Komatsu 102 Series Diesel Engine Shop Manual YEBM200101

Description

• Model List:
  • 102 Series Diesel Engine

• 0.0.1. HOW TO READ THE SHOP MANUAL
• 0.0.2. HOISTING INSTRUCTIONS
• 0.0.3. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 0.0.4. COATING MATERIALS
• 0.0.5. STANDARD TIGHTENING TORQUE
• 0.0.6. ELECTRIC WIRE CODE
• 0.0.7. UNITS
• 0.0.8. CAPSCREW MARKINGS AND TORQUE VALUES
• 0.0.9. PIPE PLUG TORQUE VALUES
• 0.0.10. SYMBOLS
• 0.0.11. ILLUSTRATIONS
• 0.1. GENERAL
• 0.1.1. APPLICABLE MACHINE
• 0.1.2. GENERAL ASSEMBLY DRAWING
• 0.1.3. ENGINE PERFORMANCE CURVE
• 0.1.4. WEIGHT TABLE
• 0.2. STRUCTURE AND FUNCTION
• 0.2.1. OUTLINE OF AIR INTAKE AND EXHAUST SYSTEMS
• 0.2.2. INTAKE AND EXHAUST DEVICES
• 0.2.3. AIR CLEANER
• 0.2.4. TURBOCHARGER
• 0.2.5. CYLINDER HEAD
• 0.2.6. CYLINDER BLOCK
• 0.2.7. MAIN MOVING PARTS
• 0.2.8. TIMING GEAR PORTION
• 0.2.9. FRONT GEAR COVER
• 0.2.10. CAMSHAFT TIMING PIN
• 0.2.11. VALVE MECHANISM
• 0.2.12. FLYWHEEL, FLYWHEEL HOUSING
• 0.2.13. LUBRICATION SYSTEM DIAGRAM
• 0.2.14. OIL PUMP
• 0.2.15. OIL FILTER, OIL COOLER
• 0.2.16. REGULATOR VALVE, SAFETY VALVE
• 0.2.17. FUEL SYSTEM DIAGRAM
• 0.2.18. FUEL INJECTION PUMP
• 0.2.19. TIMING LOCK PIN FOR FUEL INJECTION PUMP
• 0.2.20. FUEL FILTER
• 0.2.21. FUEL INJECTION NOZZLE
• 0.2.22. FUEL CUT SOLENOID
• 0.2.23. COOLING SYSTEM DIAGRAM
• 0.2.24. WATER PUMP
• 0.2.25. THERMOSTAT
• 0.2.26. FAN DRIVE
• 0.2.27. AIR COMPRESSOR
• 0.2.28. FLOW DIAGRAMSCOMPRESSED AIR SYSTEM
• 0.2.29. ALTERNATOR
• 0.2.30. ALTERNATOR(OPTIONAL)
• 0.2.31. STARTING MOTOR
• 0.2.32. STARTING MOTOR
• 0.2.33. STARTING MOTOR(OPTIONAL)
• 0.2.34. STARTING AID
• 0.3. TEATING AND ADJUSTING
• 0.3.1. SPECIAL TOOL LIST
• 0.3.2. TROUBLESHOOTIN DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM
• 0.3.3. MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION(ENGINE WITH TURBOCHARGER)
• 0.3.4. TESTING TURBOCHARGER WESTGATE VALVE(ENGINE WITH TURBOCHARGER)
• 0.3.5. TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)
• 0.3.6. TESTING ACTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER )
• 0.3.7. REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE(ENGINE WITH TURBOCHARGER)
• 0.3.8. ADJUSTING TURBOCHARGER WESTGATE ACTUATOR(ENGINE WITH TURBOCHARGER)
• 0.3.9. MEASURING EXHAUST RESISTANCE
• 0.3.10. REPLACING TURBOCHARGER(ENGINE WITH TURBOCHARGER)
• 0.3.11. TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE
• 0.3.12. ADJUSTING VALVE CLEARANCE
• 0.3.13. TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM
• 0.3.14. FUEL INJECTION PUMP CALIBRATION DATA
• 0.3.15. RUNNING IN STANDARD
• 0.3.16. PERFORMANCE TEST CRITERIA
• 0.3.17. TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(DIAPHRAGM TYPE)
• 0.3.18. TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(PISTON TYPE)
• 0.3.19. TESING AIR INSIDE FUEL SYSTEM
• 0.3.20. TESING WATER SEPARATOR FUEL FILTER
• 0.3.21. TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP(BOSCH VE, LUCAS CAV)
• 0.3.22. TESTING HIGHPRESSURE FUEL PIPING
• 0.3.23. TESING FUEL INJECTION NOZZLE
• 0.3.24. TESING FUEL DRAIN PIPING
• 0.3.25. BLEEDING AIR FROM FUEL SYSTEM
• 0.3.26. ADJUSTING FUEL INJECTION TIMING
• 0.3.27. ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)
• 0.3.28. REPLACING FUEL INJECTION NOZZLE
• 0.3.29. TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM
• 0.3.30. TESTING CARBON DEPOSIT IN AIR COMPRESSOR
• 0.3.31. TESING AIR LEAKAGE FROM AIR COMPRESSOR
• 0.3.32. TESING AIR GOVERNOR, UNLOADER VALVE
• 0.3.33. TESING AIR GOVERNOR
• 0.3.34. TESING BATTERY
• 0.3.35. TESING BATTERY TERMINAL CONNCTIONS
• 0.3.36. TESTING STARTING CIRCUIT
• 0.3.37. TESING ALTERNATOR
• 0.3.38. TESING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR
• 0.3.39. TESING WHITE SMOKE
• 0.3.40. TESING INTAKE HEATER
• 0.3.41. SIDE VIEW OF ENGINE
• 0.3.42. OUTLINE OF ENGINE PERFORMANCE TEST
• 0.3.43. BLOWBY MEASUREMENT AND REPLACEMENT TABLE
• 0.3.44. ENGINE DYNAMOMETER
• 0.3.45. ENGINE PAINWORK
• 0.3.46. TROUBLESHOOTING
• 0.4. DISASSEMBLY AND ASSEMBLY
• 0.4.1. SPECIAL TOOL LIST
• 0.4.2. OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
• 0.4.3. DISASSEMBLY OF ENGINE
• 0.4.4. ASSEMBLY OF ENGINE
• 0.4.5. INTAKE GROUP
• 0.4.6. REPLACEMENT OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)
• 0.4.7. REPLACEMENT OF AFTERCOOLER, GASKET(ENGINE WITH AFTERCOOLER)
• 0.4.8. REPLACEMENT OF INTAKE CONNECTOR
• 0.4.9. AIR CONNECTOR
• 0.4.10. REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
• 0.4.11. AIR CROSSOVER TUBE
• 0.4.12. EXHAUST GROUP
• 0.4.13. REPLACEMENT OF EXHAUST MANIFOLD, GASKET
• 0.4.14. REPLACEMENT OF TURBOCHARGER
• 0.4.15. TURBOCHARGER MOUNTING STUD(ENGINE WITH TURBOCHARGER)
• 0.4.16. CYLINDER BLOCK GROUP
• 0.4.17. CYLINDER BLOCK
• 0.4.18. CRANKSHAFT
• 0.4.19. REPLACEMENT OF TIMEING PIN
• 0.4.20. REPLACEMENT OF GEAR HOUSING, GASKET
• 0.4.21. REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
• 0.4.22. PISTON, PIN, CONNECTING ROD
• 0.4.23. BALANCER
• 0.4.24. GEAR COVER
• 0.4.25. CYLINDER HEAD
• 0.4.26. ROCKER LEVER
• 0.4.27. TAPPETS AND PUSH RODS
• 0.4.28. ENGINE MOUNT GROUP
• 0.4.29. FLYWHEEL, RING GEAR
• 0.4.30. FLYWHEEL HOUSING
• 0.4.31. FRONT SUPPORT
• 0.4.32. REMOVAL OF ENGINE
• 0.4.33. INSPECTION OF ENGINE MOUNT
• 0.4.34. INSTALLATION OF ENGINE
• 0.4.35. OIL PAN AND SUCTION TUBE
• 0.4.36. REGULATOR VALVE
• 0.4.37. OIL FILTER BYPASS VALVE
• 0.4.38. OIL COOLER
• 0.4.39. OIL PUMP
• 0.4.40. FUEL INJECTION PUMP GROUP
• 0.4.41. FUEL INJECTION NOZZLE GROUP
• 0.4.42. FEED PUMP(CYLINDER BLOCK MOUNT TYPE)
• 0.4.43. REPLACEMENT OF FUEL FILTER
• 0.4.44. FUEL PIPING
• 0.4.45. WATER PUMP
• 0.4.46. FAN HUB
• 0.4.47. BELT TENSIONER
• 0.4.48. THERMOSTAT
• 0.4.50. COOLANT
• 0.4.51. ACCESSORY DRIVE ADAPTER
• 0.4.52. ALTERNATOR
• 0.4.53. STARTING MOTOR
• 0.5. MAINTENANCE STANDARD
• 0.5.1. TURBOCHARGER
• 0.5.2. EXHAUST MANIFOLD
• 0.5.3. CYLINDER HEAD
• 0.5.4. VALVE, VALVE GUIDE
• 0.5.5. LOCKER ARM SHAFT, PUSH ROD AND TAPPET
• 0.5.6. PISTON, PISTON RING AND PISTON PIN
• 0.5.7. CONNECTING ROD
• 0.5.8. VIBRATION DAMPER
• 0.5.9. FLYWHEEL, FLYWHEEL HOUSING
• 0.5.10. FAN HUB
• 0.5.11. OIL PUMP
• 0.5.12. WATER PUMP, THERMOSTAT
• 0.5.13. FUEL INJECTION PUMP
• 0.5.14. FUEL INJECTION NOZZLE
• 0.6. REPAIR AND REPLACEMENT OF PARTS
• 0.6.1. OUTLINE
• 0.6.2. REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT
• 0.6.3. METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS
• 0.6.4. METHOD FOR REPAIRING TRPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS
• 0.6.5. METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS
• 0.6.6. PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK
• 0.6.7. INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK
• 0.6.8. INSPECTION AND INSTALLATION OF VALVE GUIDE
• 0.6.9. PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE
• 0.6.10. PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE
• 0.6.11. OUTLINE OF VALVE SEAT REPAIR
• 0.6.12. CALCULATING GRINDING DEPTH OF VALVE SEAT
• 0.6.13. METHOD OF GRINDING VALVE SEAT
• 0.6.14. METHOD OF INSTALLING VALVE SEAT
• 0.6.15. MACHINING EXHAUST VALVE INSERT POCKET
• 0.6.16. METHOD OF GRINDING VALVE
• 0.6.17. ASSEMBLY OF CYLINDER HEAD
• 0.6.18. PROCEDURE FOR REPAIRING CYLINDER BLOCK
• 0.6.19. PROCEDURE FOR REPAIRING CRANKSHAFT
• 0.6.20. PROCEDURE FOR REPAIRING CONNECTING ROD
• 0.6.21. PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS
• 1. UNDER COVER