Komatsu 102 Series Diesel Engine Workshop Repair Manual 4D102E 6D102E SAA6D102E PDF - MKMTSENG102.zip
This is a full workshop, service, and repair guide for Komatsu 102 Series Diesel Engines, complete with electrical wiring diagrams. It contains every technical detail needed to service, troubleshoot, overhaul, and rebuild these engines to the same standard as professional technicians.
The Komatsu 102 Series Diesel Engines workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM010019 - Komatsu 102 Series Diesel Engines (4D102E-1, S4D102E-1, 6D102E-1, S6D102E-1, SA6D102E-1, SAA4D102E-2, SAA6D102E-2) Shop Manual.pdf
SEBM010021 - Komatsu 102 Series Diesel Engines (4D102E-1, S4D102E-1, 6D102E-1, S6D102E-1, SA6D102E-1, SAA4D102E-2, SAA6D102E-2) Shop Manual.pdf
SEBM010023 - Komatsu 102 Series Diesel Engines Shop Manual.pdf
SRBM010005 - Komatsu 102 СЕРИЯ ДИЗЕЛЬНЫЙ ДВИГАТЕЛЬ Shop Manual (RU).pdf
PRODUCT DETAILS:
Total Pages: 3,749 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
CONTENTS...2
01 GENERAL...33
APPLICABLE MACHINE...34
SPECIFICATIONS...36
GENERAL ASSEMBLY DARWING...54
ENGINE PERFORMANCE CURVE...76
WEIGHT TABLE...116
11 STRUCTURE AND FUNCTION...118
GENERAL STRUCTURE...119
INTAKE AND EXHAUST DEVICES...121
AIR CLEANER...130
TURBOCHARGER...131
CYLINDER HEAD...135
CYLINDER BLOCK...142
MAIN MOVING PARTS...148
TIMING GEAR PORTION...155
FRONT GEAR COVER...156
CAMSHAFT TIMING PIN...157
VALVE MECHANISM...158
OIL PAN...162
FLYWHEEL,FLYWHEEL HOUSING...164
LUBRICATION SYSTEM DIAGRAM...167
OIL PUMP...174
OIL FILTER,OIL COOLER...175
REGULATOR VALVE,SAFETY VALVE...178
FUEL SYSTEM DIAGRAM...179
FUEL INJECTION PUMP...188
TIMING LOCK PIN FOR FUEL INJECTION PUMP...192
FUEL FILTER...193
FUEL INJECTION NOZZLE...194
FUEL CUT SOLENOID...195
COOLING SYSTEM DIAGRAM...196
WATER PUMP...200
THERMOSTAT...201
FAN DRIVE...202
AIR COMPRESSOR...206
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM...208
ALTERNATOR...210
STARTING MOTOR...217
STARTING AID...220
12 TESTING AND ADJUSTING...221
SPECIAL TOOL LIST...223
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM...223
SPECIAL TOOLS FOR ENGINE...224
SPECIAL TOOLS FOR FUEL SYSTEM...226
SPECIAL TOOLS FOR COMPONENTS...227
SPECIAL TOOLS FOR ELECTRICAL COMPONENTS...228
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST...229
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM...231
CLEAN AIR...231
TESTING INTAKE RESISTANCE...231
DAMAGE CAUSED BY UNFILTERED AIR...232
LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER)...232
LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER)...233
MEASURING PRESSURE OF TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER)...233
DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...234
OIL CONSUMPTION AND OIL LEAKAGE...234
NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)...235
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER)...236
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER)...237
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)...238
TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)...238
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER...239
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)...241
MEASURING EXHAUST RESISTANCE...242
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)...242
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE...243
VALVE MECHANISM AND CYLINDER HEAD...243
TESTING AIR SYSTEM AND FUEL SYSTEM...243
TESTING VALVE CLEARANCE...244
TESTING COMPRESSION...244
PISTON RING SEALING PERFORMANCE...244
VALVE SEALING PERFORMANCE...245
HEAD GASKET SEALIN PERFORMANCE...245
VALVE SEAL WEAR...246
PROTRUDING PORTION OF FUEL INJECTION NOZZLE...247
FRONT GEAR HOUSING AND GEAR TRAIN...248
VIBRATION DAMPER...248
ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT...249
