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Komatsu 102 Series Diesel Engine Service Repair Manual – PDF Download
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Komatsu 102 Series Diesel Engine Service Repair Manual SEBM010019
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Description
Komatsu 102 Series Diesel Engine Service Repair Manual SEBM010019
FILE DETAILS:
Komatsu 102 Series Diesel Engine Service Repair Manual SEBM010019
LANGUAGE:ENGLISH
PAGES:980
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU 102 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu 102 Series Diesel Engine Service Repair Manual SEBM010019
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.
TABLE OF CONTENTS:
Komatsu 102 Series Diesel Engine Service Repair Manual SEBM010019
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 CONTENTS........................................................................................................ 2 SAFETY.......................................................................................................... 7 SAFETY NOTICE............................................................................................... 7 FOREWORD........................................................................................................ 9 GENERAL..................................................................................................... 9 HOW TO READ THE SHOP MANUAL................................................................................. 10 HOISTING INSTRUCTIONS....................................................................................... 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................. 12 COATING MATERIALS........................................................................................... 14 STANDARD TIGHTENING TORQUE.................................................................................. 16 ELECTRIC WIRE CODE.......................................................................................... 19 CONVERSTION TABLE........................................................................................... 20 UNITS....................................................................................................... 26 01 GENERAL...................................................................................................... 33 APPLICABLE MACHINE.......................................................................................... 34 SPECIFICATIONS ............................................................................................. 36 GENERAL ASSEMBLY DRAWING ................................................................................... 55 ENGINE PERFORMANCE CURVE ................................................................................... 77 WEIGHT TABLE ...............................................................................................116 11 STRUCTURE AND FUNCTION.......................................................................................119 GENERAL STRUCTURE ..........................................................................................120 INTAKE AND EXHAUST DEVICES .................................................................................122 AIR CLEANER ................................................................................................131 TURBOCHARGER ...............................................................................................132 CYLINDER HEAD ..............................................................................................136 CYLINDER BLOCK .............................................................................................143 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........................................................................................222 SPECIAL TOOL LIST...........................................................................................224 SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM.............................................................224 SPECIAL TOOLS FOR ENGINE................................................................................225 SPECIAL TOOLS FOR FUEL SYSTEM...........................................................................227 SPECIAL TOOLS FOR COMPONENTS............................................................................228 SPECIAL TOOLS FOR ELECTRICAL COMPONENTS.................................................................229 SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST...............................................................230 INTAKE AND EXHAUST SYSTEM...................................................................................232 TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM .................................232 CLEAN AIR ..........................................................................................232 TESTING INTAKE RESISTANCE ..........................................................................232 DAMAGE CAUSED BY UNFILTERED AIR ....................................................................233 LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER) ............................................233 LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER) .................................................234 MEASURING PRESSURE OF TURBOCHARGED AIR (ENGINE WITH TURBOCHARGER) ................................234 DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) ...................................235 OIL CONSUMPTlON AND OIL LEAKAGE ....................................................................235 NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER) ................................................236 MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER) ....237 TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER) .......................................238 TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBORCHARGER).......................................239 TESTING ACTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER) ..................................239 REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TURBOCHARGER) .....................240 ADJUSTING TURBOCHARGER WESTGATE ACTUATOR ...............................................................242 MEASURING EXHAUST RESISTANCE ...........................................................................243 REPLACING TURBOCHARGER (ENGINE WITH TURBOCHARGER) ...................................................243 ENGINE......................................................................................................244 TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE .......................................................244 VALVE MECHANISM AND CYLINDER HEAD ..................................................................244 TESTING AIR SYSTEM AND FUEL SYSTEM .................................................................244 TESTING VALVE CLEARANCE ............................................................................245 TESTING COMPRESSION ................................................................................245 PISTON RING SEALING PERFORMANCE ....................................................................245 VALVE SEALING PERFORMANCE ..........................................................................246 HEAD GASKET SEALING PERFORMANCE ....................................................................246 VALVE SEAL WEAR ....................................................................................247 PROTRUDING PORTION OF FUEL INJECTION NOZZLE ........................................................248 FRONT GEAR HOUSING AND GEAR TRAIN .................................................................249 VIBRATION DAMPER ...................................................................................249 ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT ..........................................250 PISTON AND CONNECTING ROD ..........................................................................251 CRANKSHAFT AND MAIN BEARING ........................................................................253 CYLINDER BLOCK .....................................................................................254 FLYWHEEL HOUSING AND FLWHEEL .......................................................................255 ADJUSTING VALVE CLEARANCE ..............................................................................256 ADJUSTING 4-CYLINDER ENGINE.........................................................................257 ADJUSTING 6-CYLINDER ENGINE.........................................................................258 LUBRICATING SYSTEM..........................................................................................259 TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM ..........................................259 OUTLINE ............................................................................................259 HIGH PRESSURE.......................................................................................259 REGULATOR VALVE ....................................................................................259 LOW PRESSURE .......................................................................................260 OIL LEVEL ..........................................................................................260 OIL FILTER .........................................................................................260 OIL PRESSURE GAUGE .................................................................................261 OIL PAN SUCTION TUBE ...............................................................................261 BEARING AND OIL PUMP ...............................................................................261 UNSUITABLE OIL PUMP ................................................................................261 DILUTION OF OIL ....................................................................................262 COOLING WATER IN OIL................................................................................262 FUEL IN OIL ........................................................................................263 FUEL SYSTEM.................................................................................................266 FUEL INJECTION PUMP CALIBRATION DATA ...................................................................266 RUNNING IN STANDARD.....................................................................................323 PERFORMANCE TEST CRITERIA ..............................................................................329 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP .......................................................347 TEST 1: TESTING OUTPUT PRESSURE .................................................................... 0 TEST 2: TESTING FLOW ...............................................................................348 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE) .........................................349 TEST 1: TESTING OUTPUT PRESSURE ....................................................................350 TEST 2: TESTING FLOW ...............................................................................351 TESTING AIR INSIDE FUEL SYSTEM ........................................................................354 TESTING WATER SEPARATOR, FUEL FILTER ..................................................................355 TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV) .............................357 DEFECTIVE ACTUATION OF GOVERNOR ....................................................................358 STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT .......................................................358 LUCAS CAV ADJUSTMENT SCREW......................................................................358 BOSCH VE ADJUSTMENT SCREW.......................................................................359 MANUAL SHUT-OFF LEVER ..............................................................................359 TIMING PROPULSION ANGLE MECHANISM .................................................................360 ELECTRICAL SHUT-OFF VALVE ..........................................................................360 DELIVERY VALVE (LUCAS CAV) .........................................................................362 TROUBLESHOOTING FUEL INJECTION PUMP (BOSCH A, ZEXEL A)..................................................363 TESTING HIGH-PRESSURE FUEL PIPING......................................................................363 TESTING FUEL INJECTION NOZZLE..........................................................................364 TESTING FUEL DRAIN PIPING ..............................................................................366 BLEEDING AIR FROM FUEL SYSTEM .........................................................................366 BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER ............................................367 BLEEDING AIR FROM FUEL INJECTION PUMP .............................................................367 BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT ...........................................................368 ADJUSTING FUEL INJECTION TIMING .......................................................................368 ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE ......................................................371 ADJUSTING FUEL INiJECTlON TIMING FOR LUCAS CAV ....................................................372 ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV) .......................................................373 REPLACING FUEL INJECTION NOZZLE .......................................................................373 COOLING SYSTEM..............................................................................................377 TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM ..............................................377 TROUBLESHOOTING ....................................................................................377 RADIATOR CAP .......................................................................................379 WATER PUMP .........................................................................................380 RADIATOR, FAN & RADIATOR SHUTTER ..................................................................381 THERMOSTAT .........................................................................................383 WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD .....................................................384 COMPONENTS..................................................................................................385 TESTING CARBON DEPOSIT IN AIR COMPRESSOR ..............................................................385 TESTING AIR LEAKAGE FROM AIR COMPRESSOR ..............................................................386 TESTING AIR GOVERNOR, UNLOADER VALVE .................................................................387 TESTING AIR GOVERNOR ...................................................................................388 ELECTRICAL COMPONENTS.......................................................................................390 TESTING BATTERY ........................................................................................390 TESTING BATTERY TERMINAL CONNECTIONS ...................................................................391 TESTING STARTING CIRCUIT ...............................................................................391 TESTING BATTERY RELAY ..............................................................................391 TESTING STARTING SWITCH ............................................................................393 