Komatsu 110 Series Diesel Engine Shop Manual SEBE6138A05 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu 110 Series Diesel Engine Shop Manual SEBE6138A05 – PDF DOWNLOAD
FOREWORD:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTMENTS
This sections explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
REMOVAL AND INSTALLATION
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu 110 Series Diesel Engine Shop Manual SEBE6138A05 – PDF DOWNLOAD
COVER 1
CONTENTS 2
01 GENERAL 21
GENERAL 22
GENERAL VIEW 23
SPECIFICATIONS 25
GENERAL ASSEMBLY DRAWING 28
ENGINE PERFORMANCE CURVE 36
WEIGHT TABLE 44
11 STRUCTURE AND FUNCTION 45
STRUCTURE AND FUNCTION 46
GENERAL STRUCTURE 47
INTAKE AND EXHAUST SYSTEM 51
TURBOCHARGER 59
AFTER-COOLER (SA6D110-1) 61
ENGINE BODY 62
CYLINDER HEAD 62
MAIN MOVING PARTS 64
LUBRICATION SYSTEM 74
LUBRICATION SYSTEM CHART 74
OIL PUMP 76
REGULATOR VALVE 78
OIL FILTER (BUILT-IN SAFETY VALVE) 78
OIL FILTER (WITH ELEMENT CLOGGING CAUTION SENSOR) 79
BY-PASS OIL FILTER 80
OIL COOLER 81
FUEL SYSTEM 83
FUEL SYSTEM CHART 83
FUEL INJECTION PUMP 84
GOVERNOR 92
FEED PUMP 97
FUEL INJECTION NOZZLE 99
FUEL FILTER 101
FUEL CUT SOLENOID 103
ENGINE STOP MOTOR 104
COOLING SYSTEM 109
COOLING SYSTEM CHART 109
WATER PUMP 110
THERMOSTAT 112
ELECTRICAL SYSTEM 113
WIRING DIAGRAM 113
ALTERNATOR 115
STARTING MOTOR 116
ELECTRICAL INTAKE AIR HEATER 118
OIL PRESSURE SWITCH 120
RELAY SWITCH 120
ACCESSORY 121
AIR COMPRESSOR 121
12 TESTING AND ADJUSTING 123
TESTING AND ADJUSTING 124
INTAKE AND EXHAUST SYSTEM 125
MEASURING EXHAUST GAS COLOR 125
ADJUSTING VALVE CLEARANCE 126
ENGINE BODY 127
MEASURING COMPRESSION PRESSURE 127
MEASURING BLOW-BY PRESSURE 128
LUBRICATION SYSTEM 129
MEASURING OIL PRESSURE 129
MEASURING OIL TEMPERATURE 129
FUEL SYSTEM 130
TESTING AND ADJUSTING FUEL INJECTION TIMING 130
ADJUSTING FUEL CUT SOLENOID 132
COOLING SYSTEM 134
TESTING AND ADJUSTING FAN BELT TENSION 134
PERFORMANCE TEST 135
RUN-IN STANDARD 135
PERFORMANCE TEST CRITERIA 137
TESTING AND ADJUSTING DATA 141
FUEL INJECTION PUMP CALIBRATION DATA 141
TESTING AND ADJUSTING TOOL LIST 149
TESTING AND ADJUSTING DATA 150
TROUBLESHOOTING 155
METHOD OF READING TROUBLESHOOTING TABLE 155
TROUBLESHOOTING TABLE 157
13 DISASSEMBLY AND ASSEMBLY 177
DISASSEMBLY AND ASSEMBLY 178
OVERALL DISASSEMBLY 179
OVERALL ASSEMBLY 192
DISASSEMBLY AND ASSEMBLY OF COMPONENTS 217
TURBOCHARGER 218
DISASSEMBLY 218
ASSEMBLY 221
OIL PUMP 226
DISASSEMBLY 226
ASSEMBLY 227
WATER PUMP 228
DISASSEMBLY 228
ASSEMBLY 230
14 MAINTENANCE STANDARD 232
MAINTENANCE STANDARD 233
INTAKE AND EXHAUST SYSTEM 234
TURBOCHARGER 234
ENGINE BODY 235
CYLINDER HEAD 235
VALVE AND VALVE GUIDE 236
ROCKER ARM,PUSH ROD AND TAPPET 238
CYLINDER LINER 239
CYLINDER BLOCK 240
CRANKSHAFT 242
CAMSHAFT 243
PISTON,PISTON RING AND PISTON PIN 244
CONNECTING ROD 246
TIMING GEAR 247
FLYWHEEL AND FLYWHEEL HOUSING 248
LUBRICATION SYSTEM 249
OIL PUMP 249
REGULATOR VALVE AND SAFETY VALVE 251
COOLING SYSTEM 253
WATER PUMP AND THERMOSTAT 253
15 REPAIR AND REPLACEMENT OF PARTS 254
REPLACING VALVE SEAT INSERTS 255
REPLACING NOZZLE HOLDER SLEEVE 259
PRESSURE TEST 261
REPLACING VALVE GUIDE 262
GRINDING VALVE 263
REPLACING CAMSHAFT BUSHING 264
REPLACING CRANKSHAFT GEAR 266
REPLACING CAMSHAFT GEAR 266
REPLACING FLYWHEEL RING GEAR 267
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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