Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu 102 Series Diesel Engine Shop Manual – PDF DOWNLOAD
Original price was: $49.95.$30.95Current price is: $30.95.
Komatsu 102 Series Diesel Engine Shop Manual
Book Code: SEBM010023
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu 102 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 102 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 102 Series Diesel Engine
Serial Number: –
Book Code: SEBM010023
Language: English
Pages: 980
File Format: Portable Document Format (PDF)
KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 102 Series Diesel Engine Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu 102 Series Diesel Engine Shop Manual
COVER................................................................................................ 1 CONTENTS............................................................................................. 2 01 GENERAL........................................................................................... 32 APPLICABLE MACHINE............................................................................... 33 SPECIFICATIONS................................................................................... 35 GENERAL ASSEMBLY DARWING......................................................................... 53 ENGINE PERFORMANCE CURVE......................................................................... 75 WEIGHT TABLE.....................................................................................115 11 STRUCTURE AND FUNCTION............................................................................117 GENERAL STRUCTURE................................................................................118 INTAKE AND EXHAUST DEVICES.......................................................................120 AIR CLEANER......................................................................................129 TURBOCHARGER.....................................................................................130 CYLINDER HEAD....................................................................................134 CYLINDER BLOCK...................................................................................141 MAIN MOVING PARTS................................................................................147 TIMING GEAR PORTION..............................................................................154 FRONT GEAR COVER.................................................................................155 CAMSHAFT TIMING PIN..............................................................................156 VALVE MECHANISM..................................................................................157 OIL PAN..........................................................................................161 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...................................................................................218 STARTING AID.....................................................................................221 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 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 TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER)............................234 DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...............................235 OIL CONSUMPTION 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 TURBOCHARGER).................................239 TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)............................239 REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER..................240 ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)..............................242 MEASURING EXHAUST RESISTANCE.....................................................................243 REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER).................................................243 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 SEALIN PERFORMANCE...............................................................246 VALVE SEAL WEAR..............................................................................247 PROTRUDING PORTION OF FUEL INJECTION NOZZLE..................................................248 FRONT GEAR HOUSING AND GEAR TRAIN............................................................249 VIBRATION DAMPER.............................................................................249 ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT.......................................250 PISTON AND CONNECTING ROD....................................................................251 CRANKSHAFT AND MAIN BEARING..................................................................253 CYLINDER BLOCK...............................................................................254 FLYWHEEL HOUSING AND FLYWHEEL................................................................255 ADJUSTING VALVE CLEARANCE........................................................................256 ADJUSTING 4-CYLINDER ENGINE..................................................................257 ADJUSTING 6-CYLINDER ENGINE..................................................................258 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 INJECTION PUMP CALIBRATION DATA.............................................................266 RUNNING IN STANDARD..............................................................................322 PERFORMANCE TEST CRITERIA........................................................................328 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (DIAPHRAGM TYPE)................................346 TESTING FEED PUMP............................................................................346 TEST 1:TESTING OUTPUT PRESSURE...............................................................346 TEST 2:TESTING FLOW..........................................................................347 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)...................................348 TEST 1:TESTING OUTPUT PRESSURE...............................................................349 TEST 2:TESTING FLOW..........................................................................350 TESTING AIR INSIDE FUEL SYSTEM...................................................................353 TESTING WATER SEPARATOR,FUEL FILTER..............................................................354 TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV).............................356 DEFECTIVE ACTUATION OF GOVERNOR..............................................................357 STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT..................................................357 LUCAS CAV ADJUSTMENT SCREW...............................................................357 BOSCH VE ADJUSTMENT SCREW................................................................358 MANUAL SHUT-OFF LEVER........................................................................358 TIMING PROPULSION ANGLE MECHANISM............................................................359 ELECTRICAL SHUT-OFF VALVE....................................................................359 DELIVERY VALVE (LUCAS CAV)...................................................................361 TESTING HIGH-PRESSURE FUEL PIPING................................................................362 TESTING FUEL INJECTION NOZZLE....................................................................363 TESTING