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Komatsu Diesel Engine 108-2 Series Shop Manual_SEBM006906 – PDF DOWNLOAD
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Komatsu Diesel Engine 108-2 Series Shop Manual
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Description
Komatsu Diesel Engine 108-2 Series Shop Manual
FILE DETAILS:
Komatsu Diesel Engine 108-2 Series Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 108-2 Series Diesel Engine
Book Code: SEBM006906
Language: English
Pages: 226
File Format: Portable Document Format (PDF)
KOMATSU DIESEL ENGINE 108-2 SERIES SHOP MANUAL_SEBM006906 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Diesel Engine 108-2 Series Shop Manual
FOREWORD:
GENERAL:
- 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu Diesel Engine 108-2 Series Shop Manual
COVER....................................................................................... 1 CONTENTS.................................................................................... 4 SAFETY...................................................................................... 5 FOREWORD.................................................................................... 7 GENERAL................................................................................. 7 HOW TO READ THE SHOP MANUAL............................................................. 8 HOISTING INSTRUCTIONS................................................................... 9 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.............................. 10 COATING MATERIALS....................................................................... 12 STANDARD TIGHTENING TORQUE.............................................................. 14 ELECTRICAL WIRE CODE.................................................................... 17 CONVERSION TABLE........................................................................ 18 UNITS................................................................................... 24 01 GENERAL.................................................................................. 25 APPLICABLE MACHINE...................................................................... 26 SPECIFICATIONS.......................................................................... 28 GENERAL ASSEMBLY DRAWING................................................................ 31 ENGINE PERFORMANCE CURVE................................................................ 35 WEIGHT TABLE............................................................................ 37 11 STRUCTURE AND FUNCTION................................................................... 39 GENERAL STRUCTURE....................................................................... 40 INTAKE AND EXHAUST SYSTEM............................................................... 42 AFTERCOOLER......................................................................... 42 AIR-COOLED AFTERCOOLER MOUNT........................................................ 43 AIR CLEANER......................................................................... 47 ELECTRONIC DUST INDICATOR........................................................... 48 TURBOCHARGER........................................................................ 49 ENGINE BODY............................................................................. 52 CYLINDER HEAD....................................................................... 52 CYLINDER BLOCK...................................................................... 54 MAIN REVOLVING SYSTEM............................................................... 56 TIMING GEAR......................................................................... 58 VALVE MECHANISM..................................................................... 60 FLYWHEEL AND FLYWHEEL HOUSING....................................................... 62 LUBRICATION SYSTEM...................................................................... 64 LUBRICATION SYSTEM CHART............................................................ 64 OIL PUMP............................................................................ 65 OIL FILTER.......................................................................... 66 OIL COOLER.......................................................................... 67 FUEL SYSTEM............................................................................. 69 FUEL SYSTEM CHART................................................................... 69 FUEL INJECTION PUMP................................................................. 70 SPEED CONTROL LEVER ANGLE........................................................... 71 BOOST COMPENSATOR DEVICE............................................................ 72 FUEL INJECTION NOZZLE............................................................... 73 FUEL FILTER......................................................................... 74 FUEL INJECTION PUMP DRIVE CASE...................................................... 77 COOLING SYSTEM.......................................................................... 84 COOLING SYSTEM, CHART............................................................... 84 WATER PUMP.......................................................................... 86 THERMOSTAT.......................................................................... 88 ELECTRICAL SYSTEM....................................................................... 89 WIRING DIAGRAM...................................................................... 89 ALTERNATOR.......................................................................... 92 STARTING MOTOR...................................................................... 95 OIL PRESSURE SWITCH................................................................. 97 RELAY SWITCH........................................................................ 97 GLOW PLUG........................................................................... 98 12 TESTING AND ADJUSTING.................................................................... 99 INTAKE AND EXHAUST SYSTEM...............................................................101 ADJUSTING VALVE CLEARANCE...........................................................101 ENGINE BODY.............................................................................102 MEASURING COMPRESSION PRESSURE......................................................102 FUEL SYSTEM.............................................................................103 TESTING AND ADJUSTING FUEL INJECTION TIMING.........................................103 PROCEDURE FOR ADJUSTING FUEL CUT SOLENOID LINKAGE...................................107 PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE.....................................108 PERFORMANCE TEST........................................................................109 RUNNING IN STANDARD.................................................................109 PERFORMANCE TEST CRITERIA...........................................................110 FUEL INJECTION PUMP CALIBRATION DATA....................................................112 TROUBLESHOOTING.........................................................................120 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................121 METHOD OF USING TROUBLESHOOTING CHART...............................................123 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) ......................127 S-2 ENGINE DOES NOT START...........................................................128 (1) ENGINE DOES NOT TURN........................................................128 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)......129 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....130 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................131 S-4 ENGINE STOPS DURING OPERATIONS..................................................132 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).......................................133 S-6 ENGINE LACKS OUTPUT (NO POWER)..................................................134 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)....................................135 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...........................136 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................137 S-10 FUEL CONSUMPTION IS EXCESSIVE..................................................138 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN........139 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................140 S-13 OIL LEVEL RISES................................................................141 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ..............................142 S-15 ABNORMAL NOISE IS MADE.........................................................143 S-16 VIBRATION IS EXCESSIVE.........................................................144 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.......................................145 TESTING AND ADJUSTING DATA..............................................................147 13 DISASSEMBLY AND ASSEMBLY.................................................................150 OVERALL DISASSEMBLY.....................................................................151 OVERALL ASSEMBLY........................................................................163 14 MAINTENANCE STANDARD.....................................................................186 INTAKE AND EXHAUST SYSTEM...............................................................187 TURBOCHARGER........................................................................187 ENGINE BODY.............................................................................188 CYLINDER HEAD.......................................................................188 VALVE AND VALVE GUIDE...............................................................189 ROCKER ARM, PUSH ROD AND TAPPET.....................................................191 CYLINDER LINER......................................................................192 CYLINDER BLOCK......................................................................193 CRANKSHAFT..........................................................................195 CAMSHAFT............................................................................196 PISTON, PISTON RING AND PISTON PIN..................................................197 CONNECTING ROD......................................................................198 TIMING GEAR.........................................................................199 FLYWHEEL AND FLYWHEEL HOUSING.......................................................200 LUBRICATION SYSTEM......................................................................201 OIL PUMP............................................................................201 REGULATOR VALVE.....................................................................202 SAFETY VALVE........................................................................202 COOLING SYSTEM..........................................................................203 WATER PUMP AND THERMOSTAT...........................................................203 15 REPAIR AND REPLACEMENT OF PARTS..........................................................204 REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING....................................205 REPLACING VALVE SEAT INSERTS............................................................206 PRESSURE TEST...........................................................................210 REPLACING VALVE GUIDE...................................................................211 GRINDING THE VALVE......................................................................212 REPLACING CAM BUSHING...................................................................213 REPLACING CRANK GEAR....................................................................215 REPLACING CAM GEAR......................................................................215 REPLACING FLYWHEEL RING GEAR............................................................216 REPLACING MAIN BEARING CAP..............................................................217 GRINDING CRANKSHAFT.....................................................................218 REPLACING ENGINE REAR SEAL..............................................................223 REPLACING CONNECTING ROD SMALL END BUSHING..............................................226
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
