Komatsu 102 Series Diesel Engine Shop Manual SEBM010026 PDF DOWNLOAD

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Komatsu 102 Series Diesel Engine Shop Manual SEBM010026  – PDF DOWNLOAD

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Komatsu 102 Series Diesel Engine Shop Manual SEBM010026  – PDF DOWNLOAD

Language : English
Pages :1008
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010026  – PDF DOWNLOAD

COVER 1
CONTENTS . 2
01 GENERAL . 29
APPLICABLE MACHINE . 30
SPECIFICATIONS . 32
GENERAL ASSEMBLY DRAWING . 52
ENGINE PERFORMANCE CURVE . 74
WEIGHT TABLE . 117
11 STRUCTURE AND FUNCTION 119
GENERAL STRUCTURE 120
INTAKE AND EXHAUST DEVICES . 122
AIR CLEANER . 132
TURBOCHARGER . 133
CYLINDER HEAD 138
CYLINDER BLOCK . 146
MAIN MOVING PARTS 152
TIMING GEAR PORTION 159
FRONT GEAR COVER . 160
CAMSHAFT TIMING PIN 161
VALVE MECHANISM 162
OIL PAN . 167
FLYWHEEL, FLYWHEEL HOUSING . 170
LUBRICATION SYSTEM DIAGRAM . 173
OIL PUMP . 180
OIL FILTER, OIL COOLER 182
REGULATOR VALVE, SAFETY VALVE 186
FUEL SYSTEM DIAGRAM 187
FUEL INJECTION PUMP 196
TIMING LOCK PIN FOR FUEL INJECTION PUMP 200
FUEL FILTER . 201
FUEL INJECTION NOZZLE 202
FUEL CUT SOLENOID 203
COOLING SYSTEM DIAGRAM . 205
WATER PUMP . 209
THERMOSTAT . 210
FAN DRIVE . 211
AIR COMPRESSOR . 216
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM 218
ALTERNATOR . 220
STARTING MOTOR . 229
STARTING AID . 233
12 TESTING AND ADJUSTING . 235
SPECIAL TOOL LIST 237
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM 237
SPECIAL TOOLS FOR ENGINE . 238
SPECIAL TOOLS FOR FUEL SYSTEM 240
SPECIAL TOOLS FOR COMPONENTS . 241
SPECIAL TOOLS FOR ELECTRICAL COMPONENTS 242
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST 243
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM . 245
CLEAN AIR 245
TESTING INTAKE RESISTANCE 245
DAMAGE CAUSED BY UNFILTERED AIR 246
LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER) 246
LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER) 247
MEASURING PRESSURE OF TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER) 247
DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) . 248
OIL CONSUMPTION AND OIL LEAKAGE 248
NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER) . 249
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER) 250
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER) . 251
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER) . 252
TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER) 252
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER 253
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER) 255
MEASURING EXHAUST RESISTANCE . 256
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER) . 256
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE 257
VALVE MECHANISM AND CYLINDER HEAD 257
TESTING AIR SYSTEM AND FUEL SYSTEM . 257
TESTING VALVE CLEARANCE 258
TESTING COMPRESSION 258
PISTON RING SEALING PERFORMANCE 258
VALVE SEALING PERFORMANCE 259
HEAD GASKET SEALIN PERFORMANCE . 259
VALVE SEAL WEAR 260
