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KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL YEBM200101 – PDF DOWNLOAD
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Description
KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL YEBM200101 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL YEBM200101 – PDF DOWNLOAD
Language : English
Pages : 806
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL YEBM200101 – PDF DOWNLOAD
COVER................................................................................................... 1 SUB-COVER........................................................................................... 2 CONTENTS ........................................................................................... 3 SAFETY.............................................................................................. 4 SAFETY NOTICE................................................................................... 4 FOREWORD ........................................................................................... 6 GENERAL ...................................................................................... 6 HOW TO READ THE SHOP MANUAL ................................................................... 7 HOISTING INSTRUCTIONS........................................................................... 8 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER .................................... 9 COATING MATERIALS............................................................................... 11 STANDARD TIGHTENING TORQUE .................................................................... 13 ELECTRIC WIRE CODE ............................................................................ 16 UNITS........................................................................................... 17 CAPSCREW MARKINGS AND TORQUE VALUES ............................................................ 18 PIPE PLUG TORQUE VALUES......................................................................... 21 SYMBOLS......................................................................................... 22 ILLUSTRATIONS................................................................................... 23 01 GENERAL ........................................................................................ 24 APPLICABLE MACHINE.............................................................................. 25 GENERAL ASSEMBLY DRAWING........................................................................ 29 S6D102E-1(PC200-6)FRONT VIEW................................................................ 29 S6D102E-1(PC200-6)REAR VIEW................................................................. 30 S6D102E-1(PC200-6)LEFT-HAND VIEW............................................................ 31 S6D102E-1(PC200-6)RIGHT-HAND VIEW........................................................... 32 SAA6D102E-2(PC200/210-7)FRONT VIEW.......................................................... 33 SAA6D102E-2(PC200/210-7)REAR VIEW........................................................... 34 SAA6D102E-2(PC200/210-7)LEFT-HAND VIEW...................................................... 35 SAA6D102E-2(PC200/210-7)RIGHT-HAND VIEW..................................................... 36 SAA6D102E-2(PC220-7)FRONT VIEW.............................................................. 37 SAA6D102E-2(PC220-7)REAR VIEW............................................................... 38 SAA6D102E-2(PC220-7)LEFT-HAND VIEW.......................................................... 39 SAA6D102E-2(PC220-7)RIGHT-HAND VIEW......................................................... 40 ENGINE PERFORMANCE CURVE........................................................................ 43 S6D102E-1(PC200,200LC-6,PC200,200LC-6 HYPER GX))............................................ 44 S6D102E-1(PC200LC-6 EXCEL, PC200-6 CUSTOM).................................................. 45 SA6D102E-1(PC220, 220LC-6).................................................................. 46 SA6D102E-1(PC220,200LC-6 EXCEL)............................................................. 47 SAA6D102E-2(PC200-7,PC200LC-7,PC210-7,PC210LC-7)............................................ 48 WEIGHT TABLE.................................................................................... 50 11 STRUCTURE AND FUNCTION ......................................................................... 52 OUTLINE OF AIR INTAKE AND EXHAUST SYSTEMS....................................................... 53 INTAKE AND EXHAUST DEVICES...................................................................... 54 (S)6D102E-1(INTAKE DEVICE).................................................................. 54 (EXHAUST DEVICE)............................................................................ 55 SA6D102E-1(INTKAE DEVICE)................................................................... 56 (EXHAUST DEVICE)............................................................................ 57 AIR CLEANER..................................................................................... 58 FRG TYPE(RADIAL SEAL TYPE).................................................................. 58 FTG TYPE(CYCLOPACK TYPE).................................................................... 58 TURBOCHARGER.................................................................................... 59 S(A)6D102E-1................................................................................ 59 SAA6D102E-2................................................................................. 60 OUTLINE OF WASTE GATE VALVE................................................................. 61 LUBRICATION OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)....................................... 62 CYLINDER HEAD................................................................................... 63 (S)6D102E-1, SA6D102E-1..................................................................... 63 SAA6D102E-2................................................................................. 65 CYLINDER BLOCK.................................................................................. 68 (S)6D102E-1, SA6D102E-1 SAA6D102E-2......................................................... 68 MAIN MOVING PARTS............................................................................... 71 (S)6D102E-1, SA6D102E-1 SAA6D102E-2......................................................... 71 CRANKSHAFT AND MAIN BEARING................................................................. 73 PISTON CONNECTING ROD....................................................................... 73 TIMING GEAR PORTION............................................................................. 76 FRONT GEAR COVER................................................................................ 77 CAMSHAFT TIMING PIN............................................................................. 78 VALVE MECHANISM................................................................................. 79 (S)6D102E-1, SA6D102E-1 SAA6D102E-2........................................................ 79 (S)6D102E-1, SA6D102E-1 SAA6D102E-2........................................................ 82 FLYWHEEL, FLYWHEEL HOUSING...................................................................... 83 LUBRICATION SYSTEM DIAGRAM...................................................................... 85 FLOW OF LUBRICAING OIL ..................................................................... 86 LUBRICATION OF OUTPUT POWER RELATED EQUIPMENT............................................... 88 OIL PUMP ..................................................................................... 90 OIL FILTER, OIL COOLER.......................................................................... 91 REGULATOR VALVE, SAFETY VALVE................................................................... 92 FUEL SYSTEM DIAGRAM............................................................................. 95 (S)6D102E-1, SA6D102E-1..................................................................... 95 SAA6D102E-2................................................................................. 