Komatsu SAA6D107E-1, SAA4D107E-1, 107E-1 Series SEN00161-18 (Preview)
COVER
00 Index and foreword
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 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
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 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
Sensor
Engine controller
Control system
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
Sketches of special tools
Testing air boost pressure
Adjustment 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
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
40 Troubleshooting
General information on troubleshooting
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
Troubleshooting of electrical system (E-mode), Part 1
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
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
Troubleshooting of electrical system (E-mode), Part 2
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)
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
90 Repair and Replacement of parts
Infomation related repair and replacement
Special tool table
Parts related to cylinder head
Repair of cylinder head
Check of valve guide
Replacement of valve seat insert
Vacuum test of valve seat insert
Grinding of valve
Parts related to cylinder block
Repair of cylinder block
Repair of crankshaft
Replacement of connecting rod bushing
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