Komatsu 102 Series Diesel Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu 102 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 102 Series Diesel Engines workshop service repair manual includes:
* 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.
SEBM010019 - Komatsu 102 Series Diesel Engines (4D102E-1, S4D102E-1, 6D102E-1, S6D102E-1, SA6D102E-1, SAA4D102E-2, SAA6D102E-2) Shop Manual.pdf
SEBM010021 - Komatsu 102 Series Diesel Engines (4D102E-1, S4D102E-1, 6D102E-1, S6D102E-1, SA6D102E-1, SAA4D102E-2, SAA6D102E-2) Shop Manual.pdf
SEBM010023 - Komatsu 102 Series Diesel Engines Shop Manual.pdf
SRBM010005 - Komatsu 102 СЕРИЯ ДИЗЕЛЬНЫЙ ДВИГАТЕЛЬ Shop Manual (RU).pdf
PRODUCT DETAILS:
Total Pages: 3,749 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
CONTENTS...2
01 GENERAL...33
APPLICABLE MACHINE...34
SPECIFICATIONS...36
GENERAL ASSEMBLY DARWING...54
ENGINE PERFORMANCE CURVE...76
WEIGHT TABLE...116
11 STRUCTURE AND FUNCTION...118
GENERAL STRUCTURE...119
INTAKE AND EXHAUST DEVICES...121
AIR CLEANER...130
TURBOCHARGER...131
CYLINDER HEAD...135
CYLINDER BLOCK...142
MAIN MOVING PARTS...148
TIMING GEAR PORTION...155
FRONT GEAR COVER...156
CAMSHAFT TIMING PIN...157
VALVE MECHANISM...158
OIL PAN...162
FLYWHEEL,FLYWHEEL HOUSING...164
LUBRICATION SYSTEM DIAGRAM...167
OIL PUMP...174
OIL FILTER,OIL COOLER...175
REGULATOR VALVE,SAFETY VALVE...178
FUEL SYSTEM DIAGRAM...179
FUEL INJECTION PUMP...188
TIMING LOCK PIN FOR FUEL INJECTION PUMP...192
FUEL FILTER...193
FUEL INJECTION NOZZLE...194
FUEL CUT SOLENOID...195
COOLING SYSTEM DIAGRAM...196
WATER PUMP...200
THERMOSTAT...201
FAN DRIVE...202
AIR COMPRESSOR...206
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM...208
ALTERNATOR...210
STARTING MOTOR...217
STARTING AID...220
12 TESTING AND ADJUSTING...221
SPECIAL TOOL LIST...223
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM...223
SPECIAL TOOLS FOR ENGINE...224
SPECIAL TOOLS FOR FUEL SYSTEM...226
SPECIAL TOOLS FOR COMPONENTS...227
SPECIAL TOOLS FOR ELECTRICAL COMPONENTS...228
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST...229
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM...231
CLEAN AIR...231
TESTING INTAKE RESISTANCE...231
DAMAGE CAUSED BY UNFILTERED AIR...232
LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER)...232
LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER)...233
MEASURING PRESSURE OF TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER)...233
DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...234
OIL CONSUMPTION AND OIL LEAKAGE...234
NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)...235
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER)...236
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER)...237
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)...238
TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)...238
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER...239
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)...241
MEASURING EXHAUST RESISTANCE...242
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)...242
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE...243
VALVE MECHANISM AND CYLINDER HEAD...243
TESTING AIR SYSTEM AND FUEL SYSTEM...243
TESTING VALVE CLEARANCE...244
TESTING COMPRESSION...244
PISTON RING SEALING PERFORMANCE...244
VALVE SEALING PERFORMANCE...245
HEAD GASKET SEALIN PERFORMANCE...245
VALVE SEAL WEAR...246
PROTRUDING PORTION OF FUEL INJECTION NOZZLE...247
FRONT GEAR HOUSING AND GEAR TRAIN...248