98 FUEL INJECTION PUMP............................................................................. 99 TIMING LOCK PIN FOR FUEL INJECTION PUMP.........................................................101 FUEL FILTER.....................................................................................102 FUEL INJECTION NOZZLE...........................................................................103 FUEL CUT SOLENOID...............................................................................104 COOLING SYSTEM DIAGRAM..........................................................................105 (S)6D102E-1 SAA6D102E-2....................................................................105 SA6D102E-1..................................................................................106 WATER PUMP......................................................................................108 THERMOSTAT......................................................................................109 FAN DRIVE.......................................................................................110 OUTSIDE DIAMETER OF PULLEY..................................................................111 AIR COMPRESSOR..................................................................................113 FLOW DIAGRAMS-COMPRESSED AIR SYSTEM.............................................................115 ALTERNATOR......................................................................................117 ALTERNATOR(OPTIONAL)............................................................................118 STARTING MOTOR..................................................................................119 STARTING MOTOR..................................................................................120 STARTING MOTOR(OPTIONAL)........................................................................121 STARTING AID....................................................................................122 12 TEATING AND ADJUSTING ..........................................................................124 SPECIAL TOOL LIST...............................................................................126 SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM.................................................126 SPECIAL TOOLS FOR ENGINE....................................................................127 SPECIAL TOOLS FOR FUEL SYSTEM...............................................................129 SPECIAL TOOLS FOR COMPONENTS................................................................130 SPECIAL TOOLS FOR ELECTRICAL COMPONENTS.....................................................131 SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST...................................................132 TROUBLESHOOTIN DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM.................................134 CLEAN AIR...................................................................................134 TESTING INTAKE RESISTANCE...................................................................134 DAMAGE CAUSED BY UNFILTERED AIR.............................................................135 LEAKAGE OF INTAKE AIR(ENGINE WITH TURBOCHARGER).............................................135 LEAKAGE OF EXHAUST AIR (EINGINE WITH TURBOCHARGER)..........................................136 MEASURING PRESSURE OF TURBOCHARGED AIR(EINGINE WITH TURBOCHARGER)...........................136 DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)..............................137 OIL CONSUMPTION AND OIL LEAKAGE.............................................................137 NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)..........................................138 MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION(ENGINE WITH TURBOCHARGER)....139 TESTING TURBOCHARGER WESTGATE VALVE(ENGINE WITH TURBOCHARGER)...................................140 TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)................................141 TESTING ACTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER )..........................141 REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE(ENGINE WITH TURBOCHARGER)................142 ADJUSTING TURBOCHARGER WESTGATE ACTUATOR(ENGINE WITH TURBOCHARGER)..............................144 MEASURING EXHAUST RESISTANCE....................................................................145 REPLACING TURBOCHARGER(ENGINE WITH TURBOCHARGER)................................................145 TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE...................................................146 VALVE MECHANISM AND CYLINDER HEAD...........................................................146 TEATING AIR SYSTEM AND FUEL SYSTEM..........................................................146 TESTING VALVE CLEARANCE.....................................................................147 TEATING COMPRESSION.........................................................................147 PISTON RING SEALING PERFORMANCE.............................................................147 VALVE SEALING PERFORMANCE...................................................................148 HEAD GASKET SEALING PERFORMANCE.............................................................148 VALVE SEAL WEAR.............................................................................149 PROTRUDING PORTION OF FUEL INJECTION NOZZLE.................................................150 FRONT GEAR HOUSING AND GEAR TRAIN...........................................................151 VIBRATION DAMPER............................................................................151 ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT....................................152 PISTON AND CONNECTING ROD...................................................................153 CRANDSHAFT AND MAIN BEARING.................................................................155 CYLINDER BLOCK..............................................................................156 FLYWHEEL HOUSING AND FLYWHEEL...............................................................157 ADJUSTING VALVE CLEARANCE.......................................................................158 ADJUSTING 4-CYLINDER ENGINE.................................................................159 ADJUSTIN 6-CYLINDER ENGINE..................................................................160 TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM.......................................161 OUTLINE.....................................................................................161 HIGH PRESSURE...............................................................................161 REGULATOR VALVE.............................................................................161 LOW PRESSURE................................................................................161 OIL LEVEL...................................................................................162 OIL FILTER..................................................................................162 OIL PRESSURE GAUGE..........................................................................162 OIL PAN SUCTION TUBE .......................................................................163 BEARING AND OIL PUMP .......................................................................163 UNSUITABLE OIL PUMP.........................................................................163 DILUTION OF OIL ............................................................................163 COOLING WATER IN OIL .......................................................................164 FUEL IN OIL ................................................................................165 OIL LEAKAGE.................................................................................168 FUEL INJECTION PUMP CALIBRATION DATA............................................................171 RUNNING IN STANDARD.............................................................................180 PERFORMANCE TEST CRITERIA.......................................................................181 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(DIAPHRAGM TYPE)................................183 TEST1: TESTING OUTPUT PRESSURE..............................................................183 TEST2: TESTING FLOW.........................................................................184 TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(PISTON TYPE)...................................185 TEST1: TESTING OUTPUT PRESSURE..............................................................186 TEST2: TESTING FLOW.........................................................................187 TESING AIR INSIDE FUEL SYSTEM...................................................................190 TESING WATER SEPARATOR FUEL FILTER..............................................................191 TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP(BOSCH VE, LUCAS CAV).............................193 DEFECTIVE ACTUATION OF GOVERNOR.............................................................194 STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT.................................................194 LUCAS CAV ADJUSTIMENT SCREW.................................................................194 BOSCH VE ADJUSTMENT SCREW...................................................................195 MANUAL SHUT-OFF LEVER.......................................................................195 TIMING PROPULSION ANGLE MECHANISM...........................................................196 ELECTRICAL SHUT-OFF VALVE...................................................................196 DELIVERY VALVE(LUCAS CAV)...................................................................198 TESTING HIGH-PRESSURE FUEL PIPING...............................................................199 TESING FUEL INJECTION NOZZLE....................................................................200 TESING FUEL DRAIN PIPING .......................................................................202 BLEEDING AIR FROM FUEL SYSTEM...................................................................202 BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER......................................203 BLEEDING AIR FROM FUEL INJECTION PUMP.......................................................203 BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT.....................................................204 ADJUSTING FUEL INJECTION TIMING.................................................................204 ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE................................................207 ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV...............................................208 ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)................................................209 REPLACING FUEL INJECTION NOZZLE.................................................................209 TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM...........................................213 TROUBLESHOOTING.............................................................................213 RADIATOR CAP................................................................................215 WATER PUMP..................................................................................216 RADIATOR, FAN AND RADIATOR SHUTTER..........................................................217 THERMOSTAT..................................................................................219 WATER TEMPERATURE GAUGE, FUEL GAUGE, OOVERLOAD..............................................220 TESTING CARBON DEPOSIT IN AIR COMPRESSOR........................................................221 TESING AIR LEAKAGE FROM AIR COMPRESSOR..........................................................222 TESING AIR GOVERNOR, UNLOADER VALVE.............................................................223 TESING AIR GOVERNOR.............................................................................224 TESING BATTERY..................................................................................226 TESING BATTERY TERMINAL CONNCTIONS .............................................................227 TESTING STARTING CIRCUIT .......................................................................227 TESTING BATTERY RELAY.......................................................................227 TESING STARTING SWITCH......................................................................229 TESING STARTING MOTOR AND MAGNETIC SWITCH...................................................230 STARTING MOTOR..............................................................................231 TESTING DROP IN CRANKING SPEED..............................................................232 TESING ALTERNATOR...............................................................................233 ABNORMAL DISPLAY OF CHARGE LAMP.............................................................234 ABNORMAL ACTUATION OF CHARGING SYSTEM.......................................................235 TESING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR.........................................236 TESTING OIL PRESSURE SWITCH.................................................................236 TESTING WATER TEMPERATURE SENSOR............................................................237 TESING WHITE SMOKE..............................................................................238 NORMAL ACTUATION OF INTAKE HEATER SYSTEM....................................................238 TESING INTAKE HEATER............................................................................239 TESTING PREHEATING CYCLE....................................................................240 SIDE VIEW OF ENGINE.............................................................................241 OUTLINE OF ENGINE PERFORMANCE TEST..............................................................243 BLOW-BY MEASUREMENT AND REPLACEMENT TABLE.......................................................244 ENGINE DYNAMOMETER .............................................................................245 INSTALLING ENGINE...........................................................................245 PROCEDURE FOR RUNNING IN ENGINE.............................................................252 ENGINE PERFORMANCE TEST.....................................................................255 ENGINE PAINWORK.................................................................................257 TROUBLESHOOTING.................................................................................260 STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................261 TROUBLESHOOTING OF ENGINE (S MODE)..........................................................264 METHOD OF USING TROUBLESHOOTING CHARTS..................................................265 S-1 STRATING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)............................269 S-2 ENGINE DOES NOE START...............................................................271 (1)ENGINE DOES NOT TURN.............................................................271 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).........272 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)........273 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................274 S-4 ENGINE STOPS DURING OPERTIONS...................................................275 S-5 ENGINE DOES NOT ROTATE SMOOOTHLY (HUNTING)......................................276 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER..............................................277 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...................................278 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)..........................279 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................280 S-10 FUEL CONSUMPTION IS EXCESSIVE..................................................281 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN........282 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)......................283 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ...........................................284 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)................................285 S-15 ABNORMAL NOISE IS MADE.........................................................286 S-16 VIBRATION IS EXCESSIVE.........................................................287 13 DISASSEMBLY AND ASSEMBLY.........................................................................288 SPECIAL TOOL LIST...............................................................................293 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY..................................................293 SPECIAL TOOLS FOR ENGINE....................................................................295 SPECIAL TOOLS FOR FUEL SYSTEM...............................................................297 OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE...................................................299 OUTLINE.....................................................................................299 DISASSEMBLY.............................................................................299 ASSEMBLY ..............................................................................299 DISASSEMBLY OF ENGINE...........................................................................300 STEAM CLEANING OF ENGINE....................................................................300 REMOVAL OF STARTING MOTOR...................................................................300 WEIGHT OF ENGINE(REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER).................300 INSTALLATION TO ENGINE STAND................................................................300 DRAINING OIL................................................................................301 REMOVAL OF REAR LIFTING BRACKET.............................................................301 REMOVAL OF BELT.............................................................................301 REMOVAL OF FAN PULLEY.......................................................................302 REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY..............................................302 REMOVAL OF BELT TENSIONER...................................................................302 REMOVAL OF FAN HUB..........................................................................303 REMOVAL OF ALTERNATOR.......................................................................303 REMOVAL OF THERMOSTAT.......................................................................304 REMOVAL OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)...........................................304 REMOVAL OF EXHAUST MANIFOLD.................................................................306 REMOVAL OF FUEL FILTER......................................................................306 REMOVAL OF FUEL FILTER HEAD ................................................................307 REMOVAL OF FUEL PIPING......................................................................307 REMOVAL OF DIPSTICK.........................................................................309 REMOVAL OF INTAKE MANIFOLD COVER............................................................309 REMOVAL OF AFTERCOOLER(ENGINE WITH AFTERCOOLER).............................................310 REMOVAL OF CYLINDER HEAD COVER..............................................................310 REMOVAL OF FUEL INJECTION NOZZLE............................................................310 REMOVAL OF ROCKER LEVER.....................................................................311 REMOVAL OF PUSH ROD.........................................................................312 REMOVAL OF CYLINDER HEAD....................................................................312 REMOVAL OF FRONT COVER......................................................................312 