PROTRUDING PORTION OF FUEL INJECTION NOZZLE 261
FRONT GEAR HOUSING AND GEAR TRAIN 262
VIBRATION DAMPER . 262
ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT . 263
PISTON AND CONNECTING ROD 264
CRANKSHAFT AND MAIN BEARING 266
CYLINDER BLOCK . 267
FLYWHEEL HOUSING AND FLYWHEEL 268
ADJUSTING VALVE CLEARANCE 269
ADJUSTING 4-CYLINDER ENGINE 270
ADJUSTING 6-CYLINDER ENGINE 271
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM 272
OUTLINE 272
HIGH PRESSURE 272
REGULATOR VALVE 272
LOW PRESSURE 273
OIL LEVEL 273
OIL FILTER . 273
OIL PRESSURE GAUGE 274
OIL PAN SUCTION TUBE . 274
BEARING AND OIL PUMP . 274
UNSUITABLE OIL PUMP 274
DILUTION OF OIL 275
COOLING WATER IN OIL . 275
FUEL IN OIL 276
FUEL INJECTION PUMP CALIBRATION DATA . 279
RUNNING IN STANDARD 337
PERFORMANCE TEST CRITERIA 344
TROUBLESHOOTINGDEFECTIVE ACTUATION OFFEED PUMP (DIAPHRAGM TYPE) 362
Testing feed pump 362
TEST 1: TESTING OUTPUT PRESSURE 362
TEST 2: TESTING FLOW . 363
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE) . 364
TEST 1: TESTING OUTPUT PRESSURE 365
TEST 2: TESTING FLOW . 366
TESTING AIR INSIDE FUEL SYSTEM . 369
TESTING WATER SEPARATOR,FUEL FILTER 370
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV) . 372
DEFECTIVE ACTUATION OF GOVERNOR 373
STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT 373
LUCAS CAV ADJUSTMENT SCREW . 373
BOSCH VE ADJUSTMENT SCREW 374
MANUAL SHUT-OFF LEVER 374
TIMING PROPULSION ANGLE MECHANISM 375
ELECTRICAL SHUT-OFF VALVE 375
DELIVERY VALVE (LUCAS CAV) . 377
TESTING HIGH-PRESSURE FUEL PIPING 378
TESTING FUEL INJECTION NOZZLE 379
TESTING FUEL DRAIN PIPING 381
BLEEDING AIR FROM FUEL SYSTEM 381
BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER . 382
BLEEDING AIR FROM FUEL INJECTION PUMP 382
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT 383
ADJUSTING FUEL INJECTION TIMING 383
ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE . 386
ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV 387
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV) . 388
REPLACING FUEL INJECTION NOZZLE 388
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM 392
TROUBLESHOOTING 392
RADIATOR CAP . 394
WATER PUMP . 395
RADIATOR, FAN, AND RADIATOR SHUTTER 396
THERMOSTAT . 398
WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD 399
TESTING CARBON DEPOSIT IN AIR COMPRESSOR . 400
TESTING AIR LEAKAGE FROM AIR COMPRESSOR 401
TESTING AIR GOVERNOR, UNLOADER VALVE . 402
TESTING AIR GOVERNOR . 403
TESTING BATTERY 405
TESTING BATTERY TERMINAL CONNECTIONS . 406
TESTING STARTING CIRCUIT 406
TESTING BATTERY RELAY 406
TESTING STARTING SWITCH 408
TESTING STARTING MOTOR AND MAGNETIC SWITCH . 409
TESTING DROP IN CRANKING SPEED . 411
TESTING ALTERNATOR . 412
ABNORMAL DISPLAY OF CHARGE LAMP 413
ABNORMAL ACTUATION OF CHARGING SYSTEM 414
TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR . 415
TESTING OIL PRESSURE SWITCH 415
TESTING WATER TEMPERATURE SENSOR . 416
TESTING WHITE SMOKE 417
NORMAL AUTUATION OF INTAKE HEATER SYSTEM . 417
