21 Code [323/CA323] Disconnection, short circuit in injector No. 5..................................... 36
E-22 Code [324/CA324] Disconnection, short circuit in injector No. 3..................................... 38
E-23 Code [325/CA325] Disconnection, short circuit in injector No. 6..................................... 40
E-24 Code [331/CA331] Disconnection, short circuit in injector No. 2..................................... 42
E-25 Code [332/CA332] Disconnection, short circuit in injector No. 4..................................... 44
E-26 Code [342/CA342] Matching error in engine controller data ........................................... 46
Troubleshooting of electrical system (E-mode), Part 2 SEN00255-01
Troubleshooting of electrical system (E-mode), Part 2................................................................ 4
E-27 Code [351/CA351] Abnormality in injector drive circuit ................................................... 4
00 Index and foreword SEN00163-12
107E-1 Series 5
E-28 Code [352/CA352] Abnormally low level in sensor power supply 1 ................................ 6
E-29 Code [386/CA386] Abnormally high level in sensor power supply 1 .............................. 8
E-30 Code [428/CA428] Abnormally high level in water sensor .............................................. 10
E-31 Code [429/CA429] Abnormally low level in water sensor ............................................... 12
E-32 Code [431/CA431] Abnormality in idle validation switch ................................................. 14
E-33 Code [432/CA432] Abnormality in idle validation processing ......................................... 16
E-34 Code [435/CA435] Abnormality in engine oil pressure switch ........................................ 18
E-35 Code [441/CA441] Abnormally low power supply voltage .............................................. 20
E-36 Code [442/CA442] Abnormally high power supply voltage ............................................. 22
E-37 Code [449/CA449] Abnormally high common rail pressure 2 ......................................... 24
E-38 Code [451/CA451] Abnormally high level in common rail pressure sensor .................... 26
E-39 Code [452/CA452] Abnormally low level in common rail pressure sensor ..................... 28
E-40 Code [488/CA488] Derating of torque by abnormally high charge temperature ............. 30
E-41 Code [553/CA553] Abnormally high level in common rail pressure sensor 1 ................. 31
E-42 Code [559/CA559] No-pressure feed by supply pump 1 ................................................ 32
E-43 Code [689/CA689] Abnormality in engine Ne speed sensor ........................................... 34
E-44 Code [731/CA731] Abnormality in engine Bkup speed sensor phase ............................ 36
E-45 Code [757/CA757] Loss of all data in engine controller .................................................. 38
E-46 Code [778/CA778] Abnormality in engine Bkup speed sensor ....................................... 40
E-47 Code [1633/CA1633] Abnormality in KOMNET .............................................................. 42
E-48 Code [2185/CA2185] Abnormally high level in throttle sensor power supply ................. 44
E-49 Code [2186/CA2186] Abnormally low level in throttle sensor power supply ................... 45
E-50 Code [2249/CA2249] No-pressure feed by supply pump 2 ............................................ 46
E-51 Code [2311/CA2311] Abnormality in IMV solenoid ......................................................... 48
E-52 Code [2555/CA2555] Disconnection in intake air heater relay ....................................... 50
E-53 Code [2556/CA2556] Short circuit in intake air heater relay ........................................... 52
E-54 Code [---/B@BAZG] Derating of speed by engine oil pressure reduction....................... 54
E-55 Code [---/B@BAZG] Derating of torque by engine oil pressure reduction ...................... 54
E-56 Code [---/B@BCNS] Engine overheat............................................................................. 55
Troubleshooting of mechanical system (S-mode) SEN00253-01
Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 9
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations ........................................................................................ 13
S-5 Engine does not rotate smoothly ...................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................. 17
S-9 Oil becomes contaminated quickly ................................................................................... 18
S-10 Fuel consumption is excessive ....................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 20
S-12 Oil pressure drops ........................................................................................................... 21
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 22
S-14 Coolant temperature becomes too high (overheating).................................................... 23
S-15 Abnormal noise is made ................................................................................................. 24
S-16 Vibration is excessive ..................................................................................................... 25
SEN00163-12 00 Index and foreword
6 107E-1 Series
50 Disassembly and assembly
General information on disassembly and assembly SEN00257-02
General information on disassembly and assembly .................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Disassembly and assembly, Part 1 SEN00258-01
Disassembly and assembly ......................................................................................................... 2
General disassembly of engine ............................................................................................... 2
Disassembly and assembly, Part 2 SEN00259-02
Disassembly and assembly, Part 2 ............................................................................................. 2
General assembly of engine .................................................................................................... 2
00 Index and foreword SEN00163-12
107E-1 Series 7
8
SEN00163-12 00 Index and foreword
KOMATSU 107E-1 Series Diesel engine
Form No. SEN00163-12
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
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$31.99
This shop manual is for the Komatsu SAA4D107E-1 and SAA6D107E-1 engines. It covers both the 4 cylinder SAA4D107E-1 and the 6 cylinder SAA6D107E-1. With 371 pages, this factory engine service manual features easy-to-read text sections along with high-quality diagrams, pictures, and illustrations. The step-by-step instructions guide you through repairs and overhauls, ensuring accurate and efficient completion while saving time and preventing errors. Additionally, all specifications and tolerances are provided, and the functions of components are thoroughly explained.