VIBRATION DAMPER...248
ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT...249
PISTON AND CONNECTING ROD...250
CRANKSHAFT AND MAIN BEARING...252
CYLINDER BLOCK...253
FLYWHEEL HOUSING AND FLYWHEEL...254
ADJUSTING VALVE CLEARANCE...255
ADJUSTING 4-CYLINDER ENGINE...256
ADJUSTING 6-CYLINDER ENGINE...257
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM...258
OUTLINE...258
HIGH PRESSURE...258
REGULATOR VALVE...258
LOW PRESSURE...259
OIL LEVEL...259
OIL FILTER...259
OIL PRESSURE GAUGE...260
OIL PAN SUCTION TUBE...260
BEARING AND OIL PUMP...260
UNSUITABLE OIL PUMP...260
DILUTION OF OIL...261
COOLING WATER IN OIL...261
FUEL IN OIL...262
FUEL INJECTION PUMP CALIBRATION DATA...265
RUNNING IN STANDARD...321
PERFORMANCE TEST CRITERIA...327
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (DIAPHRAGM TYPE)...345
TESTING FEED PUMP...345
TEST 1:TESTING OUTPUT PRESSURE...345
TEST 2:TESTING FLOW...346
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)...347
TEST 1:TESTING OUTPUT PRESSURE...348
TEST 2:TESTING FLOW...349
TESTING AIR INSIDE FUEL SYSTEM...352
TESTING WATER SEPARATOR,FUEL FILTER...353
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV)...355
DEFECTIVE ACTUATION OF GOVERNOR...356
STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT...356
LUCAS CAV ADJUSTMENT SCREW...356
BOSCH VE ADJUSTMENT SCREW...357
MANUAL SHUT-OFF LEVER...357
TIMING PROPULSION ANGLE MECHANISM...358
ELECTRICAL SHUT-OFF VALVE...358
DELIVERY VALVE (LUCAS CAV)...360
TESTING HIGH-PRESSURE FUEL PIPING...361
TESTING FUEL INJECTION NOZZLE...362
TESTING FUEL DRAIN PIPING...364
BLEEDING AIR FROM FUEL SYSTEM...364
BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER...365
BLEEDING AIR FROM FUEL INJECTION PUMP...365
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT...366
ADJUSTING FUEL INJECTION TIMING...366
ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE...369
ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV...370
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)...371
REPLACING FUEL INJECTION NOZZLE...371
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM...375
TROUBLESHOOTING...375
RADIATOR CAP...377
WATER PUMP...378
RADIATOR, FAN, AND RADIATOR SHUTTER...379
THERMOSTAT...381
WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD...382
TESTING CARBON DEPOSIT IN AIR COMPRESSOR...383
TESTING AIR LEAKAGE FROM AIR COMPRESSOR...384
TESTING AIR GOVERNOR, UNLOADER VALVE...385
TESTING BATTERY...388
TESTING BATTERY TERMINAL CONNECTIONS...389
TESTING STARTING CIRCUIT ...389
TESTING BATTERY RELAY...389
TESTING STARTING SWITCH...391
TESTING STARTING MOTOR AND MAGNETIC SWITCH...392
TESTING DROP IN CRANKING SPEED...394
TESTING ALTERNATOR...395
ABNORMAL DISPLAY OF CHARGE LAMP...396
ABNORMAL ACTUATION OF CHARGING SYSTEM...397
TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR...398
TESTING OIL PRESSURE SWITCH...398
TESTING WATER TEMPERATURE SENSOR...399
TESTING WHITE SMOKE...400
NORMAL AUTUATION OF INTAKE HEATER SYSTEM...400
TESTING INTAKE HEATER...401
TESTING PREHEATING CYCLE...402
SIDE VIEW OF ENGINE...403
OUTLINE OF ENGINE PERFORMANCE TEST ...405
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE...406
ENGINE DYNAMOMETER ...407
INSTALLING ENGINE...407
PROCEDURE FOR RUNNING IN NEGINE...414
ENGINE PERFORMANCE TEST...417
ENGINE PAINTWORK...419
TROUBLESHOOTING...421
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...422
TROUBLESHOOTING OF ENGINE...443
METHOD OF USING TROUBLESHOOTING CHARTS...444