TESTING INTAKE HEATER 418
TESTING PREHEATING CYCLE . 419
SIDE VIEW OF ENGINE 420
OUTLINE OF ENGINE PERFORMANCE TEST 422
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE 423
ENGINE DYNAMOMETER 424
INSTALLING ENGINE 424
PROCEDURE FOR RUNNING IN NEGINE 431
ENGINE PERFORMANCE TEST 434
ENGINE PAINTWORK . 436
TROUBLESHOOTING 439
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING . 440
TROUBLESHOOTING OF ENGINE 461
METHOD OF USING TROUBLESHOOTING CHARTS . 462
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 466
S-2 ENGINE DOES NOT START 468
(1) ENGINE DOES NOT TURN . 468
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) . 469
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) . 470
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) . 471
S-4 ENGINE STOPS DURING OPERATIONS . 472
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING) 473
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) . 474
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) . 475
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 476
S-9 OIL BECOMES CONTAMINATED QUICKLY . 477
S-10 FUEL CONSUMPTION IS EXCESSIVE . 478
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN 479
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 480
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 481
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 482
S-15 ABNORMAL NOISE IS MADE 483
S-16 VIBRATION IS EXCESSIVE 484
13 DISASSEMBLY AND ASSEMBLY 485
SPECIAL TOOL LIST 490
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY . 490
SPECIAL TOOLS FOR ENGINE 492
SPECIAL TOOLS FOR FUEL SYSTEM 494
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE . 496
OUTLINE 496
DISASSEMBLY 496
ASSEMBLY . 496
DISASSEMBLY OF ENGINE 497
STEAM CLEANING OF ENGINE . 497
WEIGHT OF ENGINE (REFERENCEVALUE NOT INCLUDING AUXILIARIESSUCH AS MUFFLER) . 497
INSTALLATION TO ENGINE STAND . 497
DRAINING OIL . 498
REMOVAL OF REAR LIFTINGBRACKET . 498
REMOVAL OF BELT 498
REMOVAL OF FAN PULLEY 499
REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY . 499
REMOVAL OF BELT TENSIONER 499
REMOVAL OF FAN HUB 500
REMOVAL OF ALTERNATOR 500
REMOVAL OF THERMOSTAT 501
REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) . 501
REMOVAL OF EXHAUST MANIFOLD 503
REMOVAL OF FUEL FILTER . 503
REMOVAL OF FUEL FILTER HEAD 504
REMOVAL OF FUEL PIPING . 504
REMOVAL OF DIPSTICK 506
REMOVAL OF INTAKE MANIFOLD COVER . 506
REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER) . 507
REMOVAL OF CYLINDER HEAD COVER . 507
REMOVAL OF FUEL INJECTION NOZZLE . 507
REMOVAL OF ROCKER LEVER 508
REMOVAL OF PUSH ROD 509
REMOVAL OF CYLINDER HEAD . 509
REMOVAL OF FRONT COVER . 509
REMOVAL OF WATER PUMP 510
REMOVAL OF FLYWHEEL 510
REMOVAL OF FLYWHEEL HOUSING 511
REMOVAL OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.) . 511
REMOVAL OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) 511
REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE) . 514
REMOVAL OF FEED PUMP (FUEL INJECTION TYPE) . 514