REMOVAL OF WATER PUMP.......................................................................313 REMOVAL OF FLYWHEEL.........................................................................313 REMOVAL OF FLYWHEEL HOUSING.................................................................314 REMOVAL OF COMPONENTS(COMPRESSOR, HYDRAULIC PUMP, ETC.).....................................314 REMOVAL OF FUEL INJECTION PUMP(BOSCH A, ZEXEL A)............................................314 REMOVAL OF FEED PUMP(ENGINE MOUNT TYPE).....................................................317 REMOVAL OF TAPPET COVER.....................................................................317 REMOVAL OF OIL FILLER.......................................................................317 REMOVAL OF OIL COOLER.......................................................................317 REMOVAL OF WATER INLET......................................................................318 REMOVAL OF OIL PAN..........................................................................318 REMOVAL OF OIL PAN SUCTION TUBE.............................................................318 REMOVAL OF REAR SEAL COVER..................................................................319 REMOVAL OF CAMSHAFT.........................................................................319 REMOVAL OF TAPPET...........................................................................321 REMOVAL OF OIL PUMP.........................................................................321 REMOVAL OF TIMING PIN HOUSING...............................................................322 REMOVAL OF GEAR HOUSING.....................................................................322 REMOVAL OF BALANCER(WHEN BALANCER IS INSTALLED).............................................323 REMOVAL OF PISTON CONNECTING ROD............................................................325 REMOVAL OF CRANKSHAFT.......................................................................327 REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE..............................................329 REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND.................................................329 ASSEMBLY OF ENGINE..............................................................................330 PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK..................................................330 INSTALLATION OF TAPPET......................................................................330 INSTALLATION OF CRANKSHAFT..................................................................331 INSTALLATION OF PISTION AND CONNECTING ROD ASSEMBLIES.......................................335 INSTALLATION OF PISTION AND CONNECTING ROD ASSEMBLY.........................................335 INSTALLATION OF GEAR HOUSING................................................................339 INSTALLATION OF OIL PUMP....................................................................340 INSTALLATION OF CAMSHAFT....................................................................341 INSTALLATION OF TIMING PIN..................................................................344 INSTALLATION OF BALANCER....................................................................347 INSTALLATION OF REAR OIL SEAL...............................................................351 INSTALLATION OF OIL PAN SUCTION TUBE........................................................352 INSTALLATION OF OIL PAN.....................................................................353 INSTALLATION OF OIL COOLER..................................................................354 INSTALLATION OF OIL FILLER PORT.............................................................354 INSTALLATION OF FEED PUMP...................................................................355 INSTALLATION OF TAPPET COVER................................................................355 INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A)......................................357 INSTALLATION OF COMPONENTS(COMPRESSOR, HYDRAULIC PUMP, ETC.)................................362 INSTALLATION OF FLYWHEEL HOUSING............................................................362 INSTALLATION OF FLYWHEEL....................................................................363 INSTALLATION OF WATER PUMP..................................................................364 INSTALLATION OF FRONT COVER.................................................................364 INSTALLATION OF CYLINDER HEAD...............................................................366 INSTALLATION OF PUSH ROD....................................................................367 INSTALLATION OF ROCKER LEVER................................................................367 TIGHTENING OF CYLINDER HEAD.................................................................369 ADJUSTING VALVE CLEARANCE...................................................................371 INSTALLATION OF FUEL INJECTION NOZZLE.......................................................373 INSTALLATION OF CYLINDER HEAD COVER.........................................................374 INSTALLATION OF INTAKE MAINIFOLD COVER......................................................374 INSTALLATION OF FUEL FILTER HEAD............................................................376 INSTALLATION OF EXHAUST MANIFOLD............................................................377 INSTALLATION OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)......................................378 INSTALLATION OF THERMOSTAT..................................................................381 INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER.........................................382 INSTALLATION OF FAN HUB.....................................................................382 INSTALLATION OF BELT TENSIONER..............................................................382 INSTALLATION OF WATER INLET.................................................................383 INSTALLATION OF ALTERNATOR..................................................................383 INSTALLATION OF BELT........................................................................384 INSTALLATION OF OIL FILTER..................................................................385 REMOVAL OF ENGINE FROM ENGINE STAND.........................................................385 INSTALLATION OF STARTING MOTOR..............................................................385 INTAKE GROUP....................................................................................386 DISASSEMBLY AND ASSEMBLY DRAWING............................................................386 OUTLINE.....................................................................................388 REPLACEMENT OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)...........................................389 REMOVAL.....................................................................................389 INSTALLATION................................................................................390 CLEANING AND INSPECTION.....................................................................392 REPLACEMENT OF AFTERCOOLER, GASKET(ENGINE WITH AFTERCOOLER).....................................394 REMOVAL.....................................................................................394 CLEANING ..................................................................................394 INSTALLATION................................................................................395 CLEANING AND INSPECTION.....................................................................396 ASSEMBLY ..................................................................................396 REPLACEMENT OF INTAKE CONNECTOR.................................................................397 REMOVAL AND INSTALLATION....................................................................397 AIR CONNECTOR...................................................................................397 CLEANING ..................................................................................397 INSPECTION ................................................................................397 REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET....................................................397 REMOVAL.....................................................................................398 CLEANING ..................................................................................398 INSTALLATION................................................................................398 AIR CROSSOVER TUBE..............................................................................399 CLEANING ..................................................................................399 INSPECTION .................................................................................399 EXHAUST GROUP...................................................................................400 DISASSEMBLY AND ASSEMBLY DRAWING............................................................400 OUTLINE OF EXHAUST MANIFOLD.................................................................401 REPLACEMENT OF EXHAUST MANIFOLD, GASKET ........................................................402 REPLACEMENT OF EXHAUST MANIFOLD, GASKET ....................................................402 