Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103

Description

• Model List:
  • 108 Series Diesel Engine

• 1. MAIN MENU
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATIONS
• 3.2. ENGINE PERFORMANCE CURVE
• 3.3. WEIGHT TABLE
• 4. STRUCTURE AND FUNCTION
• 4.1. GENERAL STRUCTURE
• 4.2. INTAKE AND EXHAUST SYSTEM
• 4.2.1. AFTERCOOLER
• 4.2.2. AIR CLEANER
• 4.2.3. ELECTRONIC DUST INDICATOR
• 4.2.4. TURBOCHARGER
• 4.3. ENGINE BODY
• 4.3.1. CYLINDER HEAD
• 4.3.2. CYLINDER BLOCK
• 4.3.3. MAIN REVOLVING SYSTEM
• 4.3.4. TIMING GEAR
• 4.3.5. VALVE SYSTEM
• 4.3.6. FLWHEEL AND FLYWHEEL HOUSING
• 4.4. LUBRICATION SYSTEM
• 4.4.1. LUBRICATION SYSTEM CHART
• 4.4.2. OIL PUMP
• 4.4.3. OIL FILTER (BUILTIN SAFETY VALVE)
• 4.4.4. OIL COOLER
• 4.5. FUEL SYSTEM
• 4.5.1. FUEL SYSTEM CHART
• 4.5.2. FUEL INJECTION PUMP
• 4.5.3. FUEL INJECTION NOZZLE
• 4.5.4. FUEL FILTER
• 4.5.5. FUEL INJECTION PUMP DRIVE CASE
• 4.5.6. ENGINE STOP MOTOR
• 4.5.7. FUEL CUT SOLENOID
• 4.6. COOLING SYSTEM
• 4.6.1. COOLING SYSTEM CHART
• 4.6.2. THERMOSTAT
• 4.6.3. WATER PUMP
• 4.7. ELECTRICAL SYSTEM
• 4.7.1. WIRING DIAGRAM
• 4.7.2. ALTERNATOR
• 4.7.3. STARTING MOTOR
• 4.7.4. OIL PRESSURE SWITCH
• 4.7.5. RELAY SWITCH
• 4.7.6. GLOW PLUG
• 5. TESTING AND ADJUSTING
• 5.1. INTAKE AND EXHAUST SYSTEM
• 5.1.1. ADJUSTING VALVE CLEARANCE
• 5.2. ENGINE BODY
• 5.2.1. MEASURING COMPRESSION PRESSURE
• 5.3. FUEL SYSTEM
• 5.3.1. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.3.2. ADJUSTMENT FUEL CUT SOLENOID LINK
• 5.3.3. PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 5.3.4. ADJUSTING ENGINE SPEED SENSOR (MECHANICAL GOVERNOR)
• 5.4. PERFORMANCE TEST
• 5.4.1. RUNIN STANDARD
• 5.4.2. PERFORMANCE TEST CRITERIA
• 5.5. TESTING AND ADJUSTING DATA
• 5.5.1. FUEL INJECTION PUMP CALIBRATION DATA
• 5.5.2. TESTING AND ADJUSTING TOOL LIST
• 5.5.3. STANDARD VALVE TABLE
• 5.6. TROUBLESHOOTING
• 5.6.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.6.2. METHOD OF USING TROUBLESHOOTING CHART
• 5.6.3. S1 Starting performance is poor (Starting always takes time)
• 5.6.4. S2 Engine does not start
• 5.6.4.1. Engine does not turn
• 5.6.4.2. Engine turns but no exhaust gas comes out
• 5.6.4.3. Exhaust gas comes out but engine does not start (Fuel is being injected)
• 5.6.5. S3 Engine does not pick up smoothly (Followup is poor)
• 5.6.6. S4 Engine stops during operations
• 5.6.7. S5 Engine does not rotate smoothly (hunting)
• 5.6.8. S6 Engine lacks output (no power)
• 5.6.9. S7 Exhaust gas is black (incomplete combustion)
• 5.6.10. S8 Oil consumption is excessive (or exhaust gas is blue)
• 5.6.11. S9 Oil becomes contaminated quickly
• 5.6.12. S10 Fuel consumption is excessive
• 5.6.13. S11 Oil is in cooling water, or water spurts back, or water level goes down
• 5.6.14. S12 Oil pressure lamp lights up (drop in oil pressure)
• 5.6.15. S13 Oil level rises
• 5.6.16. S14 Water temperature becomes too high (overheating)
• 5.6.17. S15 Abnormal noise is made
• 5.6.18. S16 Vibration is excessive
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. OVERALL DISASSEMBLY
• 6.2. OVERALL ASSEMBLY
• 7. MAINTENANCE STANDARD
• 7.1. INTAKE AND EXHAUST SYSTEM
• 7.1.1. TURBOCHARGER
• 7.2. ENGINE BODY
• 7.2.1. CYLINDER HEAD
• 7.2.2. VALVE AND VALVE GUIDE
• 7.2.3. ROCKER ARM, PUSH ROD AND TAPPET
• 7.2.4. CYLINDER LINER
• 7.2.5. CYLINDER BLOCK
• 7.2.6. CRANKSHAFT
• 7.2.7. CAMSHAFT
• 7.2.8. PISTON, PISTON RING AND PISTON PIN
• 7.2.9. CONNECTING ROD
• 7.2.10. TIMING GEAR
• 7.2.11. FLYWHEEL AND FLYWHEEL HOUSING
• 7.3. LUBRICATION SYSTEM
• 7.3.1. OIL PUMP
• 7.3.2. REGULATOR VALVE
• 7.3.3. SAFETY VALVE
• 7.4. COOLING SYSTEM
• 7.4.1. WATER PUMP AND THERMOSTAT
• 8. REPAIR AND REPLACEMENT OF PARTS
• 8.1. REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING
• 8.2. REPLACING VALVE SEAT INSERTS
• 8.3. PRESSURE TEST
• 8.4. REPLACING VALVE GUIDE
• 8.5. GRINDING THE VALVE
• 8.6. REPLACING CAM BUSHING
• 8.7. REPLACING CRANK GEAR
• 8.8. REPLACING CAM GEAR
• 8.9. REPLACING FLYWHEEL RING GEAR
• 8.10. REPLACING MAIN BEARING CAP
• 8.11. GRINDING CRANKSHAFT
• 8.12. REPLACING ENGINE REAR SEAL