REMOVAL OF TAPPET COVER 514
REMOVAL OF OIL FILLER 514
REMOVAL OF COOLANT HEATER (IF APPLICABLE) 515
REMOVAL OF OIL COOLER 515
REMOVAL OF WATER INLET . 515
REMOVAL OF OIL PAN HEATER (IF APPLICABLE) 516
REMOVAL OF OIL PAN . 516
REMOVAL OF OIL PAN SUCTIONTUBE . 516
REMOVAL OF REAR SEAL COVER . 518
REMOVAL OF CAMSHAFT 518
REMOVAL OF TAPPET 520
REMOVAL OF OIL PUMP 520
REMOVAL OF TIMING PIN HOUSING 521
REMOVAL OF GEAR HOUSING 521
REMOVAL OF BALANCER (WHEN BALANCER IS INSTALLED) . 522
REMOVAL OF PISTON CONNECTING ROD . 524
REMOVAL OF CRANKSHAFT 526
REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE . 528
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND 528
ASSEMBLY OF ENGINE . 529
PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK . 529
INSTALLATION OF TAPPET . 529
INSTALLATION OF CRANKSHAFT . 530
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES . 534
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY . 534
INSTALLATION OF GEAR HOUSING . 538
INSTALLATION OF OIL PUMP . 539
INSTALLATION OF CAMSHAFT . 540
INSTALLATION OF TIMING PIN . 543
INSTALLATION OF BALANCER . 546
INSTALLATION OF REAR OIL SEAL 550
INSTALLATION OF OIL PAN SUCTION TUBE . 551
INSTALLATION OF OIL PAN 552
INSTALLATION OF OIL PANHEATER (IF APPLICABLE) 553
INSTALLATION OF OIL COOLER . 553
INSTALLATION OF COOLANTHEATER (IF APPLICABLE) 554
INSTALLATION OF OIL FILLERPORT . 554
INSTALLATION OF FEED PUMP 556
INSTALLATION OF FEED PUMP (FUEL INJECTION TYPE) 556
INSTALLATION OF TAPPET COVER . 556
INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) . 559
INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.) 564
INSTALLATION OF FLYWHEEL HOUSING 564
INSTALLATION OF FLYWHEEL . 565
INSTALLATION OF WEATER PUMP 566
INSTALLATION OF FRONT COVER 566
INSTALLATION OF CYLINDER HEAD 568
INSTALLATION OF PUSH ROD . 569
INSTALLATION OF ROCKER LEVER . 569
TIGHTENING OF CYLINDER HEAD 571
ADJUSTING VALVE CLEARANCE 573
INSTALLATION OF FUEL INJECTION NOZZLE 575
INSTALLATION OF CYLINDER HEAD COVER 576
INSTALLATION OF INTAKE MANIFOLD COVER 576
INSTALLATION OF FUEL FILTER HEAD . 578
INSTALLATION OF EXHAUST MANIFOLD . 579
INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) 580
INSTALLATION OF THERMOSTAT . 583
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER 584
INSTALLATION OF FAN HUB 584
INSTALLATION OF BELT TENSIONER . 584
INSTALLATION OF WATER INLET 585
INSTALLATION OF ALTERNATOR . 585
INSTALLATION OF BELT . 586
INSTALLATION OF OIL FILTER . 587
REMOVAL OF ENGINE FROM ENGINE STAND 587
INSTALLATION OF STARTING MOTOR . 587
INTAKE GROUP . 588
DISASSEMBLY AND ASSEMBLY DRAWING . 588
OUTLINE 590
REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) . 591
REMOVAL 591
INSTALLATION . 592
CLEANING AND INSPECTION 594
REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER) . 596
REMOVAL 596
CLEANING . 596
INSTALLATION . 597
CLEANING AND INSPECTION 598
ASSEMBLY . 598
REPLACEMENT OF INTAKE CONNECTOR 599
REMOVAL AND INSTALLATION . 599
AIR CONNECTOR 599
CLEANING . 599
INSPECTION . 599
REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET . 599
REMOVAL 600
CLEANING . 600
INSTALLATION . 600
AIR CROSSOVER TUBE . 601
CLEANING . 601
INSPECTION . 601
EXHAUST GROUP 602
DISASSEMBLY AND ASSEMBLY DRAWING . 602
OUTLINE OF EXHAUST MANIFOLD 603
REPLACEMENT OF EXHAUST MANIFOLD, GASKET 604
REMOVAL 604
CLEANING AND INSPECTION 604
INSTALLATION . 604
REPLACEMENT OF EXHAUST MANIFOLD 605
CLEANING . 605
INSTALLATION . 606
INSPECTION . 606
REPLACEMENT OF TURBOCHARGER 607
REMOVAL 607
INSTALLATION . 608
TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER) 611
REPLACEMENT 611
CYLINDER BLOCK GROUP . 612
DISASSEMBLY AND ASSEMBLY DRAWING . 612
OUTLINE OF CYLINDER BLOCKGROUP . 615
OUTLINE OF CAMSHAFT 615
OUTLINE OF CRANKSHAFT 615
OUTLINE OF CYLINDER BLOCK 615
OUTLINE OF OIL SEAL 615
REPLACEMENT OF FRONT OILSEAL . 616
REMOVAL 616
CLEANING AND INSPECTION 617
INSTALLATION . 617
REPLACEMENT OF REAR OIL SEAL . 619
OUTLINE OF PISTON 621
OUTLINE OF VIBRATION DAMPER 621
CHECK LIST FOR CYLINDER BLOCK GROUP 622
CYLINDER BLOCK . 623
INSPECTION BEFORE DISASSEMBLY 623
DISASSEMBLY OF CYLINDER BLOCK 623
CLEANING OF CYLINDER BLOCK . 625
INSPECTION OF CYLINDER BLOCK . 628
REMOVAL OF GLAZE FROM CYLINDER BORE 630
DISASSEMBLY 630
INSPECTION . 631
REMOVAL OF GLAZE . 631
CLEANING . 634
ASSEMBLY . 635
REMOVAL OF GLAZE FROM CYLINDER BLOCK . 636
REPLACEMENT OF PLUG 639
REMOVAL 639
CLEANING AND INSPECTION 639
INSTALLATION . 640
REPLACEMENT OF CAP . 640
REMOVAL 640
CLEANING . 641
INSTALLATION . 641
INSTALLATION OF CAP AND PLUG . 644
INSTALLATION OF CAMSHAFT CUP . 646
INSTALLATION OF CAMSHAFT BUSHING . 647
REPLACEMENT OF DIPSTICK TUBE . 648
STORING CYLINDER BLOCK . 649
CRANKSHAFT . 649
REPLACEMENT OF MAIN BEARING 650
CLEANING OF CRANKSHAFT . 657
INSTALLATION OF CRANKSHAFT . 657
REPLACEMENT OF CRANKSHAFT GEAR . 658
REPLACEMENT OF CAMSHAFT AND TAPPET . 660
REMOVAL OF CAMSHAFT 660
REMOVAL OF TAPPET 661
INSPECTION OF TAPPET . 663
STANDARDS FOR PITTING WHEN REUSING . 665
STANDARD FOR DETERIORATION (BREAKAGE) OF TIP . 666
INSPECTION OF CAMSHAFT BORE 669
REPLACEMENT OF CAMSHAFT BUSHING 669
INSTALLATION OF TAPPET . 670
INSTALLATION OF CAMSHAFT . 673
CLEANING OF CAMSHAFT . 675
INSPECTION OF CAMSHAFT, GEAR . 676
REPLACEMENT OF CAMSHAFT, GEAR 678
CLEANING AND INSPECTION 679
INSTALLATION . 680
REPLACEMENT OF TIMING PIN 682
REPLACEMENT OF GEAR HOUSING, GASKET 683
REMOVAL 683
CLEANING AND INSPECTION 684
INSTALLATION . 685
REPLACEMENT OF CAMSHAFT GEAR . 693
REMOVAL 693
INSTALLATION (SHRINK-FITTING METHOD) . 694
INSTALLATION (METHOD USING SPECIAL TOOL) . 695
INSTALLATION OF CAMSHAFTMOUNTING BOLTS . 697
REPLACEMENT OFVIBRATION DAMPER, CRANKSHAFT PULLEY 698
REMOVAL 698
INSPECTION OF RUBBER DAMPER 698
INSTALLATION . 699
INSPECTION OF VISCOUSDAMPER 699
VIBRATION DAMPER (RUBBER TYPE) . 703
PISTON, PIN, CONNECTING ROD 705
REPLACEMENT OF PISTON AND RING . 705
REMOVAL OF PISTON CONNECTING ROD . 706
DISASSEMBLY OF PISTON CONNECTING ROD . 708
CLEANING OF PISTON,PIN,CONNECTING ROD 708
