Komatsu 108 & 108-2 Diesel Engine Workshop Repair Manual S6D108-1 SA6D108-1 S6D108-2 SA6D108-2 SAA6D108-2 PDF - MKMTSENG108.zip

A full factory-level repair guide, complete with electrical wiring diagrams, covering Komatsu 108 Series diesel engines—packed with every technical detail needed to service, troubleshoot, fix, and rebuild these units the way professional technicians do.

This workshop service repair manual for Komatsu 108 and 108-2 Series diesel engines (S6D108-1, SA6D108-1, S6D108-2, SA6D108-2, SAA6D108-2) contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 948 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

SEBE62210103 - 108 Series Diesel Engines (S6D108-1, SA6D108-1) Shop Manual.pdf

SEBE62210104 - 108 Series Diesel Engines (S6D108-1, SA6D108-1) Shop Manual.pdf

SEBM006904 - 108-2 Series Diesel Engines (S6D108-2, SA6D108-2, SAA6D108-2) Shop Manual.pdf

SEBM006906 - 108-2 Series Diesel Engines Shop Manual.pdf

MAIN SECTIONS

COVER...1

CONTENTS...4

SAFETY...5

FOREWORD...7

GENERAL...7

HOW TO READ THE SHOP MANUAL...8

HOISTING INSTRUCTIONS...9

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...10

COATING MATERIALS...12

STANDARD TIGHTENING TORQUE...14

ELECTRICAL WIRE CODE...17

CONVERSION TABLE...18

UNITS...24

01 GENERAL...25

APPLICABLE MACHINE...26

SPECIFICATIONS...28

GENERAL ASSEMBLY DRAWING...31

ENGINE PERFORMANCE CURVE...35

WEIGHT TABLE...37

11 STRUCTURE AND FUNCTION...39

GENERAL STRUCTURE...40

INTAKE AND EXHAUST SYSTEM...42

AFTERCOOLER...42

AIR-COOLED AFTERCOOLER MOUNT...43

AIR CLEANER...47

ELECTRONIC DUST INDICATOR...48

TURBOCHARGER...49

ENGINE BODY...52

CYLINDER HEAD...52

CYLINDER BLOCK...54

MAIN REVOLVING SYSTEM...56

TIMING GEAR...58

VALVE MECHANISM...60

FLYWHEEL AND FLYWHEEL HOUSING...62

LUBRICATION SYSTEM...64

LUBRICATION SYSTEM CHART...64

OIL PUMP...65

OIL FILTER...66

OIL COOLER...67

FUEL SYSTEM...69

FUEL SYSTEM CHART...69

FUEL INJECTION PUMP...70

SPEED CONTROL LEVER ANGLE...71

BOOST COMPENSATOR DEVICE...72

FUEL INJECTION NOZZLE...73

FUEL FILTER...74

FUEL INJECTION PUMP DRIVE CASE...77

COOLING SYSTEM...84

COOLING SYSTEM, CHART...84

WATER PUMP...86

THERMOSTAT...88

ELECTRICAL SYSTEM...89

WIRING DIAGRAM...89

ALTERNATOR...92

STARTING MOTOR...95

OIL PRESSURE SWITCH...97

RELAY SWITCH...97

GLOW PLUG...98

12 TESTING AND ADJUSTING...99

INTAKE AND EXHAUST SYSTEM...101

ADJUSTING VALVE CLEARANCE...101

ENGINE BODY...102

MEASURING COMPRESSION PRESSURE...102

FUEL SYSTEM...103

TESTING AND ADJUSTING FUEL INJECTION TIMING...103

PROCEDURE FOR ADJUSTING FUEL CUT SOLENOID LINKAGE...107

PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE...108

PERFORMANCE TEST...109

RUNNING IN STANDARD...109

PERFORMANCE TEST CRITERIA...110

FUEL INJECTION PUMP CALIBRATION DATA...112

TROUBLESHOOTING...120

POINTS TO REMEMBER WHEN TROUBLESHOOTING...121

METHOD OF USING TROUBLESHOOTING CHART...123

S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) ...127

S-2 ENGINE DOES NOT START...128

(1) ENGINE DOES NOT TURN...128

(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...129

(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...130

S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...131

S-4 ENGINE STOPS DURING OPERATIONS...132

S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...133

S-6 ENGINE LACKS OUTPUT (NO POWER)...134

S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...135

S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...136

S-9 OIL BECOMES CONTAMINATED QUICKLY...137

S-10 FUEL CONSUMPTION IS EXCESSIVE...138

S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...139

S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...140

S-13 OIL LEVEL RISES...141

S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ...142

S-15 ABNORMAL NOISE IS MADE...143

S-16 VIBRATION IS EXCESSIVE...144

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...145

TESTING AND ADJUSTING DATA...147

13 DISASSEMBLY AND ASSEMBLY...150

OVERALL DISASSEMBLY...151

OVERALL ASSEMBLY...163

14 MAINTENANCE STANDARD...186

INTAKE AND EXHAUST SYSTEM...187

TURBOCHARGER...187

ENGINE BODY...188

CYLINDER HEAD...188

VALVE AND VALVE GUIDE...189

ROCKER ARM, PUSH ROD AND TAPPET...191

CYLINDER LINER...192

CYLINDER BLOCK...193

CRANKSHAFT...195

CAMSHAFT...196

PISTON, PISTON RING AND PISTON PIN...197

CONNECTING ROD...198

TIMING GEAR...199

FLYWHEEL AND FLYWHEEL HOUSING...200

LUBRICATION SYSTEM...201

OIL PUMP...201

REGULATOR VALVE...202

SAFETY VALVE...202

COOLING SYSTEM...203

WATER PUMP AND THERMOSTAT...203

15 REPAIR AND REPLACEMENT OF PARTS...204

REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING...205

REPLACING VALVE SEAT INSERTS...206

PRESSURE TEST...210

REPLACING VALVE GUIDE...211

GRINDING THE VALVE...212

REPLACING CAM BUSHING...213

REPLACING CRANK GEAR...215

REPLACING CAM GEAR...215

REPLACING FLYWHEEL RING GEAR...216

REPLACING MAIN BEARING CAP...217

GRINDING CRANKSHAFT...218

REPLACING ENGINE REAR SEAL...223

REPLACING CONNECTING ROD SMALL END BUSHING...226