Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104

Description

• Model List:
  • 108 Series Diesel Engine

• 1. COVER
• 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. AFTER COOLER
• 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. FLYWHEEL 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. INAKE 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. ADJUSTING FUEL CUT SOLENOID LINK
• 5.3.3. PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 5.3.4. ADJUSTING ENGINE SPEED SENSOR
• 5.4. PERFORMANCE TEST
• 5.4.1. RUNNINGIN STANDARD
• 5.4.2. PERFORMANCE TEST CRITERIA
• 5.5. TESTING AND ADJUSTING DATA
• 5.5.1. CALIBRATION DATA
• 5.5.2. TESTING AND ADJUSTING TOO LIST
• 5.5.3. TESTING AND ADJUSTING DATA
• 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 (FUEL IS NOT BEING INJECTED)
• 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 LEVER GOES DOWN
• 5.6.14. S12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRSSURE)
• 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. DISSSEMBLY AND ASSEMBLY
• 6.1. OVERALL DISASSEMBLY
• 6.2. OVERALL ASSEMBLY
• 7. MAINTENANCE STANDARD
• 7.1. TURBOCHARGER
• 7.2. CYLINDER HEAD
• 7.3. VALVE AND VALVE GUIDE
• 7.4. ROCKER ARM, PUSH ROD AND TAPPET
• 7.5. CYLINDER LINER
• 7.6. CYLINDER BLOCK
• 7.7. CRANKSHAFT
• 7.8. CAMSHAFT
• 7.9. PISION,PISTON RING AND PISTON PIN
• 7.10. CONNECTING ROD
• 7.11. TIMING GEAR
• 7.12. FLYWHEEL AND FLYWHEEL HOUSING
• 7.13. LUBRICATION SYSTEM
• 7.13.1. OIL PUMP
• 7.13.2. REGULATOR VALVE
• 7.13.3. SAFETY VALVE
• 7.14. COOLING SYSTEM
• 7.15. 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