Komatsu 102 Series Diesel Engine Shop Manual SEBM010020 PDF

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Komatsu 102 Series Diesel Engine Shop Manual SEBM010020  – PDF DOWNLOAD

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Komatsu 102 Series Diesel Engine Shop Manual SEBM010020  – PDF DOWNLOAD

Language : English
Pages : 980
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010020  – PDF DOWNLOAD

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

DESCRIPTION:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010020  – PDF DOWNLOAD

G.B 27/12/24