INSPECTION OF PISTON . 709
INSPECTION OF PISTON PIN . 710
ASSEMBLY OF PISTON CONNECTING ROD 711
INSPECTION OF PISTON RING GAP 712
INSTALLATION OF PISTON RING 713
INSTALLATION OF PISTON CONNECTING ROD 714
REPLACEMENT OF CONNECTING ROD 718
REMOVAL 718
CLEANING AND INSPECTION 719
INSTALLATION . 721
REPLACEMENT OF CONNECTING ROD BEARING 722
REMOVAL 722
CLEANING AND INSPECTION 724
INSTALLATION . 725
DISASSEMBLY OF PISTON CONNECTING ROD . 728
CLEANING OF PISTON, PIN, CONNECTING ROD 729
INSPECTION OF PISTON . 730
INSPECTION OF PISTON PIN . 731
INSPECTION OF CONNECTING ROD . 731
INSPECTION OF CONNECTING ROD BEARING CLEARANCE . 731
ASSEMBLY OF PISTON CONNECTING ROD 732
INSPECTION OF PISTON RING END GAP 733
INSTALLATION OF PISTON RING 734
BALANCER . 735
DISASSEMBLY 735
ASSEMBLY . 738
GEAR COVER . 745
REPLACEMENT OF GEAR COVER 745
REMOVAL 745
CLEANING AND INSPECTION 746
INSTALLATION . 746
INSTALLATION OF GEAR COVER . 748
INSPECTION OF GEAR HOUSING AND TIMING PIN 750
DISASSEMBLY OF GEAR HOUSING 750
REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD . 751
REPLACEMENT OF ENGINE NAME PLATE . 751
CYLINDER HEAD 754
DISASSEMBLY AND ASSEMBLY DRAWING . 754
OUTLINE 756
REPLACEMENT OF CYLINDER HEAD . 757
REMOVAL 757
INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD . 760
DISASSEMBLY OF CYLINDER HEAD . 761
CLEANING OF CYLINDER HEAD 762
INSPECTION OF VALVE 764
INSPECTION OF VALVE GUIDE 765
INSPECTION OF CYLINDER DECK 765
INSPECTION OF VALVE SEAT . 766
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING . 766
REPLACEMENT OF VALVE SPRING 767
ASSEMBLY OF CYLINDER HEAD 767
INSTALLATION OF CYLINDER HEAD 768
ADJUSTING VALVE CLEARANCE 772
INSTALLATION OF THERMOSTAT . 773
INSTALLATION OF FAN HUB 773
INSTALLATION OF BELT TENSIONER . 774
INSTALLATION OF ALTERNATOR . 774
INSTALLATION OF DRIVE BELT . 775
INSPECTION BEFORE DISASSEMBLY 775
DISASSEMBLY OF CYLINDER HEAD . 776
CLEANING OF CYLINDER HEAD 777
INSPECTION OF VALVE 779
INSPECTION OF VALVE GUIDE 780
INSPECTION OF CYLINDER HEAD COMBUSTION DECK 780
INSPECTION OF VALVE SEAT . 781
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING . 781
REPLACEMENT OF VALVE SPRING 782
REPLACEMENT OF CAP . 782
POLISHING VALVE 784
POLISHING VALVE SEAT . 785
CALCULATING GRINDING DEPTH AND MEASURING DEPTH OF VALVE 786
ASSEMBLY OF CYLINDER HEAD 790
ROCKER LEVER . 792
DISASSEMBLY AND ASSEMBLY DRAWING . 792
OUTLINE 794
REPLACEMENT OF ROCKER LEVER AND PUSH ROD 795
REMOVAL 795
DISASSEMBLY OF ROCKER LEVER 796
CLEANING OF ROCKER LEVER . 797
INSPECTION OF ROCKER LEVER . 797
ASSEMBLY OF ROCKER LEVER . 798
INSTALLATION OF ROCKER LEVER . 799
DISASSEMBLY OF ROCKER LEVER 801
CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT . 802
INSPECTION OF ROCKER LEVER . 802
INSPECTION OF ROCKER LEVER SHAFT . 803
ASSEMBLY OF ROCKER LEVER . 803
TAPPETS AND PUSH RODS 805
DISASSEMBLY AND ASSEMBLY DRAWING . 805
OUTLINE 806
CLEANING OF PUSH ROD . 807
INSPECTION OF PUSH ROD . 807
INSTALLATION OF PUSH ROD . 807
INSPECTION OF TAPPET . 808
ENGINE MOUNT GROUP . 810
