Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 – PDF DOWNLOAD

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 – PDF DOWNLOAD

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Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 – PDF DOWNLOAD

Language : English
Pages : 256
Downloadable : Yes
File Type : PDF
Size: 16.5 MB

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Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 – PDF DOWNLOAD

The Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 is a comprehensive technical guide that provides detailed information and instructions for the maintenance, repair, and overhaul of the Komatsu 108 series diesel engine. The manual covers a range of Komatsu 108 engines commonly used in various construction equipment such as dozers, excavators, wheel loaders, and motor graders.

• The manual is divided into several sections, each of which covers different aspects of engine maintenance and repair. The general specifications section provides an overview of the engine’s technical specifications, including dimensions, weight, power output, and torque ratings. It also includes information on the engine’s various components, such as the cylinder block, cylinder head, crankshaft, and pistons.
• The testing and adjusting procedures section of the manual provides step-by-step instructions for performing various tests and adjustments on the engine. These procedures include compression tests, fuel injection timing adjustment, and valve clearance adjustment. The manual also provides information on the tools and equipment required for performing these procedures.
• The disassembly and assembly instructions section of the manual provides detailed guidance on how to disassemble and reassemble the engine, including the removal and installation of various components such as the cylinder head, pistons, and crankshaft. This section also includes detailed diagrams and illustrations that provide a clear understanding of the engine’s internal components and how they fit together.
• The troubleshooting guidelines section of the manual provides information on how to diagnose and repair common problems that may occur with the engine. This section provides a list of potential symptoms and causes, along with step-by-step instructions for identifying and fixing the problem.
• The manual also covers maintenance and safety guidelines, including routine inspections, cleaning, lubrication, and safety precautions that must be followed while working with the engine.
• Overall, the Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 is an essential resource for technicians and mechanics working with the Komatsu 108 series engines. Its comprehensive coverage of maintenance, repair, and troubleshooting procedures makes it an indispensable tool for ensuring the reliable and efficient operation of Komatsu construction equipment.

TABLE OF CONTENTS:

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210103 – PDF DOWNLOAD

MAIN MENU……………………………………………………………………… 0
CONTENTS………………………………………………………………………. 2
01 GENERAL…………………………………………………………………….. 23
SPECIFICATIONS……………………………………………………………… 24
ENGINE PERFORMANCE CURVE…………………………………………………….. 28
WEIGHT TABLE……………………………………………………………….. 38
11 STRUCTURE AND FUNCTION……………………………………………………….. 41
GENERAL STRUCTURE…………………………………………………………… 42
INTAKE AND EXHAUST SYSTEM……………………………………………………. 44
AFTER-COOLER …………………………………………………………… 44
AIR CLEANER…………………………………………………………….. 45
ELECTRONIC DUST INDICATOR………………………………………………… 46
TURBOCHARGER……………………………………………………………. 47
ENGINE BODY………………………………………………………………… 54
CYLINDER HEAD…………………………………………………………… 54
CYLINDER BLOCK………………………………………………………….. 56
MAIN REVOLVING SYSTEM……………………………………………………. 58
TIMING GEAR…………………………………………………………….. 62
VALVE SYSTEM……………………………………………………………. 64
FLWHEEL AND FLYWHEEL HOUSING……………………………………………… 66
LUBRICATION SYSTEM………………………………………………………….. 70
LUBRICATION SYSTEM CHART…………………………………………………. 70
OIL PUMP……………………………………………………………….. 71
OIL FILTER (BUILT-IN SAFETY VALVE)………………………………………… 72
OIL COOLER……………………………………………………………… 73
FUEL SYSTEM………………………………………………………………… 74
FUEL SYSTEM CHART……………………………………………………….. 74
FUEL INJECTION PUMP……………………………………………………… 76
FUEL INJECTION NOZZLE……………………………………………………. 84
FUEL FILTER…………………………………………………………….. 85
FUEL INJECTION PUMP DRIVE CASE……………………………………………. 86
ENGINE STOP MOTOR……………………………………………………….. 88
FUEL CUT SOLENOID……………………………………………………….. 93
COOLING SYSTEM……………………………………………………………… 94
COOLING SYSTEM CHART…………………………………………………….. 94
THERMOSTAT……………………………………………………………… 97
WATER PUMP……………………………………………………………… 98
ELECTRICAL SYSTEM……………………………………………………………101
WIRING DIAGRAM…………………………………………………………..101
ALTERNATOR………………………………………………………………104
STARTING MOTOR…………………………………………………………..108
OIL PRESSURE SWITCH………………………………………………………110
RELAY SWITCH…………………………………………………………….110
GLOW PLUG……………………………………………………………….111
12 TESTING AND ADJUSTING…………………………………………………………113
INTAKE AND EXHAUST SYSTEM…………………………………………………….115
ADJUSTING VALVE CLEARANCE…………………………………………………115
ENGINE BODY…………………………………………………………………116
MEASURING COMPRESSION PRESSURE…………………………………………….116
FUEL SYSTEM…………………………………………………………………117
TESTING AND ADJUSTING FUEL INJECTION TIMING…………………………………117
ADJUSTMENT FUEL CUT SOLENOID LINK………………………………………….120
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE……………………………..122
ADJUSTING ENGINE SPEED SENSOR (MECHANICAL GOVERNOR)………………………….124
PERFORMANCE TEST…………………………………………………………….125
RUN-IN STANDARD………………………………………………………….125
PERFORMANCE TEST CRITERIA…………………………………………………128
TESTING AND ADJUSTING DATA……………………………………………………132
FUEL INJECTION PUMP CALIBRATION DATA……………………………………….132
TESTING AND ADJUSTING TOOL LIST……………………………………………143
STANDARD VALVE TABLE……………………………………………………..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……………………………..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 level goes down……168
S-12 Oil pressure lamp lights up (drop in oil pressure)………………………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 DISASSEMBLY AND ASSEMBLY………………………………………………………175
OVERALL DISASSEMBLY………………………………………………………….176
OVERALL ASSEMBLY…………………………………………………………….188
14 MAINTENANCE STANDARD………………………………………………………….211
INTAKE AND EXHAUST SYSTEM…………………………………………………….212
TURBOCHARGER…………………………………………………………….212
ENGINE BODY…………………………………………………………………214
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
PISTON, 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