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...448
S-2 ENGINE DOES NOT START...450
(1) ENGINE DOES NOT TURN...450
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...451
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...452
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...453
S-4 ENGINE STOPS DURING OPERATIONS...454
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING)...455
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...456
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...457
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...458
S-9 OIL BECOMES CONTAMINATED QUICKLY...459
S-10 FUEL CONSUMPTION IS EXCESSIVE...460
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...461
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...462
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...463
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...464
S-15 ABNORMAL NOISE IS MADE...465
S-16 VIBRATION IS EXCESSIVE...466
13 DISASSEMBLY AND ASSEMBLY...467
SPECIAL TOOL LIST...472
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY...472
SPECIAL TOOLS FOR ENGINE...474
SPECIAL TOOLS FOR FUEL SYSTEM...476
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE ...478
OUTLINE...478
DISASSEMBLY...478
ASSEMBLY...478
DISASSEMBLY OF ENGINE...479
STEAM CLEANING OF ENGINE...479
REMOVAL OF STARTING MOTOR...479
WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER)...479
INSTALLATION TO ENGINE STAND...479
DRAINING OIL...480
REMOVAL OF REAR LIFTING BRACKET...480
REMOVEL OF BELT...480
REMOVAL OF FAN PULLEY...481
REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY...481
REMOVAL OF BELT TENSIONER...481
REMOVAL OF FAN HUB...482
REMOVAL OF ALTERNATOR...482
REMOVAL OF THERMOSTAT...483
REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...483
REMOVAL OF EXHAUST MANIFOLD...485
REMOVAL OF FUEL FILTER...485
REMOVAL OF FUEL FILTER HEAD...486
REMOVAL OF FUEL PIPING...486
REMOVAL OF DIPSTICK...488
REMOVAL OF INTAKE MANIFOLD COVER...488
REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER)...489
REMOVAL OF CYLINDER HEAD COVER...489
REMOVAL OF FUEL INJECTION NOZZLE...489
REMOVAL OF ROCKER LEVER...490
REMOVAL OF PUSH ROD...491
REMOVAL OF CYLINDER HEAD...491
REMOVAL OF FRONT COVER...491
REMOVAL OF WATER PUMP...492
REMOVAL OF FLYWHEEL...492
REMOVAL OF FLYWHEEL HOUSING...493
REMOVAL OF COMPONENTS (COMPRESSOR,HYDRAULIC PUMP,ETC.)...493
REMOVAL OF FUEL INJECTION PUMP (BOSCH A,ZEXEL A)...493
REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE)...496
REMOVAL OF TAPPET COVER...496
REMOVAL OF OIL FILLER...496
REMOVAL OF OIL COOLER...496
REMOVAL OF WATER INLET...497
REMOVAL OF OIL PAN...497
REMOVAL OF OIL PAN SUCTION TUBE...497
REMOVAL OF REAR SEAL COVER...498
REMOVAL OF CAMSHAFT...498
REMOVAL OF TAPPET...500
REMOVAL OF OIL PUMP...500
REMOVAL OF TIMING PIN HOUSING...501
REMOVAL OF GEAR HOUSING...501
REMOVAL OF BALANCER (WHEN BALANCER IS INSTALLED)...502
REMOVAL OF PISTON CONNECTING ROD...504
REMOVAL OF CRANKSHAFT...506
REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE...508
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND...508
ASSEMBLY OF ENGINE...509
PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK...509
INSTALLATION OF TAPPET...509
INSTALLATION OF CRANKSHAFT...510
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES...514
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY...514
INSTALLATION OF GEAR HOUSING...518
INSTALLATION OF OIL PUMP...519