REMOVAL.................................................................................402 CLEANING AND INSPECTION.................................................................402 INSTALLATION............................................................................402 REPLACEMENT OF EXHAUST MANIFOLD.............................................................403 REMOVAL.................................................................................403 CLEANING ..............................................................................403 INSTALLATION............................................................................404 INSPECTION..............................................................................404 REPLACEMENT OF TURBOCHARGER.....................................................................405 REMOVAL.....................................................................................405 INSTALLATION................................................................................406 TURBOCHARGER MOUNTING STUD(ENGINE WITH TURBOCHARGER)............................................409 REPLACEMENT.................................................................................409 CYLINDER BLOCK GROUP............................................................................410 DISASSEMBLY AND ASSEMBLY DRAWING............................................................410 OUTLINE OF CYLINDER BLOCK GROUP.............................................................413 OUTLINE OF CAMSHAFT.....................................................................413 OUTLINE OF CRANKSHAFT...................................................................413 OUTLINE OF CYLINDER BLOCK...............................................................413 OUTLINE OF OIL SEAL.....................................................................413 REPLACEMENT OF FRONT OIL SEAL...............................................................414 REMOVAL.................................................................................414 CLEANING AND INSPECTION.................................................................415 INSTALLATION............................................................................415 REPLACEMENT OF REAR OIL SEAL............................................................417 OUTLINE OF PISTION......................................................................419 OUTLINE OF VIBRATION DAMPER.............................................................419 CHECK LIST FOR CYLINDER BLOCK GROUP.....................................................420 CYLINDER BLOCK..................................................................................421 CYLINDER BLOCK..............................................................................421 INSPECTION BEFORE DISASSEMBLY...........................................................421 DISASSEMBLY OF CYLINDER BLOCK...........................................................421 CLEANING OF CYLINDER BLOCK..............................................................423 INSPECTION OF CYLINDER BLOCK................................................................426 REMOVAL OF GLAZE FROM CYLINDER BORE.........................................................428 DISASSEMBLY.............................................................................428 INSPECTION..............................................................................429 REMOVAL OF GLAZE........................................................................429 CLEANING ..............................................................................432 ASSEMBLY ...............................................................................433 REMOVAL OF GLAZE FROM CYLINDER BLOCK....................................................434 REPLACEMENT OF PLUG.........................................................................437 REMOVAL.................................................................................437 CLEANING AND INSPECTION.................................................................437 INSTALLATION............................................................................438 REPLACEMENT OF CAP..........................................................................438 REMOVAL ...............................................................................438 CLEANING ..............................................................................439 INSTALLATION ..........................................................................439 INSTALLATION OF CUP PLUG................................................................440 INSTALLATION OF CAP AND PLUG................................................................442 INSTALLATION OF CAMSHAFT CUP............................................................444 INSTALLATION OF CAMSHAFT BUSHING........................................................445 REPLACEMENT OF DIPSTICK TUBE............................................................446 STORING CYLINDER BLOCK..................................................................447 CRANKSHAFT......................................................................................447 REPLACEMENT OF MAIN BEARING.................................................................448 CLEANING OF CRANKSHAFT......................................................................455 INSTALLATION OF CRANKSHAFT..................................................................455 REPLACEMENT OF CRANKSHAFT GEAR..............................................................456 REPLACEMENT OF CAMSHAFT AND TAPPET..........................................................458 REMOVAL OF CAMSHAFT.....................................................................458 REMOVAL OF TAPPET.......................................................................459 INSPECTION OF TAPPET....................................................................461 STANDARDS FOR PITTING WHEN REUSING......................................................463 STANDARD FOR DETERIORATION..............................................................464 INSPECTION OF CAMSHAFT BORE.............................................................467 REPLACEMENT OF CAMSHAFT BUSHING.............................................................467 INSTALLATION OF TAPPET..................................................................468 INSTALLATION OF CAMSHAFT................................................................471 CLEANING OF CAMSHAFT........................................................................473 INSPECTION OF CAMSHAFT, GEAR............................................................474 REPLACEMENT OF CAMSHAFT,GEAR................................................................476 REMOVAL.................................................................................476 CLEANING AND INSPECTION.................................................................477 INSTALLATION............................................................................478 REPLACEMENT OF TIMEING PIN......................................................................480 REPLACEMENT OF GEAR HOUSING, GASKET.............................................................481 REMOVAL.....................................................................................481 CLEANING AND INSPECTION.....................................................................482 INSTALLATION................................................................................483 REPOSITIONING OF TIMING PIN.................................................................486 REPLACEMENT OF CAMSHAFT GEAR................................................................491 REMOVAL.................................................................................491 INSTALLATION (SHRINK-FITTING METHOD)....................................................492 INSTALLATION (METHOD USING SPECIAL TOOL)................................................493 INSTALLATION OF CAMSHAFT MOUNTING BOLTS.................................................495 REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY..............................................496 REMOVAL ...................................................................................496 INSPECTION OF RUBBER DAMPER.................................................................496 INSTALLATION ...............................................................................497 INSPECTION OF VISCOUS DAMPER................................................................497 VIBRATION DAMPER (RUBBER TYPE)..............................................................499 CLEANING AND INSPECTION.................................................................499 CLEANING AND INSPECTION OF VIBRATION DAMPER.............................................499 PISTON, PIN, CONNECTING ROD.....................................................................501 REPLACEMENT OF PISTON AND RING..............................................................501 REMOVAL OF PISTON CONNECTING ROD............................................................502 DISASSEMBLY OF PISTON CONNECTING ROD........................................................504 CLEANING OF PISTON, PIN, CONNECTING ROD.....................................................504 INSPECTION OF PISTON........................................................................505 INSPECTION OF PISTON