TESTING STARTING MOTOR AND MAGNETIC SWITCH ........................................................394 TESTING DROP IN CRANKING SPEED .....................................................................396 TESTING ALTERNATOR .....................................................................................397 ABNORMAL DISPLAY OF CHARGE LAMP ....................................................................398 ABNORMAL ACTUATION OF CHARGING SYSTEM .............................................................399 TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR ..........................................400 TESTING OIL PRESSURE SWITCH ........................................................................400 TESTING WATER TEMPERATURE SENSOR ..................................................................401 TESTING WHITE SMOKE ....................................................................................402 NORMAL ACTUATION OF INTAKE HEATER SYSTEM ...........................................................402 TESTING INTAKE HEATER ..................................................................................403 TESTING PREHEATING CYCLE ...........................................................................404 PERFORMANCE TEST............................................................................................405 SIDE VIEW OF ENGINE ....................................................................................405 OUTLINE OF ENGINE PERFORMANCE TEST ....................................................................407 BLOW-BY MEASUREMENT AND REPLACEMENT TABLE ...........................................................408 ENGINE DYNAMOMETER .....................................................................................409 INSTALLING ENGINE ..................................................................................409 PROCEDURE FOR RUNNING IN ENGINE ....................................................................416 ENGINE PERFORMANCE TEST ............................................................................419 ENGINE PAINTWORK .......................................................................................421 TROUBLESHOOTING.............................................................................................424 STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................425 TROUBLESHOOTING OF ENGINE (S MODE)......................................................................445 METHOD OF USING TROUBLESHOOTING CHARTS..............................................................446 S-1 Starting performance is poor (Starting always takes time) .....................................450 S-2 Engine does not start ..........................................................................452 (1) Engine does not turn........................................................................452 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)....................453 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)..................454 S-3 Engine does not pick up smoothly (Follow-up is poor) ..........................................455 S-4 Engine stops during operations .................................................................456 S-5 Engine does not rotate smoothly (Hunting) ......................................................457 S-6 Engine lacks output (or lacks power) ..........................................................458 S-7 Exhaust smoke is black (Incomplete combustion) ................................................459 S-8 Oil consumption is excessive (or exhaust-smoke is blue) ........................................460 S-9 Oil becomes contaminated quickly ...............................................................461 S-10 Fuel consumption is excessive .................................................................462 S-11 Oil is in cooling water, or water spurts back, or water level goes down .....................463 S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ...................................464 S-13 Oil level rises (Water, fuel in oil) ..........................................................465 S-14 Water temperature becomes too high (Overheating) .............................................466 S-15 Abnormal noise is made ........................................................................467 S-16 Vibration is excessive ........................................................................468 13 DISASSEMBLY AND ASSEMBLY.....................................................................................469 SPECIAL TOOL LIST ..........................................................................................474 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY .............................................................474 SPECIAL TOOLS FOR ENGINE ...............................................................................476 SPECIAL TOOLS FOR FUEL SYSTEM ..........................................................................478 OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE ..............................................................480 DISASSEMBLY.............................................................................................480 ASSEMBLY................................................................................................480 DISASSEMBLY OF ENGINE ......................................................................................481 STEAM CLEANING OF ENGINE ...............................................................................481 REMOVAL OF STARTING MOTOR ..............................................................................481 WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIA- RIES SUCH AS MUFFLER) .......................481 INSTALLATION TO ENGINE STAND ...........................................................................481 DRAINING OIL ...........................................................................................482 REMOVAL OF REAR LIFTING BRACKET .......................................................................482 REMOVAL OF BELT ........................................................................................482 REMOVAL OF FAN PULLEY ..................................................................................483 REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY ........................................................483 REMOVAL OF BELT TENSIONER ..............................................................................483 REMOVAL OF FAN HUB .....................................................................................484 REMOVAL OF ALTERNATOR ..................................................................................484 REMOVAL OF THERMOSTAT ..................................................................................485 REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) ....................................................485 REMOVAL OF EXHAUST MANIFOLD ............................................................................487 REMOVAL OF FUEL FILTER .................................................................................487 REMOVAL OF FUEL FILTER HEAD ............................................................................488 REMOVAL OF FUEL PIPING .................................................................................488 REMOVAL OF DIPSTICK ....................................................................................490 REMOVAL OF INTAKE MANIFOLD COVER ......................................................................490 REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER)........................................................491 REMOVAL OF CYLINDER HEAD COVER .........................................................................491 REMOVAL OF FUEL INJECTION NOZZLE ......................................................................491 