PISTON AND CONNECTING ROD...250
CRANKSHAFT AND MAIN BEARING...252
CYLINDER BLOCK...253
FLYWHEEL HOUSING AND FLYWHEEL...254
ADJUSTING VALVE CLEARANCE...255
ADJUSTING 4-CYLINDER ENGINE...256
ADJUSTING 6-CYLINDER ENGINE...257
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM...258
OUTLINE...258
HIGH PRESSURE...258
REGULATOR VALVE...258
LOW PRESSURE...259
OIL LEVEL...259
OIL FILTER...259
OIL PRESSURE GAUGE...260
OIL PAN SUCTION TUBE...260
BEARING AND OIL PUMP...260
UNSUITABLE OIL PUMP...260
DILUTION OF OIL...261
COOLING WATER IN OIL...261
FUEL IN OIL...262
FUEL INJECTION PUMP CALIBRATION DATA...265
RUNNING IN STANDARD...321
PERFORMANCE TEST CRITERIA...327
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (DIAPHRAGM TYPE)...345
TESTING FEED PUMP...345
TEST 1:TESTING OUTPUT PRESSURE...345
TEST 2:TESTING FLOW...346
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)...347
TEST 1:TESTING OUTPUT PRESSURE...348
TEST 2:TESTING FLOW...349
TESTING AIR INSIDE FUEL SYSTEM...352
TESTING WATER SEPARATOR,FUEL FILTER...353
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV)...355
DEFECTIVE ACTUATION OF GOVERNOR...356
STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT...356
LUCAS CAV ADJUSTMENT SCREW...356
BOSCH VE ADJUSTMENT SCREW...357
MANUAL SHUT-OFF LEVER...357
TIMING PROPULSION ANGLE MECHANISM...358
ELECTRICAL SHUT-OFF VALVE...358
DELIVERY VALVE (LUCAS CAV)...360
TESTING HIGH-PRESSURE FUEL PIPING...361
TESTING FUEL INJECTION NOZZLE...362
TESTING FUEL DRAIN PIPING...364
BLEEDING AIR FROM FUEL SYSTEM...364
BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER...365
BLEEDING AIR FROM FUEL INJECTION PUMP...365
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT...366
ADJUSTING FUEL INJECTION TIMING...366
ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE...369
ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV...370
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)...371
REPLACING FUEL INJECTION NOZZLE...371
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM...375
TROUBLESHOOTING...375
RADIATOR CAP...377
WATER PUMP...378
RADIATOR, FAN, AND RADIATOR SHUTTER...379
THERMOSTAT...381
WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD...382
TESTING CARBON DEPOSIT IN AIR COMPRESSOR...383
TESTING AIR LEAKAGE FROM AIR COMPRESSOR...384
TESTING AIR GOVERNOR, UNLOADER VALVE...385
TESTING BATTERY...388
TESTING BATTERY TERMINAL CONNECTIONS...389
TESTING STARTING CIRCUIT ...389
TESTING BATTERY RELAY...389
TESTING STARTING SWITCH...391
TESTING STARTING MOTOR AND MAGNETIC SWITCH...392
TESTING DROP IN CRANKING SPEED...394
TESTING ALTERNATOR...395
ABNORMAL DISPLAY OF CHARGE LAMP...396
ABNORMAL ACTUATION OF CHARGING SYSTEM...397
TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR...398
TESTING OIL PRESSURE SWITCH...398
TESTING WATER TEMPERATURE SENSOR...399
TESTING WHITE SMOKE...400
NORMAL AUTUATION OF INTAKE HEATER SYSTEM...400
TESTING INTAKE HEATER...401
TESTING PREHEATING CYCLE...402
SIDE VIEW OF ENGINE...403
OUTLINE OF ENGINE PERFORMANCE TEST ...405
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE...406
ENGINE DYNAMOMETER ...407
INSTALLING ENGINE...407
PROCEDURE FOR RUNNING IN NEGINE...414
ENGINE PERFORMANCE TEST...417
ENGINE PAINTWORK...419
TROUBLESHOOTING...421
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...422
TROUBLESHOOTING OF ENGINE...443
METHOD OF USING TROUBLESHOOTING CHARTS...444
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...448
S-2 ENGINE DOES NOT START...450
(1) ENGINE DOES NOT TURN...450
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...451
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...452
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...453
S-4 ENGINE STOPS DURING OPERATIONS...454
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING)...455