PIN....................................................................506 ASSEMBLY OF PISTON CONNECTING ROD...........................................................507 INSPECTION OF PISTON RING GAP...............................................................508 INSTALLATION OF PISTON RING.................................................................509 INSTALLATION OF PISTON CONNECTING ROD.......................................................510 REPLACEMENT OF CONNECTING ROD...............................................................514 REMOVAL.................................................................................514 CLEANING AND INSPECTION.................................................................515 INSTALLATION............................................................................517 REPLACEMENT OF CONNECTING ROD BEARING.......................................................518 REMOVAL.................................................................................518 CLEANING AND INSPECTION.................................................................520 INSTALLATION............................................................................521 DISASSEMBLY OF PISTON CONNECTING ROD....................................................524 CLEANING OF PISTON,PIN,CONNECTING ROD...................................................525 INSPECTION OF PISTON....................................................................526 INSPECTION OF PISTON PIN................................................................527 INSPECTION OF CONNECTING ROD............................................................527 INSPECTION OF CONNECTING ROD BEARING CLEARANCE..........................................527 ASSEMBLY OF PISTON CONNECTING ROD.......................................................528 INSPECTION OF PISTON RING END GAP.......................................................529 INSTALLATION OF PISTON RING.............................................................530 BALANCER ......................................................................................531 DISASSEMBLY.................................................................................531 ASSEMBLY ..................................................................................534 GEAR COVER .....................................................................................541 REPLACEMENT OF GEAR COVER ..................................................................541 REMOVAL.................................................................................541 CLEANING AND INSPECTION.................................................................542 INSTALLATION............................................................................542 INSTALLATION OF GEAR COVER..............................................................544 INSPECTION OF GEAR HOUSING AND TIMING PIN...............................................546 DISASSEMBLY OF GEAR HOUSING.............................................................546 REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD........................................547 REPLACEMENT OF ENGINE NAME PLATE........................................................547 CYLINDER HEAD ..................................................................................550 DISASSEMBLY AND ASSEMBLY DRAWING............................................................550 OUTLINE.....................................................................................552 REPLACEMENT OF CYLINDER HEAD................................................................553 REMOVAL.................................................................................553 INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD..........................................556 DISASSEMBLY OF CYLINDER HEAD............................................................557 CLEANING OF CYLINDER HEAD...............................................................558 INSPECTION OF VALVE.....................................................................560 INSPECTION OF VALVE GUIDE...............................................................561 INSPECTION OF CYLINDER DECK.............................................................561 INSPECTION OF VALVE SEAT................................................................562 STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING......................................562 REPLACEMENT OF VALVE SPRING.............................................................563 ASSEMBLY OF CYLINDER HEAD...............................................................563 INSTALLATION OF CYLINDER HEAD...........................................................564 INSTALLATION OF PUSH ROD................................................................565 INSTALLATION OF ROCKER LEVER............................................................565 ADJUSTING VALVE CLEARANCE...............................................................568 INSTALLATION OF THERMOSTAT..............................................................569 INSTALLATION OF FAN HUB.................................................................569 INSTALLATION OF BELT TENSIONER..........................................................570 INSTALLATION OF ALTERNATOR..............................................................570 INSTALLATION OF DRIVE BELT..............................................................571 INSPECTION BEFORE DISASSEMBLY...........................................................571 DISASSEMBLY OF CYLINDER HEAD............................................................572 CLEANING OF CYLINDER HEAD...............................................................573 INSPECTION OF VALVE.....................................................................575 INSPECTION OF VALVE GUIDE...............................................................576 INSPECTION OF CYLINDER HEAD COMBUSTION DECK.............................................576 INSPECTION OF VALVE SEAT................................................................577 STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING......................................577 REPLACEMENT OF VALVE SPRING.............................................................578 REPLACEMENT OF CAP......................................................................578 POLISHING VALVE.........................................................................580 POLISHING VALVE SEAT ...................................................................581 CALCULATING GRINDING DEPTH AND MEASURING DEPTH OF VALVE.................................582 ASSEMBLY OF CYLINDER HEAD...............................................................586 ROCKER LEVER....................................................................................588 DISASSEMBLY AND ASSEMBLY DRAWING............................................................588 OUTLINE.....................................................................................590 REPLACEMENT OF ROCKER LEVER AND PUSH ROD....................................................591 REMOVAL.....................................................................................591 DISASSEMBLY OF ROCKER LEVER.................................................................592 CLEANING OF ROCKER LEVER....................................................................593 INSPECTION OF ROCKER LEVER..................................................................593 ASSEMBLY OF ROCKER LEVER....................................................................594 INSTALLATION OF ROCKER LEVER................................................................595 DISASSEMBLY OF ROCKER LEVER.................................................................597 CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT................................................598 INSPECTION OF ROCKER LEVER..................................................................598 INSPECTION OF ROCKER LEVER SHAFT............................................................599 ASSEMBLY OF ROCKER LEVER....................................................................599 TAPPETS AND PUSH RODS...........................................................................601 DISASSEMBLY AND ASSEMBLY DRAWING............................................................601 OUTLINE.....................................................................................602 CLEANING OF PUSH ROD........................................................................603 INSPECTION OF PUSH ROD..................................................................603 INSTALLATION OF PUSH ROD................................................................603 INSPECTION OF TAPPET....................................................................604 INSPECTION OF PUSH ROD..................................................................605 ENGINE MOUNT GROUP..............................................................................606 OUTLINE OF FLYWHEEL HOUSING.................................................................606 OUTLINE OF FLYWHEEL, RING GEAR..............................................................606 OUTLINE OF FRONT SUPPORT....................................................................606 FLYWHEEL, RING GEAR.............................................................................607 INSPECTION OF FLYWHEEL, RING GEAR...........................................................607 