REMOVAL OF ROCKER LEVER ................................................................................492 REMOVAL OF PUSH ROD ....................................................................................493 REMOVAL OF CYLINDER HEAD ...............................................................................493 REMOVAL OF FRONT COVER .................................................................................493 REMOVAL OF WATER PUMP ..................................................................................494 REMOVAL OF FLYWHEEL ....................................................................................494 REMOVAL OF FLYWHEEL HOUSING ............................................................................495 REMOVAL OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.) .............................................495 REMOVAL OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) .....................................................495 REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE) ..............................................................498 REMOVAL OF TAPPET COVER ................................................................................498 REMOVAL OF OIL FILLER ..................................................................................498 REMOVAL OF OIL COOLER ..................................................................................498 REMOVAL OF WATER INLET .................................................................................499 REMOVAL OF OIL PAN .....................................................................................499 REMOVAL OF OIL PAN SUCTION TUBE .......................................................................499 REMOVAL OF REAR SEAL COVER .............................................................................500 REMOVAL OF CAMSHAFT ....................................................................................500 REMOVAL OF TAPPET ......................................................................................502 REMOVAL OF OIL PUMP ....................................................................................502 REMOVAL OF TIMING PIN HOUSING ..........................................................................503 REMOVAL OF GEAR HOUSING ................................................................................503 REMOVAL OF BALANCER ....................................................................................504 REMOVAL OF PISTON CONNECTING ROD .......................................................................506 REMOVAL OF CRANKSHAFT ..................................................................................508 REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE ........................................................510 REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND ...........................................................510 ASSEMBLY OF ENGINE .........................................................................................511 PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK ............................................................511 INSTALLATION OF TAPPET .................................................................................511 INSTALLATION OF CRANKSHAFT..............................................................................512 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES. .................................................516 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY ....................................................516 INSTALLATION OF GEAR HOUSING............................................................................520 INSTALLATION OF OIL PUMP ...............................................................................521 INSTALLATION OF CAMSHAFT ...............................................................................522 INSTALLATION OF TIMING PIN .............................................................................525 INSTALLATION OF BALANCER ...............................................................................528 INSTALLATION OF REAR OIL SEAL ..........................................................................532 INSTALLATION OF OIL PAN SUCTION TUBE ...................................................................533 INSTALLATION OF OIL PAN ................................................................................534 INSTALLATION OF OIL COOLER .............................................................................535 INSTALLATION OF OIL FILLER PORT .......................................................................535 INSTALLATION OF FEED PUMP ..............................................................................536 INSTALLATION OF TAPPET COVER ...........................................................................536 INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) ................................................538 INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.) ........................................543 INSTALLATION OF FLYWHEEL HOUSING .......................................................................543 INSTALLATION OF FLYWHEEL ..............................................................................544 INSTALLATION OF WATER PUMP..............................................................................545 INSTALLATION OF FRONT COVER.............................................................................545 INSTALLATION OF CYLINDER HEAD..........................................................................547 INSTALLATION OF PUSH ROD ...............................................................................548 INSTALLATION OF ROCKER LEVER , .........................................................................548 TIGHTENING OF CYLINDER HEAD ............................................................................550 ADJUSTING VALVE CLEARANCE ..............................................................................552 INSTALLATION OF FUEL INJECTION NOZZLE ..................................................................554 INSTALLATION OF CYLINDER HEAD COVER ...................................................................555 INSTALLATION OF INTAKE MANIFOLD COVER ..................................................................555 INSTALLATION OF FUEL FILTER HEAD .......................................................................557 INSTALLATION OF EXHAUST MANIFOLD ......................................................................558 INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER).................................................559 INSTALLATION OF THERMOSTAT..............................................................................562 INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER ...................................................563 INSTALLATION OF FAN HUB ................................................................................563 INSTALLATION OF BELT TENSIONER ........................................................................563 INSTALLATION OF WATER INLET ............................................................................564 INSTALLATION OF ALTERNATOR..............................................................................564 INSTALLATION OF BELT ...................................................................................565 INSTALLATION OF OIL FILTER .............................................................................566 REMOVAL OF ENGINE FROM ENGINE STAND ....................................................................566 INSTALLATION OF STARTING MOTOR ........................................................................566 INTAKE GROUP ...............................................................................................567 DISASSEMBLY AND