INSTALLATION OF CAMSHAFT...520
INSTALLATION OF TIMING PIN...523
INSTALLATION OF BALANCER...526
INSTALLATION OF REAR OIL SEAL...530
INSTALLATION OF OIL PAN SUCTION TUBE...531
INSTALLATION OF OIL PAN...532
INSTALLATION OF OIL COOLER...533
INSTALLATION OF PIL FILLER PORT...533
INSTALLATION OF FEED PUMP...534
INSTALLATION OF TAPPET COVER...534
INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A)...536
INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.)...541
INSTALLATION OF FLYWHEEL HOUSING ...541
INSTALLATION OF FLYWHEEL...542
INSTALLATION OF WEATER PUMP...543
INSTALLATION OF FRONT COVER...543
INSTALLATION OF CYLINDER HEAD...545
INSTALLATION OF PUSH ROD ...546
INSTALLATION OF ROCKER LEVER...546
TIGHTENING OF CYLINDER HEAD...548
ADJUSTING VALVE CLEARANCE...550
INSTALLATION OF FUEL INJECTION NOZZLE...552
INSTALLATION OF CYLINDER HEAD COVER...553
INSTALLATION OF INTAKE MANIFOLD COVER...553
INSTALLATION OF FUEL FILTER HEAD...555
INSTALLATION OF EXHAUST MANIFOLD...556
INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...557
INSTALLATION OF THERMOSTAT...560
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER...561
INSTALLATION OF FAN HUB...561
INSTALLATION OF BELT TENSIONER...561
INSTALLATION OF WATER INLET...562
INSTALLATION OF ALTERNATOR...562
INSTALLATION OF BELT...563
INSTALLATION OF OIL FILTER...564
REMOVAL OF ENGINE FROM ENGINE STAND...564
INSTALLATION OF STARTING MOTOR...564
INTAKE GROUP...565
DISASSEMBLY AND ASSEMBLY DRAWING...565
OUTLINE...567
REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...568
REMOVAL...568
INSTALLATION...569
CLEANING AND INSPECTION...571
REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER)...573
REMOVAL...573
CLEANING...573
INSTALLATION...574
CLEANING AND INSPECTION...575
ASSEMBLY...575
REPLACEMENT OF INTAKE CONNECTOR...576
REMOVAL AND INSTALLATION...576
AIR CONNECTOR...576
CLEANING...576
INSPECTION...576
REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET...576
REMOVAL...577
CLEANING...577
INSTALLATION...577
AIR CROSSOVER TUBE...578
CLEANING...578
INSPECTION...578
EXHAUST GROUP...579
DISASSEMBLY AND ASSEMBLY DRAWING...579
OUTLINE OF EXHAUST MANIFOLD...580
REPLACEMENT OF EXHAUST MANIFOLD, GASKET...581
REMOVAL...581
CLEANING AND INSPECTION...581
INSTALLATION...581
REPLACEMENT OF EXHAUST MANIFOLD...582
REMOVAL...582
CLEANING...582
INSTALLATION...583
INSPECTION...583
REPLACEMENT OF TURBOCHARGER...584
REMOVAL...584
INSTALLATION...585
TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER)...588
REPLACEMENT...588
CYLINDER BLOCK GROUP...589
DISASSEMBLY AND ASSEMBLY DRAWING...589
OUTLINE OF CYLINDER BLOCK GROUP...592
OUTLINE OF CAMSHAFT...592
OUTLINE OF CRANKSHAFT...592
OUTLINE OF CYLINDER BLOCK...592
OUTLINE OF OIL SEAL...592
REPLACEMENT OF FRONT OIL SEAL...593
REMOVAL ...593
CLEANING AND INSPECTION...594
INSTALLATION...594
REPLACEMENT OF REAR OIL SEAL...596
OUTLINE OF PISTON...598
OUTLINE OF VIBRATION DAMPER...598
CHECK LIST FOR CYLINDER BLOCK GROUP...599
CYLINDER BLOCK...600
INSPECTION BEFORE DISASSEMBLY...600
DISASSEMBLY OF CYLINDER BLOCK...600
CLEANING OF CYLINDER BLOCK...602
INSPECTION OF CYLINDER BLOCK...605
REMOVAL OF GLAZE FROM CYLINDER BORE...607
DISASSEMBLY...607
INSPECTION...608
REMOVAL OF GLAZE...608
CLEANING...611
ASSEMBLY...612
REMOVAL OF GLAZE FROM CYLINDER BLOCK...613
REPLACEMENT OF PLUG...616
REMOVAL...616
CLEANING AND INSPECTION...616
INSTALLATION...617
REPLACEMENT OF CAP...617
REMOVAL...617
CLEANING...618
INSTALLATION...618
