Komatsu 102 Series Diesel Engine Shop Manual SEBM010025

Description

• Model List:
  • 102 Series Diesel Engine

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. APPLICABLE MACHINE
• 3.2. SPECIFICATIONS
• 3.3. GENERAL ASSEMBLY DRAWING
• 3.4. ENGINE PERFORMANCE CURVE
• 3.5. WEIGHT TABLE
• 4. STRUCTURE AND FUNCTION
• 4.1. GENERAL STRUCTURE
• 4.2. INTAKE AND EXHAUST DEVICES
• 4.3. AIR CLEANER
• 4.4. TURBOCHARGER
• 4.5. CYLINDER HEAD
• 4.6. CYLINDER BLOCK
• 4.7. MAIN MOVING PARTS
• 4.8. TIMING GEAR PORTION
• 4.9. FRONT GEAR COVER
• 4.10. CAMSHAFT TIMING PIN
• 4.11. VALVE MECHANISM
• 4.12. OIL PAN
• 4.13. FLYWHEEL, FLYWHEEL HOUSING
• 4.14. LUBRICATION SYSTEM DIAGRAM
• 4.15. OIL PUMP
• 4.16. OIL FILTER, OIL COOLER
• 4.17. REGULATOR VALVE, SAFETY VALVE
• 4.18. FUEL SYSTEM DIAGRAM
• 4.19. FUEL INJECTION PUMP
• 4.20. TIMING LOCK PIN FOR FUEL INJECTION PUMP
• 4.21. FUEL FILTER
• 4.22. FUEL INJECTION NOZZLE
• 4.23. FUEL CUT SOLENOID
• 4.24. COOLING SYSTEM DIAGRAM
• 4.25. WATER PUMP
• 4.26. THERMOSTAT
• 4.27. FAN DRIVE
• 4.28. AIR COMPRESSOR
• 4.29. FLOW DIAGRAMSCOMPRESSED AIR SYSTEM
• 4.30. ALTERNATOR
• 4.31. STARTING MOTOR
• 4.32. STARTING AID
• 5. TESTING AND ADJUSTING
• 5.1. SPECIAL TOOL LIST
• 5.2. TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM
• 5.3. MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER)
• 5.4. TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER)
• 5.5. TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)
• 5.6. TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)
• 5.7. REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER
• 5.8. ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)
• 5.9. MEASURING EXHAUST RESISTANCE
• 5.10. REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)
• 5.11. TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE
• 5.12. ADJUSTING VALVE CLEARANCE
• 5.13. TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM
• 5.14. FUEL INJECTION PUMP CALIBRATION DATA
• 5.15. RUNNING IN STANDARD
• 5.16. PERFORMANCE TEST CRITERIA
• 5.17. TROUBLESHOOTINGDEFECTIVE ACTUATION OFFEED PUMP (DIAPHRAGM TYPE)
• 5.18. TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)
• 5.19. TESTING AIR INSIDE FUEL SYSTEM
• 5.20. TESTING WATER SEPARATOR,FUEL FILTER
• 5.21. TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV)
• 5.22. TESTING HIGHPRESSURE FUEL PIPING
• 5.23. TESTING FUEL INJECTION NOZZLE
• 5.24. TESTING FUEL DRAIN PIPING
• 5.25. BLEEDING AIR FROM FUEL SYSTEM
• 5.26. ADJUSTING FUEL INJECTION TIMING
• 5.27. ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)
• 5.28. REPLACING FUEL INJECTION NOZZLE
• 5.29. TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM
• 5.30. TESTING CARBON DEPOSIT IN AIR COMPRESSOR
• 5.31. TESTING AIR LEAKAGE FROM AIR COMPRESSOR
• 5.32. TESTING AIR GOVERNOR, UNLOADER VALVE
• 5.33. TESTING AIR GOVERNOR
• 5.34. TESTING BATTERY
• 5.35. TESTING BATTERY TERMINAL CONNECTIONS
• 5.36. TESTING STARTING CIRCUIT
• 5.37. TESTING ALTERNATOR
• 5.38. TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR
• 5.39. TESTING WHITE SMOKE
• 5.40. TESTING INTAKE HEATER
• 5.41. SIDE VIEW OF ENGINE
• 5.42. OUTLINE OF ENGINE PERFORMANCE TEST
• 5.43. BLOWBY MEASUREMENT AND REPLACEMENT TABLE
• 5.44. ENGINE DYNAMOMETER
• 5.45. ENGINE PAINTWORK
• 5.46. TROUBLESHOOTING
• 5.47. TROUBLESHOOTING OF ENGINE
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. SPECIAL TOOL LIST
• 6.2. OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