ASSEMBLY DRAWING .......................................................................567 OUTLINE ................................................................................................569 REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) .................................................570 REMOVAL ................................................................................................570 INSTALLATION ...........................................................................................571 CLEANING AND INSPECTION.................................................................................573 REPLACEMENT OF AFTERCOOLER, GASKET (ENGING WITH AFTERCOOLER)............................................575 REMOVAL ................................................................................................575 CLEANING ...............................................................................................575 INSTALLATION............................................................................................576 CLEANING AND INSPECTION ................................................................................577 ASSEMBLY ...............................................................................................577 REPLACEMENT OF INTAKE CONNECTOR ...........................................................................578 REMOVAL AND INSTALLATION ...............................................................................578 AIR CONNECTOR ..............................................................................................578 CLEANING ...............................................................................................578 INSPECTION .............................................................................................578 REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET ............................................................578 REMOVAL ................................................................................................579 CLEANING ...............................................................................................579 INSTALLATION ...........................................................................................579 AIR CROSSOVER TUBE .........................................................................................580 CLEANING ...............................................................................................580 INSPECTION .............................................................................................580 EXHAUST GROUP ..............................................................................................581 DISASSEMBLY AND ASSEMBLY DRAWING ......................................................................581 OUTLINE OF EXHAUST MANIFOLD.............................................................................582 REPLACEMENT OF EXHAUST MANIFOLD, GASKET ..................................................................583 REMOVAL.................................................................................................583 CLEANING AND INSPECTION.................................................................................583 INSTALLATION............................................................................................583 REPLACEMENT OF EXHAUST MANIFOLD ...........................................................................584 REMOVAL ................................................................................................584 CLEANING ...............................................................................................584 INSTALLATION............................................................................................585 INSPECTION..............................................................................................585 REPLACEMENT OF TURBOCHARGER ...............................................................................586 REMOVAL ................................................................................................586 INSTALLATION ...........................................................................................587 TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER) ....................................................590 REPLACEMENT ............................................................................................590 CYLINDER BLOCK GROUP .......................................................................................591 DISASSEMBLY AND ASSEMBLY DRAWING .......................................................................591 OUTLINE OF CYLINDER BLOCK GROUP.........................................................................594 OUTLINE OF CAMSHAFT.....................................................................................594 OUTLINE OF CRANKSHAFT...................................................................................594 OUTLINE OF CYLINDER BLOCK...............................................................................594 OUTLINE OF OIL SEAL.....................................................................................594 REPLACEMENT OF FRONT OIL SEAL...............................................................................595 REMOVAL.................................................................................................595 CLEANING AND INSPECTION.................................................................................596 INSTALLATION............................................................................................596 REPLACEMENT OF REAR OIL SEAL ...............................................................................598 OUTLINE OF PISTON.......................................................................................600 OUTLINE OF VIBRATION DAMPER.............................................................................600 CHECK LIST FOR CYLINDER BLOCK GROUP.....................................................................601 CYLINDER BLOCK .............................................................................................602 INSPECTION BEFORE DISASSEMBLY...........................................................................602 DISASSEMBLY OF CYLINDER BLOCK...........................................................................602 CLEANING OF CYLINDER BLOCK..............................................................................604 INSPECTION OF CYLINDER BLOCK ...........................................................................607 REMOVAL OF GLAZE FROM CYLINDER BORE ........................................................................609 DISASSEMBLY.............................................................................................609 INSPECTION..............................................................................................610 REMOVAL OF GLAZE........................................................................................610 CLEANING................................................................................................613 ASSEMBLY ...............................................................................................614 REMOVAL OF GLAZE FROM CYLINDER BLOCK....................................................................615 REPLACEMENT OF PLUG ........................................................................................618 REMOVAL.................................................................................................618 CLEANING AND INSPECTION.................................................................................618 INSTALLATION............................................................................................619 REPLACEMENT OF CAP .........................................................................................619 REMOVAL.................................................................................................619 