Komatsu 108-2 Series Diesel Engine Shop Manual SEBM006906

Description

• Model List:
  • 108-2 Series Diesel Engine

• 0.1. HOW TO READ THE SHOP MANUAL
• 0.2. HOISTING INSTRUCTIONS
• 0.3. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 0.4. COATING MATERIALS
• 0.5. STANDARD TIGHTENING TORQUE
• 0.6. ELECTRICAL WIRE CODE
• 0.7. CONVERSION TABLE
• 0.8. UNITS
• 1. GENERAL
• 1.1. APPLICABLE MACHINE
• 1.2. SPECIFICATIONS
• 1.3. GENERAL ASSEMBLY DRAWING
• 1.4. ENGINE PERFORMANCE CURVE
• 1.5. WEIGHT TABLE
• 2. STRUCTURE AND FUNCTION
• 2.1. GENERAL STRUCTURE
• 2.2. INTAKE AND EXHAUST SYSTEM
• 2.2.1. AFTERCOOLER
• 2.2.2. AIRCOOLED AFTERCOOLER MOUNT
• 2.2.3. AIR CLEANER
• 2.2.4. ELECTRONIC DUST INDICATOR
• 2.2.5. TURBOCHARGER
• 2.3. ENGINE BODY
• 2.3.1. CYLINDER HEAD
• 2.3.2. CYLINDER BLOCK
• 2.3.3. MAIN REVOLVING SYSTEM
• 2.3.4. TIMING GEAR
• 2.3.5. VALVE MECHANISM
• 2.3.6. FLYWHEEL AND FLYWHEEL HOUSING
• 2.4. LUBRICATION SYSTEM
• 2.4.1. LUBRICATION SYSTEM CHART
• 2.4.2. OIL PUMP
• 2.4.3. OIL FILTER
• 2.4.4. OIL COOLER
• 2.5. FUEL SYSTEM
• 2.5.1. FUEL SYSTEM CHART
• 2.5.2. FUEL INJECTION PUMP
• 2.5.3. SPEED CONTROL LEVER ANGLE
• 2.5.4. BOOST COMPENSATOR DEVICE
• 2.5.5. FUEL INJECTION NOZZLE
• 2.5.6. FUEL FILTER
• 2.5.7. FUEL INJECTION PUMP DRIVE CASE
• 2.6. COOLING SYSTEM
• 2.6.1. COOLING SYSTEM, CHART
• 2.6.2. WATER PUMP
• 2.6.3. THERMOSTAT
• 2.7. ELECTRICAL SYSTEM
• 2.7.1. WIRING DIAGRAM
• 2.7.2. ALTERNATOR
• 2.7.3. STARTING MOTOR
• 2.7.4. OIL PRESSURE SWITCH
• 2.7.5. RELAY SWITCH
• 2.7.6. GLOW PLUG
• 3. TESTING AND ADJUSTING
• 3.1. INTAKE AND EXHAUST SYSTEM
• 3.1.1. ADJUSTING VALVE CLEARANCE
• 3.2. ENGINE BODY
• 3.2.1. MEASURING COMPRESSION PRESSURE
• 3.3. FUEL SYSTEM
• 3.3.1. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 3.3.2. PROCEDURE FOR ADJUSTING FUEL CUT SOLENOID LINKAGE
• 3.3.3. PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 3.4. PERFORMANCE TEST
• 3.4.1. RUNNING IN STANDARD
• 3.4.2. PERFORMANCE TEST CRITERIA
• 3.5. FUEL INJECTION PUMP CALIBRATION DATA
• 3.6. TROUBLESHOOTING
• 3.6.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 3.6.2. METHOD OF USING TROUBLESHOOTING CHART
• 3.6.3. S1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
• 3.6.4. S2 ENGINE DOES NOT START
• 3.6.4.1. ENGINE DOES NOT TURN
• 3.6.4.2. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
• 3.6.4.3. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
• 3.6.5. S3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOWUP IS POOR)
• 3.6.6. S4 ENGINE STOPS DURING OPERATIONS
• 3.6.7. S5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
• 3.6.8. S6 ENGINE LACKS OUTPUT (NO POWER)
• 3.6.9. S7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
• 3.6.10. S8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
• 3.6.11. S9 OIL BECOMES CONTAMINATED QUICKLY
• 3.6.12. S10 FUEL CONSUMPTION IS EXCESSIVE
• 3.6.13. S11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
• 3.6.14. S12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
• 3.6.15. S13 OIL LEVEL RISES
• 3.6.16. S14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
• 3.6.17. S15 ABNORMAL NOISE IS MADE
• 3.6.18. S16 VIBRATION IS EXCESSIVE
• 3.7. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 3.8. TESTING AND ADJUSTING DATA
• 4. DISASSEMBLY AND ASSEMBLY
• 4.1. OVERALL DISASSEMBLY
• 4.2. OVERALL ASSEMBLY
• 5. MAINTENANCE STANDARD
• 5.1. INTAKE AND EXHAUST SYSTEM
• 5.1.1. TURBOCHARGER
• 5.2. ENGINE BODY
• 5.2.1. CYLINDER HEAD
• 5.2.2. VALVE AND VALVE GUIDE
• 5.2.3. ROCKER ARM, PUSH ROD AND TAPPET
• 5.2.4. CYLINDER LINER
• 5.2.5. CYLINDER BLOCK
• 5.2.6. CRANKSHAFT
• 5.2.7. CAMSHAFT
• 5.2.8. PISTON, PISTON RING AND PISTON PIN
• 5.2.9. CONNECTING ROD
• 5.2.10. TIMING GEAR
• 5.2.11. FLYWHEEL AND FLYWHEEL HOUSING
• 5.3. LUBRICATION SYSTEM
• 5.3.1. OIL PUMP
• 5.3.2. REGULATOR VALVE
• 5.3.3. SAFETY VALVE
• 5.4. COOLING SYSTEM
• 5.4.1. WATER PUMP AND THERMOSTAT
• 6. REPAIR AND REPLACEMENT OF PARTS
• 6.1. REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING
• 6.2. REPLACING VALVE SEAT INSERTS
• 6.3. PRESSURE TEST
• 6.4. REPLACING VALVE GUIDE
• 6.5. GRINDING THE VALVE
• 6.6. REPLACING CAM BUSHING
• 6.7. REPLACING CRANK GEAR
• 6.8. REPLACING CAM GEAR
• 6.9. REPLACING FLYWHEEL RING GEAR
• 6.10. REPLACING MAIN BEARING CAP
• 6.11. GRINDING CRANKSHAFT
• 6.12. REPLACING ENGINE REAR SEAL
• 6.13. REPLACING CONNECTING ROD SMALL END BUSHING