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Komatsu 108 Series Diesel Engine Service Repair Manual – PDF Download
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Komatsu 108 Series Diesel Engine Service Repair Manual
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Description
Komatsu 108 Series Diesel Engine Service Repair Manual
Description:
Komatsu 108 Series Diesel Engine Service Repair Manual
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.
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” to ‘Causes’ are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
Table Of Contents:
Komatsu 108 Series Diesel Engine Service Repair Manual
COVER..................................................................................... 1 CONTENTS.................................................................................. 2 01 GENERAL................................................................................ 23 SPECIFICATIONS........................................................................ 24 ENGINE PERFORMANCE CURVE.............................................................. 28 WEIGHT TABLE.......................................................................... 37 11 STRUCTURE AND FUNCTION................................................................. 39 GENERAL STRUCTURE..................................................................... 40 INTAKE AND EXHAUST SYSTEM............................................................. 42 AFTER -COOLER..................................................................... 42 AIR CLEANER....................................................................... 43 ELECTRONIC DUST INDICATOR......................................................... 44 TURBOCHARGER...................................................................... 45 ENGINE BODY........................................................................... 52 CYLINDER HEAD..................................................................... 52 CYLINDER BLOCK.................................................................... 54 MAIN REVOLVING SYSTEM............................................................. 56 TIMING GEAR....................................................................... 60 VALVE SYSTEM...................................................................... 62 FLYWHEEL AND FLYWHEEL HOUSING..................................................... 64 LUBRICATION SYSTEM.................................................................... 68 LUBRICATION SYSTEM CHART.......................................................... 68 OIL PUMP ......................................................................... 69 OIL FILTER (BUILT-IN SAFETY VALVE)................................................ 70 OIL COOLER........................................................................ 71 FUEL SYSTEM........................................................................... 72 FUEL SYSTEM CHART................................................................. 72 FUEL INJECTION PUMP............................................................... 74 FUEL INJECTION NOZZLE............................................................. 82 FUEL FILTER....................................................................... 83 FUEL INJECTION PUMP DRIVE CASE.................................................... 84 ENGINE STOP MOTOR................................................................. 86 FUEL CUT SOLENOID................................................................. 91 COOLING SYSTEM........................................................................ 92 COOLING SYSTEM CHART.............................................................. 92 THERMOSTAT........................................................................ 95 WATER PUMP........................................................................ 96 ELECTRICAL SYSTEM..................................................................... 99 WIRING DIAGRAM.................................................................... 99 ALTERNATOR........................................................................102 STARTING MOTOR....................................................................106 OIL PRESSURE SWITCH ..............................................................108 RELAY SWITCH......................................................................108 GLOW PLUG.........................................................................109 12 TESTING AND ADJUSTING..................................................................111 INAKE AND EXHAUST SYSTEM..............................................................113 ADJUSTING VALVE CLEARANCE.........................................................113 ENGINE BODY...........................................................................114 MEASURING COMPRESSION PRESSURE....................................................114 FUEL SYSTEM...........................................................................115 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................115 ADJUSTING FUEL CUT SOLENOID LINK..................................................118 PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE...................................120 ADJUSTING ENGINE SPEED SENSOR.....................................................122 PERFORMANCE TEST......................................................................123 RUNNING-IN STANDARD...............................................................123 PERFORMANCE TEST CRITERIA.........................................................126 TESTING AND ADJUSTING DATA............................................................130 CALIBRATION DATA..................................................................130 TESTING AND ADJUSTING TOO LIST....................................................143 TESTING AND ADJUSTING DATA........................................................144 TROUBLESHOOTING.......................................................................149 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................151 METHOD OF USING TROUBLESHOOTING CHART.............................................152 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).....................156 S-2 ENGINE DOES NOT START.........................................................157 ① ENGINE DOES NOT TURN........................................................157 ② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)......158 ③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....159 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..........................160 S-4 ENGINE STOPS DURING OPERATIONS................................................161 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....................................162 S-6 ENGINE LACKS OUTPUT (NO POWER)................................................163 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)..................................164 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).........................165 S-9 OIL BECOMES CONTAMINATED QUICKLY..............................................166 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................167 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVER GOES DOWN......168 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRSSURE)............................169 S-13 OIL LEVEL RISES..............................................................170 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).............................171 S-15 ABNORMAL NOISE IS MADE.......................................................172 S-16 VIBRATION IS EXCESSIVE.......................................................173 13 DISSSEMBLY AND ASSEMBLY................................................................175 OVERALL DISASSEMBLY...................................................................176 OVERALL ASSEMBLY......................................................................188 14 MAINTENANCE STANDARD...................................................................211 TURBOCHARGER..........................................................................212 CYLINDER HEAD.........................................................................214 VALVE AND VALVE GUIDE.................................................................216 ROCKER ARM, PUSH ROD AND TAPPET.......................................................218 CYLINDER LINER........................................................................219 CYLINDER BLOCK........................................................................220 CRANKSHAFT............................................................................222 CAMSHAFT..............................................................................223 PISION,PISTON RING AND PISTON PIN.....................................................224 CONNECTING ROD........................................................................225 TIMING GEAR...........................................................................226 FLYWHEEL AND FLYWHEEL HOUSING.........................................................227 LUBRICATION SYSTEM....................................................................228 OIL PUMP .........................................................................228 REGULATOR VALVE...................................................................229 SAFETY VALVE......................................................................229 COOLING SYSTEM........................................................................230 WATER PUMP AND THERMOSTAT.............................................................230 15 REPAIR AND REPLACEMENT OF PARTS........................................................233 REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING..................................234 REPLACING VALVE SEAT INSERTS..........................................................235 PRESSURE TEST.........................................................................239 REPLACING VALVE GUIDE.................................................................240 GRINDING THE VALVE....................................................................241 REPLACING CAM BUSHING.................................................................242 REPLACING CRANK GEAR..................................................................244 REPLACING CAM GEAR....................................................................244 REPLACING FLYWHEEL RING GEAR..........................................................245 REPLACING MAIN BEARING CAP............................................................246 GRINDING CRANKSHAFT...................................................................247 REPLACING ENGINE REAR SEAL............................................................252
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KOMATSU 108 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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