FUEL DRAIN PIPING........................................................................365 BLEEDING AIR FROM FUEL SYSTEM....................................................................365 BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER.......................................366 BLEEDING AIR FROM FUEL INJECTION PUMP........................................................366 BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT......................................................367 ADJUSTING FUEL INJECTION TIMING..................................................................367 ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE.................................................370 ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV................................................371 ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV).................................................372 REPLACING FUEL INJECTION NOZZLE..................................................................372 TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM............................................376 TROUBLESHOOTING..............................................................................376 RADIATOR CAP.................................................................................378 WATER PUMP...................................................................................379 RADIATOR, FAN, AND RADIATOR SHUTTER..........................................................380 THERMOSTAT...................................................................................382 WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD................................................383 TESTING CARBON DEPOSIT IN AIR COMPRESSOR.........................................................384 TESTING AIR LEAKAGE FROM AIR COMPRESSOR..........................................................385 TESTING AIR GOVERNOR, UNLOADER VALVE.............................................................386 TESTING BATTERY..................................................................................389 TESTING BATTERY TERMINAL CONNECTIONS.............................................................390 TESTING STARTING CIRCUIT ........................................................................390 TESTING BATTERY RELAY........................................................................390 TESTING STARTING SWITCH......................................................................392 TESTING STARTING MOTOR AND MAGNETIC SWITCH...................................................393 TESTING DROP IN CRANKING SPEED...............................................................395 TESTING ALTERNATOR...............................................................................396 ABNORMAL DISPLAY OF CHARGE LAMP..............................................................397 ABNORMAL ACTUATION OF CHARGING SYSTEM........................................................398 TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR.........................................399 TESTING OIL PRESSURE SWITCH..................................................................399 TESTING WATER TEMPERATURE SENSOR.............................................................400 TESTING WHITE SMOKE..............................................................................401 NORMAL AUTUATION OF INTAKE HEATER SYSTEM.....................................................401 TESTING INTAKE HEATER............................................................................402 TESTING PREHEATING CYCLE.....................................................................403 SIDE VIEW OF ENGINE..............................................................................404 OUTLINE OF ENGINE PERFORMANCE TEST ..............................................................406 BLOW-BY MEASUREMENT AND REPLACEMENT TABLE........................................................407 ENGINE DYNAMOMETER ..............................................................................408 INSTALLING ENGINE............................................................................408 PROCEDURE FOR RUNNING IN NEGINE..............................................................415 ENGINE PERFORMANCE TEST......................................................................418 ENGINE PAINTWORK.................................................................................420 TROUBLESHOOTING..................................................................................422 STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.............................423 TROUBLESHOOTING OF ENGINE....................................................................444 METHOD OF USING TROUBLESHOOTING CHARTS...................................................445 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................449 S-2 ENGINE DOES NOT START................................................................451 (1) ENGINE DOES NOT TURN.............................................................451 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).........452 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).......453 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).................................454 S-4 ENGINE STOPS DURING OPERATIONS.......................................................455 S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING)............................................456 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).................................................457 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).......................................458 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..............................459 S-9 OIL BECOMES CONTAMINATED QUICKLY.....................................................460 S-10 FUEL CONSUMPTION IS EXCESSIVE.......................................................461 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..............462 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..........................463 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)................................................464 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................465 S-15 ABNORMAL NOISE IS MADE..............................................................466 S-16 VIBRATION IS EXCESSIVE..............................................................467 13 DISASSEMBLY AND ASSEMBLY..........................................................................468 SPECIAL TOOL LIST................................................................................473 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY...................................................473 SPECIAL TOOLS FOR ENGINE.....................................................................475 SPECIAL TOOLS FOR FUEL SYSTEM................................................................477 OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE ...................................................479 OUTLINE......................................................................................479 DISASSEMBLY..................................................................................479 ASSEMBLY.....................................................................................479 DISASSEMBLY OF ENGINE............................................................................480 STEAM CLEANING OF