OUTLINE OF FLYWHEEL HOUSING 810
OUTLINE OF FLYWHEEL, RING GEAR . 810
OUTLINE OF FRONT SUPPORT . 810
FLYWHEEL, RING GEAR 811
INSPECTION OF FLYWHEEL, RING GEAR 811
REPLACEMENT OF FLYWHEEL, RING GEAR . 811
FLYWHEEL HOUSING . 813
REPLACEMENT OF REAR OIL SEAL . 813
REMOVAL 813
CLEANING AND INSPECTION 815
INSTALLATION . 815
REPLACEMENT OF FLYWHEEL HOUSING 818
REMOVAL 818
CLEANING AND INSPECTION 819
INSTALLATION (DRY CLUTCH SPECIFICATION) 820
INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING 821
INSPECTION OF FACE RUNOUT OF FLTWHEEL HOUSING 823
INSTALLATION (WET CLUTCH SPECIFICATION) 824
INSPECTION . 826
INSTALLATION . 827
FRONT SUPPORT 828
CLEANING AND INSPECTION 828
REMOVAL OF ENGINE 829
INSPECTION OF ENGINE MOUNT . 831
INSTALLATION OF ENGINE . 832
OIL PAN AND SUCTION TUBE . 836
DISASSEMBLY AND ASSEMBLY DRAWING . 836
REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET . 837
CLEANING AND INSPECTION 839
REGULATOR VALVE 840
REPLACEMENT OF REGULATOR VALVE, SPRING . 840
DISASSEMBLY 840
CLEANING AND INSPECTION 840
OIL FILTER BYPASS VALVE 843
REPLACEMENT 843
OIL COOLER . 844
DISASSEMBLY AND ASSEMBLY DRAWING . 844
REPLACEMENT OF OIL COOLER CORE, GASKET . 845
CLEANING . 847
INSPECTION . 848
OIL PUMP 849
DISASSEMBLY AND ASSEMBLY DRAWING . 849
REPLACEMENT OF OIL PUMP 850
CLEANING AND INSPECTION 851
INSTALLATION OF OIL PUMP . 854
INSPECTION . 855
FUEL INJECTION PUMP GROUP 859
DISASSEMBLY AND ASSEMBLY DRAWING . 859
FUEL INJECTION NOZZLE GROUP 860
DISASSEMBLY AND ASSEMBLY DRAWING . 860
FUEL INJECTION NOZZLE 861
DISASSEMBLY 861
CLEANING AND INSPECTION 862
ASSEMBLY . 864
FEED PUMP (CYLINDER BLOCK MOUNT TYPE) 867
REPLACEMENT OF FEED PUMP (DIAPHRAGM TYPE) 867
REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE) . 869
REMOVAL 869
CLEANING . 870
ASSEMBLY . 870
INSTALLATION . 871
CLEANING AND INSPECTION 871
REPLACEMENT OF FUEL FILTER . 874
FUEL PIPING 876
REPLACEMENT OF HIGH-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV) . 876
REPLACEMENT OF FUEL SUPPLY PIPING (BOSCH VE, LUCAS CAV) 877
CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING . 879
REPLACEMENT OF FUEL RETURN PIPING (BOSCH VE, LUCAS CAV) 880
CLEANING AND INSPECTION OF FUEL DRAIN PIPING . 882
REPLACEMENT OF LOW-PRES-SURE FUEL PIPING (BOSCH VE, LUCAS CAV) . 882
CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING 883
REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE (BOSCH VE) 884
WATER PUMP . 885
DISASSEMBLY AND ASSEMBLY DRAWING . 885
REPLACEMENT OF WATER PUMP 886
INSPECTION . 887
FAN HUB 887
REPLACEMENT OF FAN PULLEY 887
REPLACEMENT OF FAN HUB . 888
INSPECTION . 888
DISASSEMBLY 889
ASSEMBLY . 890
BELT TENSIONER . 892
DISASSEMBLY AND ASSEMBLY DRAWING . 892
REPLACEMENT OF BELT 893
REPLACEMENT OF BELT TENSIONER 893
INSPECTION . 893
THERMOSTAT . 894
DISASSEMBLY AND ASSEMBLY DRAWING . 894
REPLACEMENT OF THERMOSTAT 895
INSPECTION . 896
FAN 898
COOLANT 898
ACCESSORY DRIVE ADAPTER 900
DISASSEMBLY AND ASSEMBLY DRAWING . 900
CLEANING . 901
INSPECTION . 901
DISASSEMBLY 901