INSTALLATION OF CAP AND PLUG...621
INSTALLATION OF CAMSHAFT CUP...623
INSTALLATION OF CAMSHAFT BUSHING...624
REPLACEMENT OF DIPSTICK TUBE...625
STORING CYLINDER BLOCK...626
CRANKSHAFT...626
REPLACEMENT OF MAIN BEARING...627
CLEANING OF CRANKSHAFT...633
INSTALLATION OF CRANKSHAFT...633
REPLACEMENT OF CRANKSHAFT GEAR...634
REPLACEMENT OF CAMSHAFT AND TAPPET...636
REMOVAL OF CAMSHAFT...636
REMOVAL OF TAPPET...637
INSPECTION OF TAPPET...639
STANDARDS FOR PITTING WHEN REUSING...641
STANDARD FOR DETERIORATION (BREAKAGE) OF TIP...642
INSPECTION OF CAMSHAFT BORE...645
REPLACEMENT OF CAMSHAFT BUSHING...645
INSTALLATION OF TAPPET...646
INSTALLATION OF CAMSHAFT...649
CLEANING OF CAMSHAFT...651
INSPECTION OF CAMSHAFT,GEAR...652
REPLACEMENT OF CAMSHAFT,GEAR...654
CLEANING AND INSPECTION...655
INSTALLATION...656
REPLACEMENT OF TIMING PIN...658
REPLACEMENT OF GEAR HOUSING, GASKET...659
REMOVAL...659
CLEANING AND INSPECTION...660
INSTALLATION...661
REPOSITIONING OF TIMING PIN...664
REPLACEMENT OF CAMSHAFT GEAR...669
REMOVAL...669
INSTALLATION (SHRINK-FITTING METHOD)...670
INSTALLATION (METHOD USING SPECIAL TOOL)...671
INSTALLATION OF CAMSHAFT MOUNTING BOLTS...673
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY ...674
REMOVAL...674
INSPECTION OF RUBBER DAMPER...674
INSTALLATION...675
INSPECTION OF VISCOUS DAMPER...675
VIBRATION DAMPER (RUBBER TYPE)...679
CLEANING AND INSPECTION...679
PISTON,PIN,CONNECTING ROD...681
REPLACEMENT OF PISTON AND RING...681
REMOVAL OF PISTON CONNECTING ROD...682
DISASSEMBLY OF PISTON CONNECTING ROD...684
CLEANING OF PISTON,PIN,CONNECTING ROD...684
INSPECTION OF PISTON...685
INSPECTION OF PISTON PIN...686
ASSEMBLY OF PISTON CONNECTING ROD...687
INSPECTION OF PISTON RING GAP...688
INSTALLATION OF PISTON RING...689
INSTALLATION OF PISTON CONNECTING ROD...690
REPLACEMENT OF CONNECTING ROD...694
REMOVAL...694
CLEANING AND INSPECTION...695
INSTALLATION...697
REPLACEMENT OF CONNECTING ROD BEARING...698
REMOVAL...698
CLEANING AND INSPECTION...700
INSTALLATION...701
DISASSEMBLY OF PISTON CONNECTING ROD...704
CLEANING OF PISTON, PIN, CONNECTING ROD...705
INSPECTION OF PISTON...706
INSPECTION OF PISTON PIN...707
INSPECTION OF CONNECTING ROD...707
INSPECTION OF CONNECTING ROD BEARING CLEARANCE...707
ASSEMBLY OF PISTON CONNECTING ROD...708
INSPECTION OF PISTON RING END GAP...709
INSTALLATION OF PISTON RING...710
BALANCER...711
DISASSEMBLY...711
ASSEMBLY...714
GEAR COVER...721
REPLACEMENT OF GEAR COVER...721
REMOVAL...721
CLEANING AND INSPECTION...722
INSTALLATION...722
INSTALLATION OF GEAR COVER...724
INSPECTION OF GEAR HOUSING AND TIMING PIN...726
DISASSEMBLY OF GEAR HOUSING...726
REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD...727
REPLACEMENT OF ENGINE NAME PLATE...727
CYLINDER HEAD...729
DISASSEMBLY AND ASSEMBLY DRAWING...729
OUTLINE...731
REPLACEMENT OF CYLINDER HEAD...732
REMOVAL...732
INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD...735
DISASSEMBLY OF CYLINDER HEAD...736
CLEANING OF CYLINDER HEAD...737
INSPECTION OF VALVE...739
INSPECTION OF VALVE GUIDE...740
INSPECTION OF CYLINDER DECK...740
INSPECTION OF VALVE SEAT...741
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING...741
REPLACEMENT OF VALVE SPRING...742
ASSEMBLY OF CYLINDER HEAD...742
ADJUSTING VALVE CLEARANCE...747
INSTALLATION OF BELT TENSIONER...749
INSTALLATION OF ALTERNATOR...749
INSTALLATION OF DRIVE BELT...750
INSPECTION BEFORE DISASSEMBLY...750
DISASSEMBLY OF CYLINDER HEAD...751
CLEANING OF CYLINDER HEAD...752