ENGINE.....................................................................480 REMOVAL OF STARTING MOTOR....................................................................480 WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER).................480 INSTALLATION TO ENGINE STAND.................................................................480 DRAINING OIL.................................................................................481 REMOVAL OF REAR LIFTING BRACKET..............................................................481 REMOVEL OF BELT..............................................................................481 REMOVAL OF FAN PULLEY........................................................................482 REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY...............................................482 REMOVAL OF BELT TENSIONER....................................................................482 REMOVAL OF FAN HUB...........................................................................483 REMOVAL OF ALTERNATOR........................................................................483 REMOVAL OF THERMOSTAT........................................................................484 REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...........................................484 REMOVAL OF EXHAUST MANIFOLD..................................................................486 REMOVAL OF FUEL FILTER.......................................................................486 REMOVAL OF FUEL FILTER HEAD..................................................................487 REMOVAL OF FUEL PIPING.......................................................................487 REMOVAL OF DIPSTICK..........................................................................489 REMOVAL OF INTAKE MANIFOLD COVER.............................................................489 REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER).............................................490 REMOVAL OF CYLINDER HEAD COVER...............................................................490 REMOVAL OF FUEL INJECTION NOZZLE.............................................................490 REMOVAL OF ROCKER LEVER......................................................................491 REMOVAL OF PUSH ROD..........................................................................492 REMOVAL OF CYLINDER HEAD.....................................................................492 REMOVAL OF FRONT COVER.......................................................................492 REMOVAL OF WATER PUMP........................................................................493 REMOVAL OF FLYWHEEL..........................................................................493 REMOVAL OF FLYWHEEL HOUSING..................................................................494 REMOVAL OF COMPONENTS (COMPRESSOR,HYDRAULIC PUMP,ETC.).......................................494 REMOVAL OF FUEL INJECTION PUMP (BOSCH A,ZEXEL A).............................................494 REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE).....................................................497 REMOVAL OF TAPPET COVER......................................................................497 REMOVAL OF OIL FILLER........................................................................497 REMOVAL OF COOLANT HEATER (IF APPLICABLE)....................................................497 REMOVAL OF OIL COOLER........................................................................498 REMOVAL OF WATER INLET.......................................................................498 REMOVAL OF OIL PAN HEATER (IF APPLICABLE)....................................................498 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 (WHEN BALANCER IS INSTALLED).............................................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 PAN HEATER (IF APPLICABLE)...............................................535 INSTALLATION OF OIL COOLER...................................................................535 INSTALLATION OF COOLANT HEATER (IF APPLICABLE)...............................................536 INSTALLATION OF OIL FILLER PORT..............................................................536 INSTALLATION OF FEED PUMP....................................................................537 INSTALLATION OF TAPPET COVER.................................................................537 INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A).......................................539 INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.)................................544 INSTALLATION OF FLYWHEEL HOUSING ............................................................544 INSTALLATION OF FLYWHEEL.....................................................................545 INSTALLATION OF WEATER PUMP..................................................................546 INSTALLATION OF FRONT COVER..................................................................546 INSTALLATION OF CYLINDER HEAD................................................................548 INSTALLATION OF PUSH ROD ....................................................................549 INSTALLATION OF ROCKER LEVER.................................................................549 TIGHTENING OF CYLINDER HEAD..................................................................551 ADJUSTING VALVE CLEARANCE....................................................................553 INSTALLATION OF FUEL INJECTION NOZZLE........................................................555 INSTALLATION OF CYLINDER HEAD COVER..........................................................556 INSTALLATION OF INTAKE MANIFOLD COVER........................................................556 INSTALLATION OF FUEL FILTER HEAD.............................................................558 INSTALLATION OF EXHAUST MANIFOLD.............................................................559 INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)......................................560 INSTALLATION OF THERMOSTAT...................................................................563 INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER..........................................564 INSTALLATION OF FAN HUB......................................................................564 INSTALLATION OF BELT TENSIONER...............................................................564 INSTALLATION OF WATER INLET..................................................................565 INSTALLATION OF ALTERNATOR...................................................................565 INSTALLATION OF BELT.........................................................................566 INSTALLATION OF OIL FILTER...................................................................567 REMOVAL OF ENGINE FROM ENGINE STAND..........................................................567 INSTALLATION OF STARTING MOTOR...............................................................567 INTAKE GROUP.....................................................................................568 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................568 OUTLINE......................................................................................570 REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...........................................571 REMOVAL......................................................................................571 