Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

Description

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

FOREWORD:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
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 ADJUSTMENTS
This sections 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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

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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