INSPECTION OF VALVE...754
INSPECTION OF VALVE GUIDE...755
INSPECTION OF CYLINDER HEAD COMBUSTION DECK...755
INSPECTION OF VALVE SEAT...756
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING...756
REPLACEMENT OF VALVE SPRING...757
REPLACEMENT OF CAP...757
POLISHING VALVE...759
POLISHING VALVE SEAT...760
ROCKER LEVER...767
DISASSEMBLY AND ASSEMBLY DRAWING...767
OUTLINE...769
REPLACEMENT OF ROCKER LEVER AND PUSH ROD ...770
REMOVAL...770
DISASSEMBLY OF ROCKER LEVER...771
CLEANING OF ROCKER LEVER...772
INSPECTION OF ROCKER LEVER...772
ASSEMBLY OF ROCKER LEVER...773
INSTALLATION OF ROCKER LEVER...774
DISASSEMBLY OF ROCKER LEVER...776
CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT...777
INSPECTION OF ROCKER LEVER...777
INSPECTION OF ROCKER LEVER SHAFT...778
ASSEMBLY OF ROCKER LEVER...778
TAPPETS AND PUSH RODS...780
DISASSEMBLY AND ASSEMBLY DRAWING...780
OUTLINE...781
CLEANING OF PUSH ROD...782
INSPECTION OF PUSH ROD...782
INSTALLATION OF PUSH ROD...782
INSPECTION OF TAPPET...783
ENGINE MOUNT GROUP...785
OUTLINE OF FLYWHEEL HOUSING...785
OUTLINE OF FLYWHEEL, RING GEAR...785
OUTLINE OF FRONT SUPPORT...785
FLYWHEEL, RING GEAR...786
INSPECTION OF FLYWHEEL, RING GEAR...786
REPLACEMENT OF FLYWHEEL, RING GEAR...786
FLYWHEEL HOUSING...788
REPLACEMENT OF REAR OIL SEAL...788
REMOVAL...788
CLEANING AND INSPECTION...790
INSTALLATION...790
REPLACEMENT OF FLYWHEEL HOUSING...793
REMOVAL...793
CLEANING AND INSPECTION...794
INSTALLATION (DRY CLUTCH SPECIFICATION)...795
INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING...796
INSPECTION OF FACE RUNOUT OF FLTWHEEL HOUSING...798
INSTALLATION (WET CLUTCH SPECIFICATION)...799
INSPECTION...801
INSTALLATION...802
FRONT SUPPORT...803
CLEANING AND INSPECTION...803
REMOVAL OF ENGINE...804
INSPECTION OF ENGINE MOUNT...806
INSTALLATION OF ENGINE...807
OIL PAN AND SUCTION TUBE...811
DISASSEMBLY AND ASSEMBLY DRAWING...811
REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET...812
CLEANING AND INSPECTION...814
REGULATOR VALVE...815
REPLACEMENT OF REGULATOR VALVE, SPRING...815
DISASSEMBLY...815
CLEANING AND INSPECTION...815
OIL FILTER BYPASS VALVE...818
REPLACEMENT...818
OIL COOLER...819
DISASSEMBLY AND ASSEMBLY DRAWING...819
REPLACEMENT OF OIL COOLER CORE, GASKET...820
CLEANING...822
INSPECTION...823
OIL PUMP...824
DISASSEMBLY AND ASSEMBLY DRAWING...824
REPLACEMENT OF OIL PUMP...825
CLEANING AND INSPECTION...826
INSTALLATION OF OIL PUMP...829
INSPECTION...830
FUEL INJECTION PUMP GROUP...834
DISASSEMBLY AND ASSEMBLY DRAWING...834
FUEL INJECTION NOZZLE GROUP...835
FUEL INJECTION NOZZLE...836
DISASSEMBLY...836
CLEANING AND INSPECTION...837
ASSEMBLY...839
FEED PUMP (CYLINDER BLOCK MOUNT TYPE)...842
REPLACEMENT OF FEED PUMP (DIAPHRAGM TYPE)...842
REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE)...844
CLEANING...845
ASSEMBLY...845
INSTALLATION...846
REPLACEMENT OF FUEL FILTER...849
FUEL PIPING...851
REPLACEMENT OF HIGH-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV)...851
REPLACEMENT OF FUEL SUPPLY PIPING (BOSCH VE, LUCAS CAV)...852
CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING...854
REPLACEMENT OF FUEL RETURN PIPING (BOSCH VE, LUCAS CAV)...855
CLEANING AND INSPECTION OF FUEL DRAIN PIPING...857
REPLACEMENT OF LOW-PRES-SURE FUEL PIPING (BOSCH VE, LUCAS CAV)...857
CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING...858
REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE (BOSCH VE)...859
WATER PUMP...860
DISASSEMBLY AND ASSEMBLY DRAWING...860
