Factory Shop Manual For Komatsu Diesel Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 980
Number: SEBM010019 (may 2004)
Bookmarks: Yes
Searchable: Yes
Model
Komatsu 102 Series Diesel Engine
40102E-1
S4D102E-1
6D102E-1
S6D102E-1
SA6D102E-1
SAA4D102E-2
SAA6D102E-2
Contents
-SAFETY
Safety Notice
-FOREWORD
General
How To Read The Shop Manual
Hoisting Instructions
Method Of Disassembling, Connecting Push-Pull Type Coupler
Coating Materials
Standard Tightening Torque
Electric Wire Code
Conversation Table
Units
-GENERAL
Applicable Machine
Specifications
General Assembly Drawing
Engine Performance Curve
Weight Table
-STRUCTURE AND FUNCTION
General Structure
Intake And Exhaust Devices
Air Cleaner
Turbocharger
Cylinder Head
Cylinder Block
Main Moving Parts
Timing Gear Portion
Front Gear Cover
Camshaft Timing Pin
Valve Mechanism
Oil Pan
Flywheel, Flywheel Housing
Lubrication System Diagram
Oil Pump
Oil Filter, Oil Cooler
Regulator Valve, Safety Valve
Fuel System Diagram
Fuel Injection Pump
Timing Lock Pin For Fuel Injection Pump
Fuel Filter
Fuel Injection Nozzle
Fuel Cut Solenoid
Cooling System Diagram
Water Pump
Thermostat
Fan Drive
Air Compressor
Flow Diagrams-Compressed Air System
Alternator
Starting Motor
Starting Aid
-TESTING AND ADJUSTING
Special Tool List
Intake And Exhaust System
Engine
Lubricating System
Fuel System
Cooling System
Components
Electrical Components
Performance Test
Troubleshooting
-DISASSEMBLY AND ASSEMBLY
Special Tool List
Outline Of Disassembly And Assembly Of Engine
Disassembly Of Engine
Assembly Of Engine
Intake Group
Replacement Of Turbocharger (Engine With Turbocharger)
Replacement Of Intake Connector
Air Connector
Replacement Of Intake Manifold Cover, Gasket
Air Crossover Tube
Exhaust Group
Replacement Of Exhaust Manifold, Gasket
Replacement Of Exhaust Manifold
Replacement Of Turbocharger
Turbocharger Mounting Stud (Engine With Turbocharger)
Cylinder Block Group
Replacement Of Front Oil Seal
Replacement Of Rear Oil Seal
Cylinder Block
Removal Of Glaze From Cylinder Bore
Replacement Of Plug
Replacement Of Cap
Installation Of Cap And Plug
Crankshaft
Replacement Of Camshaft, Gear
Replacement Of Timing Pin
Replacement Of Gear Housing, Gasket
Replacement Of Camshaft Gear
Replacement Of Vibration Damper, Crankshaft Pulley
Piston, Pin, Connecting Rod
Replacement Of Connecting Rod
Balancer
Gear Cover
Cylinder Head
Rocker Lever
Tappets And Push Rods
Engine Mount Group
Flywheel, Ring Gear
Flywheel Housing
Front Support
Removal Of Engine
Inspection Of Engine Mount
Installation Of Engine
Oil Pan And Suction Tube
Regulator Valve
Oil Filter Bypass Valve
Oil Cooler
Oil Pump
Fuel Injection Pump Group
Fuel Injection Nozzle Group
Feed Pump (Cylinder Block Mount Type)
Replacement, Assembly Of Feed Pump (Piston Type)
Replacement Of Fuel Filter
Fuel Piping
Water Pump
Fan Hub
Belt Tensioner
Thermostat
Fan
Coolant
Component Drive Unit
Disassembly Of Unloader Valve, Cylinder Head
Alternator
Starting Motor
-MAINTENANCE STANDARD
Intake And Exhaust System
Engine Proper
Lubricating System
Cooling System
Fuel System
-REPAIR AND REPLACEMENT OF PARTS
Outline
Repair Methods For Screws Using Coil Thread Insert
Method For Using Taper Thread Plugs To Seal Pockets And Small Holes In Castings
Method For Repairing Taper Thread Plug Holes Worn By Large Size Copper Plated Plugs
Method Of Using Filler Metal In Emergency Repairs
Procedure And Tools For Repairing Cylinder Block
Inspection And Grinding To Repair Combustion Deck
Inspection And Installation Of Valve Guide
Procedure 1 For Building Up Using Service Valve Guide
Procedure 2 For Building Up Using Service Valve Guide
Outline Of Valve Seat Repair
Calculating Grinding Depth Of Valve Seat
Method Of Grinding Valve Seat
Method Of Installing Valve Seat
Machining Exhaust Valve Insert Pocket
Method Of Grinding Valve
Assembly Of Cylinder Head
Procedure For Repairing Cylinder Block
Procedure For Repairing Crankshaft
Procedure For Repairing Connecting Rod
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