Komatsu 107E-1 Series Engine Service Manual
583 pages · Publication SEN00161-26
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- Models
- 107E-1 Series
- Manual type
- Service Manual
- Pages
- 583
- Publication
- SEN00161-26
- Condition
- Brand new
What's inside
From the manual's own table of contents: 8 sections, 178 entries. See sample pages (PDF, 586 KB)
Index and foreword11 topics
- Composition of shop manual
- 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 for 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
Specification5 topics
- General
- Specifications
- General view
- Dimensions table
- Engine performance curves
Structure, function and maintenance standard28 topics
- Intake system
- Exhaust system
- Lubricating oil system
- Cooling system
- Fuel system
- Fuel supply pump
- CRI system
- 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
- Water pump drive and fan drive
- Water pump
- Thermostat
- Alternator
- Starting motor
- Sensor
- Engine controller
- Control system
Standard value table2 topics
- Standard value table for testing, adjusting and troubleshooting
- Running-in standard and performance test criteria
Testing and adjusting17 topics
- Testing and adjusting tools list
- Sketches of special tools
- Testing boost pressure
- Adjustment of valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Handling fuel system parts
- Releasing remaining pressure in fuel system
- Testing fuel pressure
- Reduced cylinder mode operation
- No-injection cranking
- Testing fuel delivery, return and leak amount
- Bleeding air from fuel circuit
- Testing fuel system for leakage
- Handling controller high-voltage circuit
- Replacing the fan belt
Troubleshooting93 topics
- Points on troubleshooting
- Error and failure code table
- Troubleshooting method for open circuit in wiring harness of pressure sensor system
- Information in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- 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] Charge pressure sensor high error
- E-4 Code [123/CA123] Charge pressure sensor low error
- E-5 Code [131/CA131] Throttle sensor power supply high error
- E-6 Code [132/CA132] Throttle sensor power supply low error
- E-7 Code [144/CA144] Coolant temperature sensor high error
- E-8 Code [145/CA145] Coolant temperature sensor low error
- E-9 Code [153/CA153] Charge temperature sensor high error
- E-10 Code [154/CA154] Charge temperature sensor low error
- E-11 Code [155/CA155] Derating of speed by charge temperature high error
- E-12 Code [187/CA187] Sensor power supply 2 low error
- E-13 Code [221/CA221] Atompspheric pressure sensor high error
- E-14 Code [222/CA222] Atompspheric pressure sensor low error
- E-15 Code [227/CA227] Sensor power supply 2 high error
- E-16 Code [234/CA234] Engine overspeed
- E-17 Code [238/CA238] Abnormallity 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] Calibration error in engine controller data
- E-27 Code [351/CA351] Abnormality in injector drive circuit
- E-28 Code [352/CA352] Sensor power supply 1 low error
- E-29 Code [386/CA386] Sensor power supply 1 high error
- E-30 Code [428/CA428] Water-in-fuel sensor high error
- E-31 Code [429/CA429] Water-in-fuel sensor low error
- 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] Common rail pressure high error 2
- E-38 Code [451/CA451] Common rail pressure sensor high error
- E-39 Code [452/CA452] Common rail pressure sensor low error
- E-40 Code [488/CA488] Derating of torque by charge temperature high error
- E-41 Code [553/CA553] Common rail pressure high error 1
- E-42 Code [559/CA559] No-pressure feed 1 by supply pump
- 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] Throttle sensor power supply high error
- E-49 Code [2186/CA2186] Throttle sensor power supply low error
- E-50 Code [2249/CA2249] No-pressure feed 2 by supply pump
- 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@BAZK] Engine oil level low
- E-56 Code [---/B@BCNS] Engine overheat
- E-57 Code [A8] Rated Speed Adjustment Volume (Isochronous) High Error
- E-58 Code [A9] Rated Speed Adjustment Volume (Isochronous) Low Error
- E-59 Code [AA] Rated Speed Adjustment Volume (Droop) High Error
- E-60 Code [AB] Rated Speed Adjustment Volume (Droop) Low Error
- E-61 Code [AF] Abnormality in KOMNET (CR710 error recognition)
- E-62 Code [b6] Droop Rate Adjustment Volume High Error
- E-63 Code [b7] Droop Rate Adjustment Volume Low Error
- E-64 Code [b8] Low Idle Speed Adjustment Volume High Error
- E-65 Code [b9] Low Idle Speed Adjustment Volume Low Error
- E-66 Code [bc] Rated Speed Median Adjustment Volume High Error
- E-67 Code [b9] Rated Speed Median Adjustment Volume Low Error
- E-68 Code [bE] Ramp Time Adjustment Volume High Error
- E-69 Code [bF] Ramp Time Adjustment Volume Low Error
- 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
Disassembly and assembly5 topics
- How to read this manual
- Coating materials list
- Special tools list
- General disassembly of engine
- General assembly of engine
Repair and replacement of parts9 topics
- Special tool table
- Repair of cylinder head
- Check of valve guide
- Replacement of valve seat insert
- Vacuum test of valve seat insert
- Grinding of valve
- Repair of cylinder block
- Repair of crankshaft
- Replacement of connecting rod bushing
Inside this manual
Real pages from this service manual (583 pages). Open the sample pages (PDF, 586 KB)
- Specifications, page 62: 01 Specification
- Troubleshooting, page 296: Information in troubleshooting table
- Diagram, page 359: E-12 Code [187/CA187] Sensor power supply 2 low error
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 583 pages
Quantity one is the manual described above.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).