INSTALLATION.................................................................................572 CLEANING AND INSPECTION......................................................................574 REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER).....................................576 REMOVAL......................................................................................576 CLEANING.....................................................................................576 INSTALLATION.................................................................................577 CLEANING AND INSPECTION......................................................................578 ASSEMBLY.....................................................................................578 REPLACEMENT OF INTAKE CONNECTOR..................................................................579 REMOVAL AND INSTALLATION.....................................................................579 AIR CONNECTOR....................................................................................579 CLEANING.....................................................................................579 INSPECTION...................................................................................579 REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET.....................................................579 REMOVAL......................................................................................580 CLEANING.....................................................................................580 INSTALLATION.................................................................................580 AIR CROSSOVER TUBE...............................................................................581 CLEANING.....................................................................................581 INSPECTION...................................................................................581 EXHAUST GROUP....................................................................................582 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................582 OUTLINE OF EXHAUST MANIFOLD..................................................................583 REPLACEMENT OF EXHAUST MANIFOLD, GASKET..........................................................584 REMOVAL......................................................................................584 CLEANING AND INSPECTION......................................................................584 INSTALLATION.................................................................................584 REPLACEMENT OF EXHAUST MANIFOLD..................................................................585 REMOVAL......................................................................................585 CLEANING.....................................................................................585 INSTALLATION.................................................................................586 INSPECTION...................................................................................586 REPLACEMENT OF TURBOCHARGER......................................................................587 REMOVAL......................................................................................587 INSTALLATION.................................................................................588 TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER)............................................591 REPLACEMENT..................................................................................591 CYLINDER BLOCK GROUP.............................................................................592 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................592 OUTLINE OF CYLINDER BLOCK GROUP..............................................................595 OUTLINE OF CAMSHAFT..........................................................................595 OUTLINE OF CRANKSHAFT........................................................................595 OUTLINE OF CYLINDER BLOCK....................................................................595 OUTLINE OF OIL SEAL..........................................................................595 REPLACEMENT OF FRONT OIL SEAL....................................................................596 REMOVAL .....................................................................................596 CLEANING AND INSPECTION......................................................................597 INSTALLATION.................................................................................597 REPLACEMENT OF REAR OIL SEAL.....................................................................599 OUTLINE OF PISTON............................................................................601 OUTLINE OF VIBRATION DAMPER..................................................................601 CHECK LIST FOR CYLINDER BLOCK GROUP..........................................................602 CYLINDER BLOCK...................................................................................603 INSPECTION BEFORE DISASSEMBLY................................................................603 DISASSEMBLY OF CYLINDER BLOCK................................................................603 CLEANING OF CYLINDER BLOCK...................................................................605 INSPECTION OF CYLINDER BLOCK.................................................................608 REMOVAL OF GLAZE FROM CYLINDER BORE..............................................................610 DISASSEMBLY..................................................................................610 INSPECTION...................................................................................611 REMOVAL OF GLAZE.............................................................................611 CLEANING.....................................................................................614 ASSEMBLY.....................................................................................615 REMOVAL OF GLAZE FROM CYLINDER BLOCK.........................................................616 REPLACEMENT OF PLUG..............................................................................619 REMOVAL......................................................................................619 CLEANING AND INSPECTION......................................................................619 INSTALLATION.................................................................................620 REPLACEMENT OF CAP...............................................................................620 REMOVAL......................................................................................620 CLEANING.....................................................................................621 INSTALLATION.................................................................................621 INSTALLATION OF CAP AND PLUG.....................................................................624 INSTALLATION OF CAMSHAFT CUP.................................................................626 INSTALLATION OF CAMSHAFT BUSHING.............................................................627 REPLACEMENT OF DIPSTICK TUBE.................................................................628 STORING CYLINDER BLOCK.......................................................................629 