REPLACEMENT OF WATER PUMP...861
INSPECTION...862
FAN HUB...862
REPLACEMENT OF FAN PULLEY...862
REPLACEMENT OF FAN HUB...863
INSPECTION...863
DISASSEMBLY...864
ASSEMBLY...865
BELT TENSIONER...867
DISASSEMBLY AND ASSEMBLY DRAWING...867
REPLACEMENT OF BELT...868
REPLACEMENT OF BELT TENSIONER...868
INSPECTION...868
THERMOSTAT...869
DISASSEMBLY AND ASSEMBLY DRAWING...869
REPLACEMENT OF THERMOSTAT...870
INSPECTION...871
FAN...873
COOLANT...873
ACCESSORY DRIVE ADAPTER...875
DISASSEMBLY AND ASSEMBLY DRAWING...875
CLEANING...876
INSPECTION...876
DISASSEMBLY...876
ASSEMBLY...877
DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD...879
CLEANING...880
INSPECTION...881
ASSEMBLY...885
REPLACEMENT OF AIR COMPRESSOR...888
REMOVAL...888
INSPECTION...889
INSTALLATION...891
ALTERNATOR...894
INSPECTION...895
STARTING MOTOR...895
INSPECTION...896
14 MAINTENANCE STANDARD...898
TURBOCHARGER...899
EXHAUST MANIFOLD...901
CYLINDER HEAD...902
VALVE, VALVE GUIDE...904
LOCKER ARM SHAFT, PUSH ROD AND TAPPET...906
CYLINDER BLOCK...908
CYLINDER...910
CRANKSHAFT...911
CAMSHAFT...913
TIMING GEAR...917
PISTON, PISTON RING AND PISTON PIN...918
CONNECTING ROD...920
VIBRATION DAMPER...922
FLYWHEEL, FLYWHEEL HOUSING...923
FAN HUB...925
OIL PUMP...926
WATER PUMP, THERMOSTAT...927
FUEL INJECTION PUMP...928
FUEL INJECTION NOZZLE...929
15 REPAIR AND REPLACEMENT OF PARTS...931
OUTLINE...932
REPAIR GUIDELINE...932
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT...932
INSPECTION...932
TO ENSURE SAFETY,FOLLOW ALL INSTRUCTIONS IN MANUAL...932
FOLLOW WASHING METHODS GIVEN IN MANUAL...932
FOLLOW INSPECTION METHODS GIVEN IN MANUAL...932
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT...933
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS...934
REPAIR PROCEDURE...934
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS...937
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS...938
PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK...939
INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK...939
INSPECTION AND INSTALLATION OF VALVE GUIDE...940
PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE...941
PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE...942
OUTLINE OF VALVE SEAT REPAIR...942
CALCULATING GRINDING DEPTH OF VALVE SEAT...943
METHOD OF GRINDING VALVE SEAT...943
METHOD OF INSTALLING VALVE SEAT...947
MACHINING EXHAUST VALVE INSET POCKET...947
REPLACING VALVE SEAT...950
METHOD OF GRINDING VALVE...951
CHECKING TENSION OF VALVE SPRING...952
ASSEMBLY OF CYLINDER HEAD...953
PROCEDURE FOR REPAIRING CYLINDER BLOCK...954
REPAIR TOOLS...954
COMBUSTION DECK...954
CAM BORE...955
OUTLINE OF REPAIR OF CYLINDER BORE...956
CYLINDER BORE...956
INSTALLATION OF REPAIR SLEEVE...958
PROCEDURE FOR REPAIRING CRANKSHAFT...962
REPAIR TOOLS...962
OUTLINE OF GRINDING CRANKSHAFT...962
REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL...963
REGRINDING CRANKSHAFT JOURNAL RADIUS...964
SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL...965
REGRINDING CRANKSHAFT ROD JOURNAL RADIUS...965
OPTIONAL PROCEDURE...966
PROCEDURE FOR REPAIRING CONNECTING ROD...967
INSTALLATION OF PIN BORE BUSHING...969
MACHINING OF CONNECTING ROD BUSHING...971
INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD...972
TESTING ALIGNMENT OF CONNECTING ROD...973
INSPECTION OF TWISTING OF CONNECTING ROD...973
REPLACING VALVE SEAT INSERT...974
PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS...977
Komatsu 102 Series Diesel Engines Repair Service Manual
