Komatsu Engine 102E-1 102E-2 series workshop service manual

Description Komatsu Engine 102E-1 102E-2 series workshop service manual

Komatsu Engines 4D102E-1, S4D102E-1, 6D102E-1, S6D102E-1, SA6D102E-1, SAA4D102E-2, SAA6D102E-2 series pdf workshop service & repair manual

Technical data, specifications, testing, troubleshooting, maintenance, adjusting, schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
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
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER)
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER)
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)
TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)
MEASURING EXHAUST RESISTANCE
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE
ADJUSTING VALVE CLEARANCE
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM
FUEL INJECTION PUMP CALIBRATION DATA
RUNNING IN STANDARD
PERFORMANCE TEST CRITERIA
TROUBLESHOOTINGDEFECTIVE ACTUATION OFFEED PUMP (DIAPHRAGM TYPE)
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)
TESTING AIR INSIDE FUEL SYSTEM
TESTING WATER SEPARATOR,FUEL FILTER
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV)
TESTING HIGH-PRESSURE FUEL PIPING
TESTING FUEL INJECTION NOZZLE
TESTING FUEL DRAIN PIPING
BLEEDING AIR FROM FUEL SYSTEM
ADJUSTING FUEL INJECTION TIMING
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)
REPLACING FUEL INJECTION NOZZLE
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM
TESTING CARBON DEPOSIT IN AIR COMPRESSOR
TESTING AIR LEAKAGE FROM AIR COMPRESSOR
TESTING AIR GOVERNOR, UNLOADER VALVE
TESTING AIR GOVERNOR
TESTING BATTERY
TESTING BATTERY TERMINAL CONNECTIONS
TESTING STARTING CIRCUIT
TESTING ALTERNATOR
TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR
TESTING WHITE SMOKE
TESTING INTAKE HEATER
SIDE VIEW OF ENGINE
OUTLINE OF ENGINE PERFORMANCE TEST
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE
ENGINE DYNAMOMETER
ENGINE PAINTWORK
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE

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 AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER)
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 OILSEAL
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 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
REPLACEMENT OF CONNECTING ROD BEARING
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 OF FUEL FILTER
FUEL PIPING
WATER PUMP
FAN HUB
BELT TENSIONER
THERMOSTAT
FAN
COOLANT
ACCESSORY DRIVE ADAPTER
DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD
ALTERNATOR
STARTING MOTOR

MAINTENANCE STANDARD
TURBOCHARGER
EXHAUST MANIFOLD
CYLINDER HEAD
VALVE, VALVE GUIDE
LOCKER ARM SHAFT, PUSH ROD AND TAPPET
CYLINDER BLOCK
CYLINDER
CRANKSHAFT
CAMSHAFT
TIMING GEAR
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
VIBRATION DAMPER
FLYWHEEL, FLYWHEEL HOUSING
FAN HUB
OIL PUMP
WATER PUMP, THERMOSTAT
FUEL INJECTION PUMP
FUEL INJECTION NOZZLE

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 INSET POCKET
METHOD OF GRINDING VALVE
ASSEMBLY OF CYLINDER HEAD
PROCEDURE FOR REPAIRING CYLINDER BLOCK
PROCEDURE FOR REPAIRING CRANKSHAFT
PROCEDURE FOR REPAIRING CONNECTING ROD