CRANKSHAFT.......................................................................................629 REPLACEMENT OF MAIN BEARING..................................................................630 CLEANING OF CRANKSHAFT.......................................................................636 INSTALLATION OF CRANKSHAFT...................................................................636 REPLACEMENT OF CRANKSHAFT GEAR...............................................................637 REPLACEMENT OF CAMSHAFT AND TAPPET...........................................................639 REMOVAL OF CAMSHAFT..........................................................................639 REMOVAL OF TAPPET............................................................................640 INSPECTION OF TAPPET.........................................................................642 STANDARDS FOR PITTING WHEN REUSING...........................................................644 STANDARD FOR DETERIORATION (BREAKAGE) OF TIP.................................................645 INSPECTION OF CAMSHAFT BORE..................................................................648 REPLACEMENT OF CAMSHAFT BUSHING..............................................................648 INSTALLATION OF TAPPET...................................................................649 INSTALLATION OF CAMSHAFT.................................................................652 CLEANING OF CAMSHAFT.........................................................................654 INSPECTION OF CAMSHAFT,GEAR..............................................................655 REPLACEMENT OF CAMSHAFT,GEAR.................................................................657 CLEANING AND INSPECTION..................................................................658 INSTALLATION.............................................................................659 REPLACEMENT OF TIMING PIN........................................................................661 REPLACEMENT OF GEAR HOUSING, GASKET..............................................................662 REMOVAL......................................................................................662 CLEANING AND INSPECTION......................................................................663 INSTALLATION.................................................................................664 REPOSITIONING OF TIMING PIN..................................................................667 REPLACEMENT OF CAMSHAFT GEAR.....................................................................672 REMOVAL......................................................................................672 INSTALLATION (SHRINK-FITTING METHOD).........................................................673 INSTALLATION (METHOD USING SPECIAL TOOL).....................................................674 INSTALLATION OF CAMSHAFT MOUNTING BOLTS......................................................676 REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY ..............................................677 REMOVAL......................................................................................677 INSPECTION OF RUBBER DAMPER..................................................................677 INSTALLATION.................................................................................678 INSPECTION OF VISCOUS DAMPER.................................................................678 VIBRATION DAMPER (RUBBER TYPE)...............................................................682 CLEANING AND INSPECTION......................................................................682 PISTON,PIN,CONNECTING ROD........................................................................684 REPLACEMENT OF PISTON AND RING...............................................................684 REMOVAL OF PISTON CONNECTING ROD.............................................................685 DISASSEMBLY OF PISTON CONNECTING ROD.........................................................687 CLEANING OF PISTON,PIN,CONNECTING ROD........................................................687 INSPECTION OF PISTON.........................................................................688 INSPECTION OF PISTON PIN.....................................................................689 ASSEMBLY OF PISTON CONNECTING ROD............................................................690 INSPECTION OF PISTON RING GAP................................................................691 INSTALLATION OF PISTON RING..................................................................692 INSTALLATION OF PISTON CONNECTING ROD........................................................693 REPLACEMENT OF CONNECTING ROD....................................................................697 REMOVAL......................................................................................697 CLEANING AND INSPECTION......................................................................698 INSTALLATION.................................................................................700 REPLACEMENT OF CONNECTING ROD BEARING............................................................701 REMOVAL......................................................................................701 CLEANING AND INSPECTION......................................................................703 INSTALLATION.................................................................................704 DISASSEMBLY OF PISTON CONNECTING ROD.........................................................707 CLEANING OF PISTON, PIN, CONNECTING ROD......................................................708 INSPECTION OF PISTON.........................................................................709 INSPECTION OF PISTON PIN.....................................................................710 INSPECTION OF CONNECTING ROD.................................................................710 INSPECTION OF CONNECTING ROD BEARING CLEARANCE...............................................710 ASSEMBLY OF PISTON CONNECTING ROD............................................................711 INSPECTION OF PISTON RING END GAP............................................................712 INSTALLATION OF PISTON RING..................................................................713 BALANCER.........................................................................................714 DISASSEMBLY..................................................................................714 ASSEMBLY.....................................................................................717 GEAR COVER.......................................................................................724 REPLACEMENT OF GEAR COVER....................................................................724 REMOVAL..................................................................................724 CLEANING AND INSPECTION..................................................................725 INSTALLATION.............................................................................725 INSTALLATION OF GEAR COVER...............................................................727 INSPECTION OF GEAR HOUSING AND TIMING PIN................................................729 DISASSEMBLY OF GEAR HOUSING..............................................................729 REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD.........................................730 REPLACEMENT OF ENGINE NAME