Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

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Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

Language : English
Pages : 254
Downloadable : Yes
File Type : PDF
Size: 11.1 MB

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Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

The Komatsu 108 Series Diesel Engine is a powerful and reliable engine that is commonly used in heavy-duty applications. The engine has a four-stroke cycle and is designed to deliver high performance with excellent fuel efficiency. To ensure the proper operation and maintenance of this engine, Komatsu has created the Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104.

The manual is comprehensive and covers all aspects of the engine, including its construction, maintenance, and repair. It is divided into several sections, each focusing on a different aspect of the engine. The sections are as follows:

1. General: This section provides an overview of the engine, including specifications, features, and system diagrams. It also includes safety information and precautions that should be taken when working on the engine.
2. Structure and Function: This section describes the structure and function of the engine, including its major components, such as the cylinder head, piston, connecting rod, and crankshaft. It also explains the engine’s lubrication and cooling systems and how they work.
3. Testing and Adjusting: This section covers the testing and adjustment procedures that should be performed on the engine to ensure proper operation. It includes procedures for checking and adjusting the valve clearance, injection timing, fuel system, and other key components.
4. Disassembly and Assembly: This section provides step-by-step instructions for disassembling and assembling the engine. It includes detailed diagrams and illustrations to help ensure that the process is carried out correctly.
5. Maintenance Standard: This section outlines the recommended maintenance schedule for the engine, including oil changes, filter replacements, and other routine maintenance tasks.
6. Repair and Replacement: This section provides information on repairing and replacing various components of the engine, including the cylinder head, piston, connecting rod, and crankshaft. It includes detailed instructions for each repair or replacement procedure, along with diagrams and illustrations to help ensure that the work is carried out correctly.

Overall, the Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 is a comprehensive resource for anyone who owns or works on this engine. It provides detailed information on every aspect of the engine, from its construction and operation to its maintenance and repair. With this manual, engine owners and technicians can ensure that the engine operates at its best and remains reliable and efficient for years to come.

TABLE OF CONTENTS:

Komatsu 108 Series Diesel Engine Shop Manual SEBE62210104 – PDF DOWNLOAD

COVER…………………………………………………………………………. 1
CONTENTS………………………………………………………………………. 2
01 GENERAL…………………………………………………………………….. 23
SPECIFICATIONS……………………………………………………………… 24
ENGINE PERFORMANCE CURVE…………………………………………………….. 28
WEIGHT TABLE……………………………………………………………….. 37
11 STRUCTURE AND FUNCTION……………………………………………………….. 39
GENERAL STRUCTURE…………………………………………………………… 40
INTAKE AND EXHAUST SYSTEM……………………………………………………. 42
AFTER -COOLER…………………………………………………………… 42
AIR CLEANER…………………………………………………………….. 43
ELECTRONIC DUST INDICATOR………………………………………………… 44
TURBOCHARGER……………………………………………………………. 45
ENGINE BODY………………………………………………………………… 52
CYLINDER HEAD…………………………………………………………… 52
CYLINDER BLOCK………………………………………………………….. 54
MAIN REVOLVING SYSTEM……………………………………………………. 56
TIMING GEAR…………………………………………………………….. 60
VALVE SYSTEM……………………………………………………………. 62
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………….. 64
LUBRICATION SYSTEM………………………………………………………….. 68
LUBRICATION SYSTEM CHART…………………………………………………. 68
OIL PUMP ………………………………………………………………. 69
OIL FILTER (BUILT-IN SAFETY VALVE)………………………………………… 70
OIL COOLER……………………………………………………………… 71
FUEL SYSTEM………………………………………………………………… 72
FUEL SYSTEM CHART……………………………………………………….. 72
FUEL INJECTION PUMP……………………………………………………… 74
FUEL INJECTION NOZZLE……………………………………………………. 82
FUEL FILTER…………………………………………………………….. 83
FUEL INJECTION PUMP DRIVE CASE……………………………………………. 84
ENGINE STOP MOTOR……………………………………………………….. 86
FUEL CUT SOLENOID……………………………………………………….. 91
COOLING SYSTEM……………………………………………………………… 92
COOLING SYSTEM CHART…………………………………………………….. 92
THERMOSTAT……………………………………………………………… 95
WATER PUMP……………………………………………………………… 96
ELECTRICAL SYSTEM…………………………………………………………… 99
WIRING DIAGRAM………………………………………………………….. 99
ALTERNATOR………………………………………………………………102
STARTING MOTOR…………………………………………………………..106
OIL PRESSURE SWITCH ……………………………………………………..108
RELAY SWITCH…………………………………………………………….108
GLOW PLUG……………………………………………………………….109
12 TESTING AND ADJUSTING…………………………………………………………111
INAKE AND EXHAUST SYSTEM……………………………………………………..113
ADJUSTING VALVE CLEARANCE…………………………………………………113
ENGINE BODY…………………………………………………………………114
MEASURING COMPRESSION PRESSURE…………………………………………….114
FUEL SYSTEM…………………………………………………………………115
TESTING AND ADJUSTING FUEL INJECTION TIMING…………………………………115
ADJUSTING FUEL CUT SOLENOID LINK…………………………………………..118
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE……………………………..120
ADJUSTING ENGINE SPEED SENSOR……………………………………………..122
PERFORMANCE TEST…………………………………………………………….123
RUNNING-IN STANDARD………………………………………………………123
PERFORMANCE TEST CRITERIA…………………………………………………126
TESTING AND ADJUSTING DATA……………………………………………………130
CALIBRATION DATA…………………………………………………………130
TESTING AND ADJUSTING TOO LIST…………………………………………….143
TESTING AND ADJUSTING DATA………………………………………………..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 (FUEL IS NOT BEING INJECTED)……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 LEVER GOES DOWN……168
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRSSURE)……………………….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 DISSSEMBLY AND ASSEMBLY……………………………………………………….175
OVERALL DISASSEMBLY………………………………………………………….176
OVERALL ASSEMBLY…………………………………………………………….188
14 MAINTENANCE STANDARD………………………………………………………….211
TURBOCHARGER………………………………………………………………..212
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
PISION,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