Komatsu 108-2 Series Diesel Engine Service Repair Shop Manual - SEBM006904

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the 108-2 Series Komatsu Diesel Engine 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.


APPLICABLE MODELS :

Engine Model : S6D108-2
EG150BS-5 Generator
DCA150SSK MO generator

Engine Model : SA6D108-2
DCA180SPKE DENYO generator
DCA180SSK MO generator

Engine Model : SAA6D108-2
PC300-6, PC340-6,PC360-6,PC380-6 Hydraulic excavator
CD110R-1 Crawler carrier


TABLE OF CONTENTS :

01 GENERAL
-- APPLICABLE MACHINE
-- SPECIFICATIONS
-- GENERAL ASSEMBLY DRAWING
-- ENGINE PERFORMANCE CURVE
-- WEIGHT TABLE
11 STRUCTURE AND FUNCTION
-- GENERAL STRUCTURE
-- INTAKE AND EXHAUST SYSTEM
-- ENGINE BODY
-- LUBRICATION SYSTEM
-- FUEL SYSTEM
-- COOLING SYSTEM
-- ELECTRICAL SYSTEM
12 TESTING AND ADJUSTING
-- INTAKE AND EXHAUST SYSTEM
-- ENGINE BODY
-- FUEL SYSTEM
-- PERFORMANCE TEST
-- FUEL INJECTION PUMP CALIBRATION DATA
-- TROUBLESHOOTING
-- TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
-- TESTING AND ADJUSTING DATA
13 DISASSEMBLY AND ASSEMBLY
-- OVERALL DISASSEMBLY
-- OVERALL ASSEMBLY
14 MAINTENANCE STANDARD
-- INTAKE AND EXHAUST SYSTEM
-- ENGINE BODY
-- LUBRICATION SYSTEM
-- COOLING SYSTEM
15 REPAIR AND REPLACEMENT OF PARTS
-- REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING
-- REPLACING VALVE SEAT INSERTS
-- PRESSURE TEST
-- REPLACING VALVE GUIDE
-- GRINDING THE VALVE
-- REPLACING CAM BUSHING
-- REPLACING CRANK GEAR
-- REPLACING CAM GEAR
-- REPLACING FLYWHEEL RING GEAR
-- REPLACING MAIN BEARING CAP
-- GRINDING CRANKSHAFT
-- REPLACING ENGINE REAR SEAL
-- REPLACING CONNECTING ROD SMALL END BUSHING


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM006904
Total Pages : 211


This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.

TESTING AND ADJUSTING
This section 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" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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More Info : www.SITELUX.com

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COVER PAGE
CONTENTS
SAFETY
FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRICAL WIRE CODE
CONVERSION TABLE
UNITS

01 GENERAL
APPLICABLE MACHINE
SPECIFICATIONS
GENERAL ASSEMBLY DRAWING
ENGINE PERFORMANCE CURVE
WEIGHT TABLE

11 STRUCTURE AND FUNCTION
GENERAL STRUCTURE
INTAKE AND EXHAUST SYSTEM
AFTERCOOLER
AIR-COOLED AFTERCOOLER MOUNT
AIR CLEANER
ELECTRONIC DUST INDICATOR
TURBOCHARGER
ENGINE BODY
CYLINDER HEAD
CYLINDER BLOCK
MAIN REVOLVING SYSTEM
TIMING GEAR
VALVE MECHANISM
FLYWHEEL AND FLYWHEEL HOUSING
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
OIL PUMP
OIL FILTER
OIL COOLER
FUEL SYSTEM
FUEL SYSTEM CHART
FUEL INJECTION PUMP
SPEEDCONTROL LEVER ANGLE
BOOST COMPENSATOR DEVICE
FUEL INJECTION NOZZLE
FUEL FILTER
FUEL INJECTION PUMP DRIVE CASE
COOLING SYSTEM
COOLING SYSTEM, CHART
WATER PUMP
THERMOSTAT
ELECTRICAL SYSTEM
WIRING DIAGRAM
ALTERNATOR
STARTING MOTOR
OIL PRESSURE SWITCH
RELAY SWITCH
GLOW PLUG

12 TESTING AND ADJUSTING
INTAKE AND EXHAUST SYSTEM
ADJUSTING VALVE CLEARANCE
ENGINE BODY
MEASURING COMPRESSION PRESSURE
FUEL SYSTEM
TESTING AND ADJUSTING FUEL INJECTION TIMING
PROCEDURE FOR ADJUSTING FUEL CUT SOLENOID LINKAGE
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
PERFORMANCE TEST
RUNNING IN STANDARD
PERFORMANCE TEST CRITERIA
FUEL INJECTION PUMP CALIBRATION DATA
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHART
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START (1) ENGINE DOES NOT TURN
(1) ENGINE DOES NOT START (1) ENGINE DOES NOT TURN
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (NO POWER)
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING DATA

13 DISASSEMBLY AND ASSEMBLY
OVERALL DISASSEMBLY
OVERALL ASSEMBLY

14 MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM
TURBOCHARGER
ENGINE BODY
CYLINDER HEAD
VALVE AND VALVE GUIDE
ROCKER ARM, PUSH ROD AND TAPPET
CYLINDER LINER
CYLINDER BLOCK
CRANKSHAFT
CAMSHAFT
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
TIMING GEAR
FLYWHEEL AND FLYWHEEL HOUSING
LUBRICATION SYSTEM
OIL PUMP
REGULATOR VALVE
SAFETY VALVE
COOLING SYSTEM
WATER PUMP AND THERMOSTAT

15 REPAIR AND REPLACEMENT OF PARTS
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING
REPLACING VALVE SEAT INSERTS
PRESSURE TEST
REPLACING VALVE GUIDE
GRINDING THE VALVE
REPLACING CAM BUSHING
REPLACING CRANK GEAR
REPLACING CAM GEAR
REPLACING FLYWHEEL RING GEAR
REPLACING MAIN BEARING CAP
GRINDING CRANKSHAFT
REPLACING ENGINE REAR SEAL
REPLACING CONNECTING ROD SMALL END BUSHING

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