CLEANING................................................................................................620 INSTALLATION............................................................................................620 INSTALLATION OF CAP AND PLUG................................................................................623 INSTALLATION OF CAMSHAFT CUP............................................................................625 INSTALLATION OF CAMSHAFT BUSHING........................................................................626 REPLACEMENT OF DIPSTICK TUBE............................................................................627 STORING CYLINDER BLOCK..................................................................................628 CRANKSHAFT .................................................................................................628 REPLACEMENT OF MAIN BEARING ............................................................................629 INSPECTION OF CRANKSHAFT................................................................................629 CLEANING OF CRANKSHAFT .................................................................................635 INSTALLATION OF CRANKSHAFT .............................................................................635 REPLACEMENT OF CRANKSHAFT GEAR ........................................................................636 REPLACEMENT OF CAMSHAFT AND TAPPET......................................................................638 REMOVAL OF CAMSHAFT.....................................................................................638 REMOVAL OF TAPPET.......................................................................................639 INSPECTION OF TAPPET....................................................................................641 STANDARDS FOR PITTING WHEN REUSING......................................................................643 STANDARD FOR DETERIORATION (BREAKAGE) OF TIP............................................................644 INSPECTION OF CAMSHAFT BORE.............................................................................647 REPLACEMENT OF CAMSHAFT BUSHING .......................................................................647 INSTALLATION OF TAPPET..............................................................................648 INSTALLATION OF CAMSHAFT............................................................................651 CLEANING OF CAMSHAFT ...................................................................................653 REPLACEMENT OF CAMSHAFT, GEAR .............................................................................656 CLEANING AND INSPECTION.................................................................................657 INSTALLATION............................................................................................658 INSPECTION OF CAMSHAFT, GEAR............................................................................654 REPLACEMENT OF TIMING PIN .................................................................................660 REPLACEMENT OF GEAR HOUSING, GASKET.........................................................................661 REMOVAL.................................................................................................661 CLEANING AND INSPECTION.................................................................................662 INSTALLATION............................................................................................663 REPOSITIONING OF TIMING PIN.............................................................................666 REPLACEMENT OF CAMSHAFT GEAR................................................................................671 REMOVAL ................................................................................................671 INSTALLATION (SHRINK-FITTING METHOD)....................................................................672 INSTALLATION (METHOD USING SPECIAL TOOL)................................................................673 INSTALLATION OF CAMSHAFT MOUNTING BOLTS.................................................................675 REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY .....................................................676 REMOVAL ................................................................................................676 INSPECTION OF RUBBER DAMPER.............................................................................676 INSTALLATION ...........................................................................................677 INSPECTION OF VISCOUS DAMPER............................................................................677 INSPECTlON DAMPER (RUBBER TYPE).........................................................................679 CLEANING AND INSPECTION.................................................................................679 PISTON, PIN, CONNECTING ROD.................................................................................681 REPLACEMENT OF PISTION 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 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 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 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 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 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 INSPECTION OF PUSH ROD .................................................................................782 INSTALLATION OF PUSH ROD ...............................................................................782 INSPECTION OF TAPPET ...................................................................................783 INSPECTION OF PUSH ROD .................................................................................784 FLYWHEEL, RING GEAR ........................................................................................786 INSPECTION OF FLYWHEEL, RING GEAR .....................................................................786 REPLACEMENT OF FLYWHEEL, RING GEAR ....................................................................786 REPLACEMENT OF RING GEAR ...........................................................................786 INSTALLATION OF FLYWHEEL ...........................................................................787 REPLACEMENT OF RING GEAR ...........................................................................787 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 FLYWHEEL 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 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 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 REMOVAL.................................................................................................844 CLEANING................................................................................................845 ASSEMBLY................................................................................................845 INSTALLATION............................................................................................846 CLEANING AND INSPECTION.................................................................................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-PRESSURE 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 COMPONENT DRIVE UNIT........................................................................................