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...456
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...457
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...458
S-9 OIL BECOMES CONTAMINATED QUICKLY...459
S-10 FUEL CONSUMPTION IS EXCESSIVE...460
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...461
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...462
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...463
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...464
S-15 ABNORMAL NOISE IS MADE...465
S-16 VIBRATION IS EXCESSIVE...466
13 DISASSEMBLY AND ASSEMBLY...467
SPECIAL TOOL LIST...472
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY...472
SPECIAL TOOLS FOR ENGINE...474
SPECIAL TOOLS FOR FUEL SYSTEM...476
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE ...478
OUTLINE...478
DISASSEMBLY...478
ASSEMBLY...478
DISASSEMBLY OF ENGINE...479
STEAM CLEANING OF ENGINE...479
REMOVAL OF STARTING MOTOR...479
WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER)...479
INSTALLATION TO ENGINE STAND...479
DRAINING OIL...480
REMOVAL OF REAR LIFTING BRACKET...480
REMOVEL OF BELT...480
REMOVAL OF FAN PULLEY...481
REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY...481
REMOVAL OF BELT TENSIONER...481
REMOVAL OF FAN HUB...482
REMOVAL OF ALTERNATOR...482
REMOVAL OF THERMOSTAT...483
REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)...483
REMOVAL OF EXHAUST MANIFOLD...485
REMOVAL OF FUEL FILTER...485
REMOVAL OF FUEL FILTER HEAD...486
REMOVAL OF FUEL PIPING...486
REMOVAL OF DIPSTICK...488
REMOVAL OF INTAKE MANIFOLD COVER...488
REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER)...489
REMOVAL OF CYLINDER HEAD COVER...489
REMOVAL OF FUEL INJECTION NOZZLE...489
REMOVAL OF ROCKER LEVER...490
REMOVAL OF PUSH ROD...491
REMOVAL OF CYLINDER HEAD...491
REMOVAL OF FRONT COVER...491
REMOVAL OF WATER PUMP...492
REMOVAL OF FLYWHEEL...492
REMOVAL OF FLYWHEEL HOUSING...493
REMOVAL OF COMPONENTS (COMPRESSOR,HYDRAULIC PUMP,ETC.)...493
REMOVAL OF FUEL INJECTION PUMP (BOSCH A,ZEXEL A)...493
REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE)...496
REMOVAL OF TAPPET COVER...496
REMOVAL OF OIL FILLER...496
REMOVAL OF OIL COOLER...496
REMOVAL OF WATER INLET...497
REMOVAL OF OIL PAN...497
REMOVAL OF OIL PAN SUCTION TUBE...497
REMOVAL OF REAR SEAL COVER...498
REMOVAL OF CAMSHAFT...498
REMOVAL OF TAPPET...500
REMOVAL OF OIL PUMP...500
REMOVAL OF TIMING PIN HOUSING...501
REMOVAL OF GEAR HOUSING...501
REMOVAL OF BALANCER (WHEN BALANCER IS INSTALLED)...502
REMOVAL OF PISTON CONNECTING ROD...504
REMOVAL OF CRANKSHAFT...506
REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE...508
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND...508
ASSEMBLY OF ENGINE...509
PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK...509
INSTALLATION OF TAPPET...509
INSTALLATION OF CRANKSHAFT...510
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES...514
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY...514
INSTALLATION OF GEAR HOUSING...518
INSTALLATION OF OIL PUMP...519
INSTALLATION OF CAMSHAFT...520
INSTALLATION OF TIMING PIN...523
INSTALLATION OF BALANCER...526
INSTALLATION OF REAR OIL SEAL...530
INSTALLATION OF OIL PAN SUCTION TUBE...531
INSTALLATION OF OIL PAN...532
INSTALLATION OF OIL COOLER...533
INSTALLATION OF PIL FILLER PORT...533
INSTALLATION OF FEED PUMP...534
INSTALLATION OF TAPPET COVER...534
INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A)...536
INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.)...541
INSTALLATION OF FLYWHEEL HOUSING ...541
INSTALLATION OF FLYWHEEL...542
INSTALLATION OF WEATER PUMP...543
INSTALLATION OF FRONT COVER...543
INSTALLATION OF CYLINDER HEAD...545
INSTALLATION OF PUSH ROD ...546
INSTALLATION OF ROCKER LEVER...546
TIGHTENING OF CYLINDER HEAD...548
ADJUSTING VALVE CLEARANCE...550