REPLACEMENT OF FLYWHEEL, RING GEAR..........................................................607 REPLACEMENT OF RING GEAR................................................................607 INSTALLTION OF FLYWHEEL.................................................................608 REPLACEMENT OF RING GEAR................................................................608 FLYWHEEL HOUSING................................................................................609 REPLACEMENT OF REAR OIL SEAL ...............................................................609 REMOVAL.................................................................................609 CLEANING AND INSPECTION.................................................................611 INSTALLATION............................................................................611 REPLACEMENT OF FLYWHEEL HOUSING.............................................................614 REMOVAL.................................................................................614 CLEANING AND INSPECTION.................................................................615 INSTALLATION(DRY CLUTCH SPECIFICATION)..................................................616 INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING.........................................617 INSPECTION OF FACE RUNOUT OF FLYWHEEL HOUSING...........................................619 INSTALLATION (WET CLUTCH SPECIFICATION).................................................620 INSPECTION..............................................................................622 INSTALLATION............................................................................623 FRONT SUPPORT...................................................................................624 CLEANING AND INSPECTION.....................................................................624 REMOVAL OF ENGINE...............................................................................625 INSPECTION OF ENGINE MOUNT......................................................................627 INSTALLATION OF ENGINE..........................................................................628 CONNECTION OF FUEL CONTROL LEVER............................................................629 OIL PAN AND SUCTION TUBE........................................................................632 DISASSEMBLY AND ASSEMBLY DRAWING............................................................632 REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET................................................633 CLEANING AND INSPECTION.....................................................................635 REGULATOR VALVE.................................................................................636 REPLACEMENT OF REGULATOR VALVE, SPRING......................................................636 DISASSEMBLY.............................................................................636 CLEANING AND INSPECTION.....................................................................636 ASSEMBLY ..............................................................................637 DISASSEMBLY ............................................................................637 INSPECTION..............................................................................638 ASSEMBLY ...............................................................................638 OIL FILTER BYPASS VALVE.........................................................................639 REPLACEMENT.................................................................................639 OIL COOLER......................................................................................640 DISASSEMBLY AND ASSEMBLY DRAWING............................................................640 REPLACEMENT OF OIL COOLER CORE, GASKET......................................................641 CLEANING ..................................................................................643 INSPECTION ................................................................................644 OIL PUMP ......................................................................................645 DISASSEMBLY AND ASSEMBLY DRAWING............................................................645 REPLACEMENT OF OIL PUMP.....................................................................646 REMOVAL OF OIL PUMP.....................................................................646 CLEANING AND INSPECTION.................................................................647 INSTALLATION OF OIL PUMP....................................................................650 INSPECTION..................................................................................651 FUEL INJECTION PUMP GROUP.......................................................................655 DISASSEMBLY AND ASSEMBLY DRAWING............................................................655 FUEL INJECTION NOZZLE GROUP.....................................................................656 FUEL INJECTION NOZZLE.......................................................................657 DISASSEMBLY.............................................................................657 CLEANING AND INSPECTION.....................................................................658 ASSEMBLY ...............................................................................660 TEST....................................................................................662 FEED PUMP(CYLINDER BLOCK MOUNT TYPE)............................................................663 REPLACEMENT OF FEED PUMP(DIAPHRAGM TYPE)....................................................663 REPLACEMENT, ASSEMBLY OF FEED PUMP(PISTON TYPE).............................................665 REMOVAL.................................................................................665 CLEANING ..............................................................................666 ASSEMBLY ...............................................................................666 INSTALLATION............................................................................667 CLEANING AND INSPECTION.................................................................667 ASSEMBLY(PISTON TYPE)...................................................................669 CLEANING ..............................................................................669 ASSEMBLY ..............................................................................670 REPLACEMENT OF FUEL FILTER ....................................................................670 FUEL PIPING.....................................................................................672 REPLACEMENT OF HIGH-PRESSURE FUEL PIPING(BOSCH VE, LUCAS CAV) ..............................672 REPLACEMENT OF FUEL SUPPLY PIPING(BOSCH VE, LUCAS CAV) .....................................673 CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING........................................675 REPLACEMENT OF FUEL RETURN PIPING(BOSCH VE, LUCAS CAV) .................................676 CLEANING AND INSPECTION OF FUEL DRAIN PIPING............................................678 REPLACEMENT OF LOW-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV)...............................678 CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING.........................................679 REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE(BOSCH VE) .......................................680 WATER PUMP......................................................................................681 DISASSEMBLY AND ASSEMBLY DRAWING............................................................681 REPLACEMENT OF WATER PUMP...................................................................682 INSPECTION..................................................................................683 FAN HUB.........................................................................................683 REPLACEMENT OF FAN PULLEY...................................................................683 REPLACEMENT OF FAN HUB......................................................................684 INSPECTION..................................................................................684 DISASSEMBLY.................................................................................685 ASSEMBLY ..................................................................................686 BELT TENSIONER..................................................................................688 DISASSEMBLY AND ASSEMBLY DRAWING............................................................688 REPLACEMENT OF BELT.........................................................................689 REPLACEMENT OF BELT TENSIONER...............................................................689 INSPECTION..................................................................................689 THERMOSTAT......................................................................................690 DISASSEMBLY AND ASSEMBLY DRAWING............................................................690 REPLACEMENT OF THERMOSTAT...................................................................691 INSPECTION..................................................................................692 FAN.............................................................................................694 