Description
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Model List:
- 102 Series Diesel Engine
- 0.1. HOW TO READ THE SHOP MANUAL
- 0.2. HOISTING INSTRUCTIONS
- 0.3. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
- 0.4. COATING MATERIALS
- 0.5. STANDARD TIGHTENING TORQUE
- 0.6. ELECTRIC WIRE CODE
- 0.7. CONVERSTION TABLE
- 0.8. UNITS
- 1. GENERAL
- 1.1. APPLICABLE MACHINE
- 1.2. SPECIFICATIONS
- 1.3. GENERAL ASSEMBLY DRAWING
- 1.4. ENGINE PERFORMANCE CURVE
- 1.5. WEIGHT TABLE
- 2. STRUCTURE AND FUNCTION
- 2.1. GENERAL STRUCTURE
- 2.2. INTAKE AND EXHAUST DEVICES
- 2.3. AIR CLEANER
- 2.4. TURBOCHARGER
- 2.5. CYLINDER HEAD
- 2.6. CYLINDER BLOCK
- 2.7. MAIN MOVING PARTS
- 2.8. TIMING GEAR PORTION
- 2.9. FRONT GEAR COVER
- 2.10. CAMSHAFT TIMING PIN
- 2.11. VALVE MECHANISM
- 2.12. OIL PAN
- 2.13. FLYWHEEL, FLYWHEEL HOUSING
- 2.14. LUBRICATION SYSTEM DIAGRAM
- 2.15. OIL PUMP
- 2.16. OIL FILTER, OIL COOLER
- 2.17. REGULATOR VALVE, SAFETY VALVE
- 2.18. FUEL SYSTEM DIAGRAM
- 2.19. FUEL INJECTION PUMP
- 2.20. TIMING LOCK PIN FOR FUEL INJECTION PUMP
- 2.21. FUEL FILTER
- 2.22. FUEL INJECTION NOZZLE
- 2.23. FUEL CUT SOLENOID
- 2.24. COOLING SYSTEM DIAGRAM
- 2.25. WATER PUMP
- 2.26. THERMOSTAT
- 2.27. FAN DRIVE
- 2.28. AIR COMPRESSOR
- 2.29. FLOW DIAGRAMSCOMPRESSED AIR SYSTEM
- 2.30. ALTERNATOR
- 2.31. STARTING MOTOR
- 2.32. STARTING AID
- 3. TESTING AND ADJUSTING
- 3.1. SPECIAL TOOL LIST
- 3.2. INTAKE AND EXHAUST SYSTEM
- 3.3. ENGINE
- 3.4. LUBRICATING SYSTEM
- 3.5. FUEL SYSTEM
- 3.6. COOLING SYSTEM
- 3.7. COMPONENTS
- 3.8. ELECTRICAL COMPONENTS
- 3.9. PERFORMANCE TEST
- 3.10. TROUBLESHOOTING
- 4. DISASSEMBLY AND ASSEMBLY
- 4.1. SPECIAL TOOL LIST
- 4.2. OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
- 4.3. DISASSEMBLY OF ENGINE
- 4.4. ASSEMBLY OF ENGINE
- 4.5. INTAKE GROUP
- 4.6. REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
- 4.7. REPLACEMENT OF INTAKE CONNECTOR
- 4.8. AIR CONNECTOR
- 4.9. REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
- 4.10. AIR CROSSOVER TUBE
- 4.11. EXHAUST GROUP
- 4.12. REPLACEMENT OF EXHAUST MANIFOLD, GASKET
- 4.13. REPLACEMENT OF EXHAUST MANIFOLD
- 4.14. REPLACEMENT OF TURBOCHARGER
- 4.15. TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER)
- 4.16. CYLINDER BLOCK GROUP
- 4.17. REPLACEMENT OF FRONT OIL SEAL
- 4.18. REPLACEMENT OF REAR OIL SEAL
- 4.19. CYLINDER BLOCK
- 4.20. REMOVAL OF GLAZE FROM CYLINDER BORE
- 4.21. REPLACEMENT OF PLUG
- 4.22. REPLACEMENT OF CAP
- 4.23. INSTALLATION OF CAP AND PLUG
- 4.24. CRANKSHAFT
- 4.25. REPLACEMENT OF CAMSHAFT, GEAR
- 4.26. REPLACEMENT OF TIMING PIN
- 4.27. REPLACEMENT OF GEAR HOUSING, GASKET
- 4.28. REPLACEMENT OF CAMSHAFT GEAR
- 4.29. REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
- 4.30. PISTON, PIN, CONNECTING ROD
- 4.31. REPLACEMENT OF CONNECTING ROD
- 4.32. BALANCER
- 4.33. GEAR COVER
- 4.34. CYLINDER HEAD
- 4.35. ROCKER LEVER
- 4.36. TAPPETS AND PUSH RODS
- 4.37. ENGINE MOUNT GROUP
- 4.38. FLYWHEEL, RING GEAR
- 4.39. FLYWHEEL HOUSING
- 4.40. FRONT SUPPORT
- 4.41. REMOVAL OF ENGINE
- 4.42. INSPECTION OF ENGINE MOUNT
- 4.43. INSTALLATION OF ENGINE
- 4.44. OIL PAN AND SUCTION TUBE
- 4.45. REGULATOR VALVE
- 4.46. OIL FILTER BYPASS VALVE
- 4.47. OIL COOLER
- 4.48. OIL PUMP
- 4.49. FUEL INJECTION PUMP GROUP
- 4.50. FUEL INJECTION NOZZLE GROUP
- 4.51. FEED PUMP (CYLINDER BLOCK MOUNT TYPE)
- 4.52. REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE)
- 4.53. REPLACEMENT OF FUEL FILTER
- 4.54. FUEL PIPING
- 4.55. WATER PUMP
- 4.56. FAN HUB
- 4.57. BELT TENSIONER
- 4.58. THERMOSTAT
- 4.60. COOLANT
- 4.61. COMPONENT DRIVE UNIT
- 4.62. DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD
- 4.63. ALTERNATOR
- 4.64. STARTING MOTOR
- 5. MAINTENANCE STANDARD
- 5.1. INTAKE AND EXHAUST SYSTEM
- 5.2. ENGINE PROPER
- 5.3. LUBRICATING SYSTEM
- 5.4. COOLING SYSTEM
- 5.5. FUEL SYSTEM
- 6. REPAIR AND REPLACEMENT OF PARTS
- 6.1. OUTLINE
- 6.2. REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT
- 6.3. METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS
- 6.4. METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS
- 6.5. METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS
- 6.6. PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK
- 6.7. INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK
- 6.8. INSPECTION AND INSTALLATION OF VALVE GUIDE
- 6.9. PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE
- 6.10. PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE
- 6.11. OUTLINE OF VALVE SEAT REPAIR
- 6.12. CALCULATING GRINDING DEPTH OF VALVE SEAT
- 6.13. METHOD OF GRINDING VALVE SEAT
- 6.14. METHOD OF INSTALLING VALVE SEAT
- 6.15. MACHINING EXHAUST VALVE INSERT POCKET
- 6.16. METHOD OF GRINDING VALVE
- 6.17. ASSEMBLY OF CYLINDER HEAD
- 6.18. PROCEDURE FOR REPAIRING CYLINDER BLOCK
- 6.19. PROCEDURE FOR REPAIRING CRANKSHAFT
- 6.20. PROCEDURE FOR REPAIRING CONNECTING ROD
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