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 REPLACEMENT OF ALTERNATOR...............................................................................894 STARTING MOTOR .............................................................................................895 INSPECTION..............................................................................................896 14 MAINTENANCE STANDARD.........................................................................................898 INTAKE AND EXHAUST SYSTEM...................................................................................899 TURBOCHARGER ...........................................................................................899 EXHAUST MANIFOLD .......................................................................................901 ENGINE PROPER...............................................................................................902 CYLINDER HEAD ..........................................................................................902 VALVE, VALVE GUIDE .....................................................................................904 ROCKER 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 .....................................................................919 CONNECTING ROD .........................................................................................921 VIBRATION DAMPER .......................................................................................923 FLYWHEEL, FLYWHEEL HOUSING .............................................................................925 FAN HUB ................................................................................................927 LUBRICATING SYSTEM..........................................................................................928 OIL PUMP ...............................................................................................928 COOLING SYSTEM..............................................................................................929 WATER PUMP, THERMOSTAT .................................................................................929 FUEL SYSTEM.................................................................................................930 FUEL INJECTION PUMP ....................................................................................930 FUEL INJECTION NOZZLE ..................................................................................931 15 REPAIR AND REPLACEMENT OF PARTS..............................................................................933 OUTLINE ....................................................................................................934 REPAIR GUIDELINE........................................................................................934 WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT..........................................................934 INSPECTION..............................................................................................934 TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL.....................................................934 FOLLOW WASHING METHODS GIVEN IN MANUAL..................................................................934 FOLLOW INSPECTION METHODS GIVEN IN MANUAL INSPECTION .................................................934 REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT .........................................................935 METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS ..................936 REPAIR PROCEDURE .......................................................................................936 METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS ...................939 METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS ......................................................940 PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK ........................................................941 INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK ......................................................941 INSPECTION AND INSTALLATION OF VALVE GUIDE ..............................................................942 PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE ....................................................943 PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE ..................................................944 OUTLINE OF VALVE SEAT REPAIR................................................................................944 CALCULATING GRINDING DEPTH OF VALVE SEAT ..................................................................945 METHOD OF GRINDING VALVE SEAT ............................................................................945 METHOD OF INSTALLING VALVE SEAT ..........................................................................949 MACHINING EXHAUST VALVE INSERT POCKET ..................................................................949 REPLACING VALVE SEAT ...................................................................................952 METHOD OF GRINDING VALVE ..................................................................................953 CHECKING TENSION OF VALVE SPRING .......................................................................954 ASSEMBLY OF CYLINDER HEAD .................................................................................955 PROCEDURE FOR REPAIRING CYLINDER BLOCK ...................................................................956 REPAIR TOOLS ...........................................................................................956 COMBUSTION DECK ........................................................................................956 CAM BORE ...............................................................................................957 OUTLINE OF REPAIR OF CYLINDER BORE ....................................................................958 CYLINDER BORE ..........................................................................................958 INSTALLATION OF REPAIR SLEEVE ..........................................................................960 PROCEDURE FOR REPAIRING CRANKSHAFT ........................................................................964 REPAIR TOOLS ...........................................................................................964 OUTLINE OF GRINDING CRANKSHAFT .........................................................................964 REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL .......................................................965 REGRINDING CRANKSHAFT JOURNAL RADIUS ..................................................................966 SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL ....................................................967 REGRINDING CRANKSHAFT ROD JOURNAL RADIUS ...............................................................967 OPTIONAL PROCEDURE .....................................................................................968 PROCEDURE FOR REPAIRING CONNECTING ROD ...................................................................969 REMOVAL OF PIN BORE BUSHING ............................................................................969 INSTALLATION OF PIN BORE BUSHING .......................................................................971 MACHINING OF CONNECTING ROD BUSHING.....................................................................973 INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD ................................................974 TESTING ALIGNMENT OF CONNECTING ROD ...................................................................975 INSPECTION OF TWISTING OF CONNECTING ROD ...............................................................975 REPLACING VALVE SEAT INSERT ............................................................................976 PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS.................................................979
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4 reviews for Komatsu 102 Series Diesel Engine Service Repair Manual – PDF Download
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Damari Henrik –
We’ll see. Haven’t got it yet.
Easton Yahir –
Tried downloading after 1 month, it says download link expired!!! I paid
Beau Zayne –
This is a great site. heydownloads has it all .
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