PLATE.........................................................730 CYLINDER HEAD....................................................................................732 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................732 OUTLINE......................................................................................734 REPLACEMENT OF CYLINDER HEAD.................................................................735 REMOVAL..................................................................................735 INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD...........................................738 DISASSEMBLY OF CYLINDER HEAD.............................................................739 CLEANING OF CYLINDER HEAD................................................................740 INSPECTION OF VALVE......................................................................742 INSPECTION OF VALVE GUIDE................................................................743 INSPECTION OF CYLINDER DECK..............................................................743 INSPECTION OF VALVE SEAT.................................................................744 STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING.......................................744 REPLACEMENT OF VALVE SPRING..............................................................745 ASSEMBLY OF CYLINDER HEAD................................................................745 ADJUSTING VALVE CLEARANCE................................................................750 INSTALLATION OF BELT TENSIONER...........................................................752 INSTALLATION OF ALTERNATOR...............................................................752 INSTALLATION OF DRIVE BELT...............................................................753 INSPECTION BEFORE DISASSEMBLY............................................................753 DISASSEMBLY OF CYLINDER HEAD.............................................................754 CLEANING OF CYLINDER HEAD................................................................755 INSPECTION OF VALVE......................................................................757 INSPECTION OF VALVE GUIDE................................................................758 INSPECTION OF CYLINDER HEAD COMBUSTION DECK..............................................758 INSPECTION OF VALVE SEAT.................................................................759 STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING.......................................759 REPLACEMENT OF VALVE SPRING..............................................................760 REPLACEMENT OF CAP.......................................................................760 POLISHING VALVE..........................................................................762 POLISHING VALVE SEAT.....................................................................763 ROCKER LEVER.....................................................................................770 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................770 OUTLINE......................................................................................772 REPLACEMENT OF ROCKER LEVER AND PUSH ROD ....................................................773 REMOVAL..................................................................................773 DISASSEMBLY OF ROCKER LEVER..................................................................774 CLEANING OF ROCKER LEVER.....................................................................775 INSPECTION OF ROCKER LEVER...................................................................775 ASSEMBLY OF ROCKER LEVER.....................................................................776 INSTALLATION OF ROCKER LEVER.................................................................777 DISASSEMBLY OF ROCKER LEVER..................................................................779 CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT.................................................780 INSPECTION OF ROCKER LEVER...................................................................780 INSPECTION OF ROCKER LEVER SHAFT.............................................................781 ASSEMBLY OF ROCKER LEVER.....................................................................781 TAPPETS AND PUSH RODS............................................................................783 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................783 OUTLINE......................................................................................784 CLEANING OF PUSH ROD.........................................................................785 INSPECTION OF PUSH ROD.......................................................................785 INSTALLATION OF PUSH ROD.....................................................................785 INSPECTION OF TAPPET.........................................................................786 ENGINE MOUNT GROUP...............................................................................788 OUTLINE OF FLYWHEEL HOUSING..................................................................788 OUTLINE OF FLYWHEEL, RING GEAR...............................................................788 OUTLINE OF FRONT SUPPORT.....................................................................788 FLYWHEEL, RING GEAR..............................................................................789 INSPECTION OF FLYWHEEL, RING GEAR............................................................789 REPLACEMENT OF FLYWHEEL, RING GEAR...........................................................789 FLYWHEEL HOUSING.................................................................................791 REPLACEMENT OF REAR OIL SEAL.................................................................791 REMOVAL..................................................................................791 CLEANING AND INSPECTION..................................................................793 INSTALLATION.............................................................................793 REPLACEMENT OF FLYWHEEL HOUSING..............................................................796 REMOVAL..................................................................................796 CLEANING AND INSPECTION..................................................................797 INSTALLATION (DRY CLUTCH SPECIFICATION)..................................................798 INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING..........................................799 INSPECTION OF FACE RUNOUT OF FLTWHEEL HOUSING............................................801 INSTALLATION (WET CLUTCH SPECIFICATION)..................................................802 INSPECTION...............................................................................804 INSTALLATION.............................................................................805 FRONT SUPPORT....................................................................................806 CLEANING AND INSPECTION......................................................................806 REMOVAL OF ENGINE................................................................................807 INSPECTION OF ENGINE MOUNT.......................................................................809 INSTALLATION OF ENGINE...........................................................................810 OIL PAN