komatsu 102 series diesel engine shop manual sebm010023 1 1

komatsu 102 series diesel engine shop manual sebm010023 2 1

komatsu 102 series diesel engine shop manual sebm010023 3 1

komatsu 102 series diesel engine shop manual sebm010023 4 2

komatsu 102 series diesel engine shop manual sebm010023 5 1

Komatsu 102 Series Diesel Engine Shop Manual SEBM010023

$40.00

Type Of Manual: Shop Manual
Manual ID: SEBM010023
Format: PDF
Size: 33.6MB
Number of Pages: 980

Category: Komatsu Shop Manual PDF

Model List:
- 102 Series Diesel Engine

1. COVER
2. CONTENTS
3. GENERAL
3.1. APPLICABLE MACHINE
3.2. SPECIFICATIONS
3.3. GENERAL ASSEMBLY DARWING
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. TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED 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 BATTERY
5.34. TESTING BATTERY TERMINAL CONNECTIONS
5.35. TESTING STARTING CIRCUIT
5.36. TESTING ALTERNATOR
5.37. TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR
5.38. TESTING WHITE SMOKE
5.39. TESTING INTAKE HEATER
5.40. SIDE VIEW OF ENGINE
5.41. OUTLINE OF ENGINE PERFORMANCE TEST
5.42. BLOWBY MEASUREMENT AND REPLACEMENT TABLE
5.43. ENGINE DYNAMOMETER
5.44. ENGINE PAINTWORK
5.45. TROUBLESHOOTING
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 OIL SEAL
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 OF VIBRATION 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. REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET
6.47. REGULATOR VALVE
6.48. OIL FILTER BYPASS VALVE
6.49. OIL COOLER
6.50. OIL PUMP
6.51. FUEL INJECTION PUMP GROUP
6.52. FUEL INJECTION NOZZLE GROUP
6.53. FEED PUMP (CYLINDER BLOCK MOUNT TYPE)
6.54. REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE)
6.55. REPLACEMENT OF FUEL FILTER
6.56. FUEL PIPING
6.57. WATER PUMP
6.58. FAN HUB
6.59. BELT TENSIONER
6.60. THERMOSTAT
6.62. COOLANT
6.63. ACCESSORY DRIVE ADAPTER
6.64. DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD
6.65. ALTERNATOR
6.66. 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

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