ASSEMBLY . 902
DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD . 904
CLEANING . 905
INSPECTION . 906
ASSEMBLY . 910
REPLACEMENT OF AIR COMPRESSOR 913
REMOVAL 913
INSPECTION . 914
INSTALLATION . 916
CLEANING AND INSPECTION 918
INSPECTION . 918
ALTERNATOR . 919
REPLACEMENT OF ALTERNATOR 919
INSPECTION . 920
STARTING MOTOR . 920
INSPECTION . 920
14 MAINTENANCE STANDARD 923
TURBOCHARGER . 924
EXHAUST MANIFOLD . 926
CYLINDER HEAD 928
VALVE, VALVE GUIDE . 930
LOCKER ARM SHAFT, PUSH ROD AND TAPPET 932
CYLINDER BLOCK . 934
CYLINDER . 936
CRANKSHAFT . 938
CAMSHAFT . 940
TIMING GEAR 944
PISTON, PISTON RING AND PISTON PIN . 946
CONNECTING ROD . 948
VIBRATION DAMPER . 950
FLYWHEEL, FLYWHEEL HOUSING . 952
FAN HUB 954
OIL PUMP . 955
WATER PUMP, THERMOSTAT . 956
FUEL INJECTION PUMP 957
FUEL INJECTION NOZZLE 958
15 REPAIR AND REPLACEMENT OF PARTS . 961
OUTLINE 962
REPAIR GUIDELINE . 962
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT 962
INSPECTION . 962
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL 962
FOLLOW WASHING METHODS GIVEN IN MANUAL . 962
FOLLOW INSPECTION METHODS GIVEN IN MANUAL 962
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT . 963
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS 964
REPAIR PROCEDURE . 964
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS 967
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS 968
PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK . 969
INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK 969
INSPECTION AND INSTALLATION OF VALVE GUIDE . 970
PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE 971
PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE 972
OUTLINE OF VALVE SEAT REPAIR . 972
CALCULATING GRINDING DEPTH OF VALVE SEAT . 973
METHOD OF GRINDING VALVE SEAT 973
METHOD OF INSTALLING VALVE SEAT 977
MACHINING EXHAUST VALVE INSET POCKET . 977
REPLACING VALVE SEAT . 980
METHOD OF GRINDING VALVE . 981
CHECKING TENSION OF VALVE SPRING . 982
ASSEMBLY OF CYLINDER HEAD 983
PROCEDURE FOR REPAIRING CYLINDER BLOCK . 984
REPAIR TOOLS . 984
COMBUSTION DECK 984
CAM BORE . 985
OUTLINE OF REPAIR OF CYLINDER BORE . 986
CYLINDER BORE 986
INSTALLATION OF REPAIR SLEEVE 988
PROCEDURE FOR REPAIRING CRANKSHAFT . 992
REPAIR TOOLS . 992
OUTLINE OF GRINDING CRANKSHAFT . 992
REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL . 993
REGRINDING CRANKSHAFT JOURNAL RADIUS . 993
SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL 995
REGRINDING CRANKSHAFT ROD JOURNAL RADIUS . 995
OPTIONAL PROCEDURE . 996
PROCEDURE FOR REPAIRING CONNECTING ROD . 997
INSTALLATION OF PIN BORE BUSHING . 999
MACHINING OF CONNECTING ROD BUSHING 1001
INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD .1002
TESTING ALIGNMENT OF CONNECTING ROD 1003
INSPECTION OF TWISTING OF CONNECTING ROD .1003
REPLACING VALVE SEAT INSERT 1004
PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS 1007

DESCRIPTION:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010026 – PDF DOWNLOAD

G.B 25/12/24