AND SUCTION TUBE.........................................................................814 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................814 REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET.....................................................815 CLEANING AND INSPECTION......................................................................817 REGULATOR VALVE..................................................................................818 REPLACEMENT OF REGULATOR VALVE, SPRING.......................................................818 DISASSEMBLY..............................................................................818 CLEANING AND INSPECTION......................................................................818 OIL FILTER BYPASS VALVE..........................................................................821 REPLACEMENT..................................................................................821 OIL COOLER.......................................................................................822 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................822 REPLACEMENT OF OIL COOLER CORE, GASKET.......................................................823 CLEANING.....................................................................................825 INSPECTION...................................................................................826 OIL PUMP.........................................................................................827 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................827 REPLACEMENT OF OIL PUMP......................................................................828 CLEANING AND INSPECTION......................................................................829 INSTALLATION OF OIL PUMP.....................................................................832 INSPECTION...................................................................................833 FUEL INJECTION PUMP GROUP........................................................................837 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................837 FUEL INJECTION NOZZLE GROUP......................................................................838 FUEL INJECTION NOZZLE........................................................................839 DISASSEMBLY..............................................................................839 CLEANING AND INSPECTION......................................................................840 ASSEMBLY.................................................................................842 FEED PUMP (CYLINDER BLOCK MOUNT TYPE)............................................................845 REPLACEMENT OF FEED PUMP (DIAPHRAGM TYPE)....................................................845 REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE).................................................847 CLEANING.....................................................................................848 ASSEMBLY.....................................................................................848 INSTALLATION.................................................................................849 REPLACEMENT OF FUEL FILTER.......................................................................852 FUEL PIPING......................................................................................854 REPLACEMENT OF HIGH-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV)...............................854 REPLACEMENT OF FUEL SUPPLY PIPING (BOSCH VE, LUCAS CAV)......................................855 CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING.........................................857 REPLACEMENT OF FUEL RETURN PIPING (BOSCH VE, LUCAS CAV)......................................858 CLEANING AND INSPECTION OF FUEL DRAIN PIPING.................................................860 REPLACEMENT OF LOW-PRES-SURE FUEL PIPING (BOSCH VE, LUCAS CAV)...............................860 CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING..........................................861 REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE (BOSCH VE)........................................862 WATER PUMP.......................................................................................863 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................863 REPLACEMENT OF WATER PUMP....................................................................864 INSPECTION...................................................................................865 FAN HUB..........................................................................................865 REPLACEMENT OF FAN PULLEY....................................................................865 REPLACEMENT OF FAN HUB.......................................................................866 INSPECTION...................................................................................866 DISASSEMBLY..................................................................................867 ASSEMBLY.....................................................................................868 BELT TENSIONER...................................................................................870 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................870 REPLACEMENT OF BELT..........................................................................871 REPLACEMENT OF BELT TENSIONER................................................................871 INSPECTION...................................................................................871 THERMOSTAT.......................................................................................872 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................872 REPLACEMENT OF THERMOSTAT....................................................................873 INSPECTION...................................................................................874 FAN..............................................................................................876 COOLANT..........................................................................................876 ACCESSORY DRIVE ADAPTER..........................................................................878 DISASSEMBLY AND ASSEMBLY DRAWING.............................................................878 CLEANING.....................................................................................879 INSPECTION...................................................................................879 DISASSEMBLY..................................................................................879 ASSEMBLY.....................................................................................880 DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD.....................................................882 CLEANING.....................................................................................883 INSPECTION...................................................................................884 ASSEMBLY.....................................................................................888 REPLACEMENT OF AIR COMPRESSOR................................................................891 REMOVAL......................................................................................891 INSPECTION...................................................................................892 INSTALLATION.................................................................................894 