COOLANT.........................................................................................694 FILLING WITH WATER..........................................................................695 ACCESSORY DRIVE ADAPTER.........................................................................696 DISASSEMBLY AND ASSEMBLY DRAWING............................................................696 CLEANING ..................................................................................697 INSPECTION .................................................................................697 DISASSEMBLY ................................................................................697 ASSEMBLY ...................................................................................698 DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD................................................700 CLEANING ...............................................................................701 INSPECTION .............................................................................702 ASSEMBLY ..............................................................................706 REPLACEMENT OF AIR COMPRESSOR...............................................................709 REMOVAL.................................................................................709 POWER STEERING COUPLING(WHEN USED) .....................................................711 INSTALLATION............................................................................712 CLEANING AND INSPECTION.....................................................................714 INSPECTION..............................................................................714 ALTERNATOR......................................................................................715 REPLACEMENT OF ALTERNATOR...................................................................715 INSPECTION..................................................................................716 STARTING MOTOR..................................................................................716 REPLACEMENT OF STARTING MOTOR...............................................................716 INSPECTION..................................................................................717 REPLACE HYDRAULIC SWITCH................................................................717 REPLACEMENT OF WATER TEMPERATURE SENSOR.................................................717 14 MAINTENANCE STANDARD.............................................................................719 TURBOCHARGER....................................................................................720 EXHAUST MANIFOLD................................................................................722 CYLINDER HEAD...................................................................................724 VALVE, VALVE GUIDE..............................................................................726 LOCKER ARM SHAFT, PUSH ROD AND TAPPET...........................................................728 CYLINDER BLOCK..................................................................................730 CYLINDER .....................................................................................734 CRANKSHAFT ....................................................................................736 CAMSHAFT ......................................................................................738 TIMING GEAR.....................................................................................742 PISTON, PISTON RING AND PISTON PIN..............................................................744 CONNECTING ROD..................................................................................746 VIBRATION DAMPER................................................................................748 FLYWHEEL, FLYWHEEL HOUSING......................................................................750 FAN HUB.........................................................................................752 OIL PUMP ......................................................................................753 WATER PUMP, THERMOSTAT..........................................................................754 FUEL INJECTION PUMP ............................................................................755 FUEL INJECTION NOZZLE...........................................................................756 15 REPAIR AND REPLACEMENT OF PARTS..................................................................759 OUTLINE.........................................................................................760 REPAIR GUIDELINE............................................................................760 WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT...............................................760 INSPECTION..................................................................................760 TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL.........................................760 FOLLOW WASHING METHODS GIVEN IN MANUAL......................................................760 FOLLOW INSPECTION METHODS GIVEN IN MANUAL...................................................760 REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT..............................................761 METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS.................762 METHOD FOR REPAIRING TRPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS.............765 METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS...............................................766 PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK................................................767 INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK...............................................767 INSPECTION AND INSTALLATION OF VALVE GUIDE......................................................768 PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE...........................................769 PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE...........................................770 OUTLINE OF VALVE SEAT REPAIR....................................................................770 CALCULATING GRINDING DEPTH OF VALVE SEAT........................................................771 METHOD OF GRINDING VALVE SEAT...................................................................771 METHOD OF INSTALLING VALVE SEAT.................................................................775 MACHINING EXHAUST VALVE INSERT POCKET...........................................................775 REPLACING VALVE SEAT........................................................................778 METHOD OF GRINDING VALVE........................................................................779 CHECKING TENSION OF VALVE SPRING............................................................780 ASSEMBLY OF CYLINDER HEAD.......................................................................781 PROCEDURE FOR REPAIRING CYLINDER BLOCK..........................................................782 COMBUSTION DECK.............................................................................782 CAM BORE ..................................................................................783 OUTLINE OF REPAIR OF CYLINDER BORE ........................................................784 CYLINDER BORE .............................................................................784 INSTALLATION OF REPAIR SLEEVE...............................................................786 PROCEDURE FOR REPAIRING CRANKSHAFT..............................................................790 REPAIR TOOLS................................................................................790 OUTLINE OF GRINDING GRANKSHAFT..............................................................790 REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL............................................791 REGRINDING CRANKSHAFT JOURNAL RADIUS........................................................792 SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL.........................................793 REGRINDING CRANKSHAFT ROD JOURNAL RADIUS....................................................793 OPTIONAL PROCEDURE..........................................................................794 PROCEDURE FOR REPAIRING CONNECTING ROD..........................................................795 REMOVAL OF PIN BORE BUSHING.................................................................795 INSTALLATION OF PIN BORE BUSHING............................................................797 MACHINING OF CONNECTING ROD BUSHING.........................................................799 INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD......................................800 TESTING ALIGNMENT OF CONNECTING ROD.........................................................801 INSPECTION OF TWISTING OF CONNECTING ROD....................................................801 REPLACING VALVE SEAT INSERT.................................................................802 PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS.........................................805 UNDER COVER.............................................................................................806
DESCRIPTION:
KOMATSU 102 SERIES DIESEL ENGINE SHOP MANUAL YEBM200101 – PDF DOWNLOAD
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.
S.S 21/12/24