• 6.3. DISASSEMBLY OF ENGINE
• 6.4. ASSEMBLY OF ENGINE
• 6.5. INTAKE GROUP
• 6.6. REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
• 6.7. REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER)
• 6.8. REPLACEMENT OF INTAKE CONNECTOR
• 6.9. AIR CONNECTOR
• 6.10. REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
• 6.11. AIR CROSSOVER TUBE
• 6.12. EXHAUST GROUP
• 6.13. REPLACEMENT OF EXHAUST MANIFOLD, GASKET
• 6.14. REPLACEMENT OF EXHAUST MANIFOLD
• 6.15. REPLACEMENT OF TURBOCHARGER
• 6.16. TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER)
• 6.17. CYLINDER BLOCK GROUP
• 6.18. REPLACEMENT OF FRONT OILSEAL
• 6.19. REPLACEMENT OF REAR OIL SEAL
• 6.20. CYLINDER BLOCK
• 6.21. REMOVAL OF GLAZE FROM CYLINDER BORE
• 6.22. REPLACEMENT OF PLUG
• 6.23. REPLACEMENT OF CAP
• 6.24. INSTALLATION OF CAP AND PLUG
• 6.25. CRANKSHAFT
• 6.26. REPLACEMENT OF TIMING PIN
• 6.27. REPLACEMENT OF GEAR HOUSING, GASKET
• 6.28. REPLACEMENT OF CAMSHAFT GEAR
• 6.29. REPLACEMENT OFVIBRATION DAMPER, CRANKSHAFT PULLEY
• 6.30. PISTON, PIN, CONNECTING ROD
• 6.31. REPLACEMENT OF CONNECTING ROD
• 6.32. REPLACEMENT OF CONNECTING ROD BEARING
• 6.33. BALANCER
• 6.34. GEAR COVER
• 6.35. CYLINDER HEAD
• 6.36. ROCKER LEVER
• 6.37. TAPPETS AND PUSH RODS
• 6.38. ENGINE MOUNT GROUP
• 6.39. FLYWHEEL, RING GEAR
• 6.40. FLYWHEEL HOUSING
• 6.41. FRONT SUPPORT
• 6.42. REMOVAL OF ENGINE
• 6.43. INSPECTION OF ENGINE MOUNT
• 6.44. INSTALLATION OF ENGINE
• 6.45. OIL PAN AND SUCTION TUBE
• 6.46. REGULATOR VALVE
• 6.47. OIL FILTER BYPASS VALVE
• 6.48. OIL COOLER
• 6.49. OIL PUMP
• 6.50. FUEL INJECTION PUMP GROUP
• 6.51. FUEL INJECTION NOZZLE GROUP
• 6.52. FEED PUMP (CYLINDER BLOCK MOUNT TYPE)
• 6.53. REPLACEMENT OF FUEL FILTER
• 6.54. FUEL PIPING
• 6.55. WATER PUMP
• 6.56. FAN HUB
• 6.57. BELT TENSIONER
• 6.58. THERMOSTAT
• 6.60. COOLANT
• 6.61. ACCESSORY DRIVE ADAPTER
• 6.62. DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD
• 6.63. ALTERNATOR
• 6.64. STARTING MOTOR
• 7. MAINTENANCE STANDARD
• 7.1. TURBOCHARGER
• 7.2. EXHAUST MANIFOLD
• 7.3. CYLINDER HEAD
• 7.4. VALVE, VALVE GUIDE
• 7.5. LOCKER ARM SHAFT, PUSH ROD AND TAPPET
• 7.6. PISTON, PISTON RING AND PISTON PIN
• 7.7. CONNECTING ROD
• 7.8. VIBRATION DAMPER
• 7.9. FLYWHEEL, FLYWHEEL HOUSING
• 7.10. FAN HUB
• 7.11. OIL PUMP
• 7.12. WATER PUMP, THERMOSTAT
• 7.13. FUEL INJECTION PUMP
• 7.14. FUEL INJECTION NOZZLE
• 8. REPAIR AND REPLACEMENT OF PARTS
• 8.1. OUTLINE
• 8.2. REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT
• 8.3. METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS
• 8.4. METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS
• 8.5. METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS
• 8.6. PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK
• 8.7. INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK
• 8.8. INSPECTION AND INSTALLATION OF VALVE GUIDE
• 8.9. PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE
• 8.10. PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE
• 8.11. OUTLINE OF VALVE SEAT REPAIR
• 8.12. CALCULATING GRINDING DEPTH OF VALVE SEAT
• 8.13. METHOD OF GRINDING VALVE SEAT
• 8.14. METHOD OF INSTALLING VALVE SEAT
• 8.15. MACHINING EXHAUST VALVE INSET POCKET
• 8.16. METHOD OF GRINDING VALVE
• 8.17. ASSEMBLY OF CYLINDER HEAD
• 8.18. PROCEDURE FOR REPAIRING CYLINDER BLOCK
• 8.19. PROCEDURE FOR REPAIRING CRANKSHAFT
• 8.20. PROCEDURE FOR REPAIRING CONNECTING ROD