ALTERNATOR.......................................................................................897 INSPECTION...................................................................................898 STARTING MOTOR...................................................................................898 INSPECTION...................................................................................899 14 MAINTENANCE STANDARD..............................................................................901 TURBOCHARGER.....................................................................................902 EXHAUST MANIFOLD.................................................................................904 CYLINDER HEAD....................................................................................905 VALVE, VALVE GUIDE...............................................................................907 LOCKER ARM SHAFT, PUSH ROD AND TAPPET............................................................909 CYLINDER BLOCK...................................................................................911 CYLINDER.........................................................................................913 CRANKSHAFT.......................................................................................914 CAMSHAFT.........................................................................................916 TIMING GEAR......................................................................................920 PISTON, PISTON RING AND PISTON PIN...............................................................921 CONNECTING ROD...................................................................................923 VIBRATION DAMPER.................................................................................925 FLYWHEEL, FLYWHEEL HOUSING.......................................................................926 FAN HUB..........................................................................................928 OIL PUMP.........................................................................................929 WATER PUMP, THERMOSTAT...........................................................................930 FUEL INJECTION PUMP..............................................................................931 FUEL INJECTION NOZZLE............................................................................932 15 REPAIR AND REPLACEMENT OF PARTS...................................................................934 OUTLINE..........................................................................................935 REPAIR GUIDELINE.............................................................................935 WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT................................................935 INSPECTION...................................................................................935 TO ENSURE SAFETY,FOLLOW ALL INSTRUCTIONS IN MANUAL...........................................935 FOLLOW WASHING METHODS GIVEN IN MANUAL.......................................................935 FOLLOW INSPECTION METHODS GIVEN IN MANUAL....................................................935 REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT...............................................936 METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS..................937 REPAIR PROCEDURE.............................................................................937 METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS..............940 METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS................................................941 PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK.................................................942 INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK................................................942 INSPECTION AND INSTALLATION OF VALVE GUIDE.......................................................943 PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE............................................944 PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE............................................945 OUTLINE OF VALVE SEAT REPAIR.....................................................................945 CALCULATING GRINDING DEPTH OF VALVE SEAT.........................................................946 METHOD OF GRINDING VALVE SEAT....................................................................946 METHOD OF INSTALLING VALVE SEAT..................................................................950 MACHINING EXHAUST VALVE INSET POCKET.............................................................950 REPLACING VALVE SEAT.........................................................................953 METHOD OF GRINDING VALVE.........................................................................954 CHECKING TENSION OF VALVE SPRING.............................................................955 ASSEMBLY OF CYLINDER HEAD........................................................................956 PROCEDURE FOR REPAIRING CYLINDER BLOCK...........................................................957 REPAIR TOOLS.................................................................................957 COMBUSTION DECK..............................................................................957 CAM BORE.....................................................................................958 OUTLINE OF REPAIR OF CYLINDER BORE...........................................................959 CYLINDER BORE................................................................................959 INSTALLATION OF REPAIR SLEEVE................................................................961 PROCEDURE FOR REPAIRING CRANKSHAFT...............................................................965 REPAIR TOOLS.................................................................................965 OUTLINE OF GRINDING CRANKSHAFT...............................................................965 REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL.............................................966 REGRINDING CRANKSHAFT JOURNAL RADIUS.........................................................967 SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL..........................................968 REGRINDING CRANKSHAFT ROD JOURNAL RADIUS.....................................................968 OPTIONAL PROCEDURE...........................................................................969 PROCEDURE FOR REPAIRING CONNECTING ROD...........................................................970 INSTALLATION OF PIN BORE BUSHING.............................................................972 MACHINING OF CONNECTING ROD BUSHING..........................................................974 INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD.......................................975 TESTING ALIGNMENT OF CONNECTING ROD..........................................................976 INSPECTION OF TWISTING OF CONNECTING ROD.....................................................976 REPLACING VALVE SEAT INSERT..................................................................977 PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS......................................980
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
2 reviews for Komatsu 102 Series Diesel Engine Shop Manual – PDF DOWNLOAD
Add a review
Finnley Carter –
Adriel Dennis –