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: 924
Number: SEBM030700 (december 2002)
Model
Komatsu Diesel Engine
102 Series
SA6D102E-2
Contents
-INTRODUCTION
About The Manuals
Acronyms and Abbreviations
General Cleaning Instructions
General Repair Instructions
General Safety Instructions
How to Use the Manual
Illustrations
Symbols
-ENGINE IDENTIFICATION
Engine Diagrams
Engine Identification
-FAMILIARIZATION
Air Intake System – Overview
Cam Followers/Tappets – Overview
Complete Engine – Overview
Compressed Air System – Overview
Cooling System-Overview
Cylinder Head Overview
Electrical Equipment – Overview
Electronic Wiring Diagrams
Engine Testing-Overview
Flow Diagrams, Air Intake System
Flow Diagram, Compressed Air System
Flow Diagram, Cooling System
Flow Diagram, Exhaust System
Flow Diagram, Fuel System
Flow Diagram, Lubricating Oil System
Fuel System – Overview
Lubricating Oil System – Overview
-TROUBLESHOOTING SYMPTOMS
Troubleshooting Procedures and Techniques
Troubleshooting Symptoms Charts
-COMPLETE ENGINE
Engine installation
Engine Painting
Engine Removal
Service Tools
-CYLINDER BLOCK
Bearings, Connecting Rod
Bearings, Main
Camshaft
Camshaft Bushings
Camshaft Gear (Camshaft Removed)
Connecting Rod
Crankshaft
Crankshaft Gear, Front (Crankshaft Installed)
Crankshaft Seal, Front
Crankshaft Seal, Rear
Crankshaft Wear Sleeve, Front
Crankshaft Wear Sleeve, Rear
Cylinder Block
Engine Dataplate
Gear Cover, Front
Gear Housing, Front
Piston
Piston And Connecting Rod Assembly
Piston Rings
Service Tools
Timing Pin Housing
Vibration Damper, Viscous
-CYLINDER HEAD
Cylinder Head
Cylinder Head Gasket
Service Tools
Valve, Cylinder Head
Valve Guide Seal, Cylinder Head
-ROCKER LEVERS
Closed Crankcase Ventilation Hoses
Closed Crankcase Ventilation Valve
Crankcase Breather Tube
Overhead Set
Rocker Lever Cover
Service Tools
-CAM FOLLOWERS/TAPPETS
Push Rods or Tubes
Service Tools
Tappet
-FUEL SYSTEMS
AFC Assembly
Cold Start Timing Advance System (KSB) Remote
Cold Start Timing Advance System Pump Mounted
Cold Start Timing Advance System Temperature Switch
Engine Fuel Heater, Electric
Fuel Consumption
Fuel Flow
Fuel Injection Pump, In-Line, Spill Port Timing
Fuel Injection Pump, Rotary
Fuel Injection Pumps, In-Line
Fuel Lift Pump
Fuel Pump Back Leakage Valve
Fuel Pump Control Lever and Spring
Fuel Pump High Idle Speed
Fuel Pump Pressure Regulator
Fuel Pump Support Bracket
Fuel Pump Timing
Fuel Recommendations And Specifications
Fuel Shutoff Valve
Service Tools
Speed Drop Governor
-INJECTORS AND FUEL LINES
AFC Air Tube
Air In Fuel
Fuel Drain Line Restriction
Fuel Filter (Spin-On Type)
Fuel Inlet Restriction
Fuel Manifold (Drain)
Fuel Return Overflow Valve
Fuel Supply Lines
Fuel-Water Separator
Injector
Injector Supply Lines (High Pressure)
Service Tools
-LUBRICATING SYSTEM
Engine Oil Heater
Lubricating Oil Contamination
Lubricating Oil Cooler
Lubricating Oil Dipstick
Lubricating Oil Dipstick Tube
Lubricating Oil Filter (Spin-On)
Lubricating Oil Level
Lubricating Oil Pan
Lubricating Oil Pressure Regulator (Main Rifle)
Lubricating Oil Pressure Sensor, OEM
Lubricating Oil Pump
Lubricating Oil Suction Tube (Block-Mounted)
Lubricating Oil System Diagnostics
Service Tools
-COOLING SYSTEM
Coolant Heater
Coolant Temperature Sensor, OEM
Coolant Thermostat
Coolant Thermostat Housing
Cooling Fan Belt Tensioner
Cooling System
Cooling System – Air or Combustion Gas Test
Cooling System Diagnostics
Drive Belt, Cooling Fan
Fan Clutch, Electric
Fan, Cooling
Fan Hub, Belt Driven
Fan Shroud Assembly
Fan Spacer and Pulley
Radiator
Radiator Hoses
Radiator Pressure Cap
Radiator Shutter Assembly
Sea Water Heat Exchanger
Sea Water Pump
Service Tools
Water Pump
-DRIVE UNITS
Hydraulic Pump Drive
Hydraulic Pump Drive Gear and Shaft
-AIR INTAKE SYSTEM
Aftercooler
Air Crossover
Air Intake Manifold
Air Intake Manifold Heater
Air Intake Restriction
Air Leaks, Air Intake and Exhaust Systems
Charge-Air Cooler
Intake Manifold Air Heater Control Module
Intake Manifold Air Heater Element
Intake Manifold Air Heater Solenoid Switch
Intake Manifold Air Heater Speed Sensor
Intake Manifold Air Heater Temperature Sensor
Intake Manifold Air Heater Wiring Harness
Intake Manifold Pressure
Service Tools
Turbocharger
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Turbocharger Wastegate Actuator
Turbocharger Wastegate Valve Body
-EXHAUST SYSTEM
Exhaust Manifold, Dry
Exhaust Restriction
Service Tools
-COMPRESSED AIR SYSTEM
Air Compressor Carbon Buildup
Air Compressor Coolant Lines
Air Compressor Cylinder Head (Holset QE Models)
Air Compressor Cylinder Head (Holset SS191 Model)
Air Compressor Pin Bore Wear
Air Compressor Unloader and Valve Assembly
Air Governor (Air Compressor Pumps Continuously)
Air Governor (Air Compressor Will Not Pump)
Air Leaks, Compressed Air System
Service Tools
-ELECTRICAL EQUIPMENT
Alternator
Alternator Bracket
Alternator Pulley
Batteries
Batteries
Battery Cables And Connections
Service Tools
Starter Magnetic Switch
Starter Solenoid
Starter Switch
Starting Motor
-ENGINE TESTING
Crankcase Blowby, Measure
Engine Run-In (Chassis Dynamometer)
Engine Run-in (Engine Dynamometer)
Engine Run-in (Without Dynamometer)
Engine Testing (Chassis Dynamometer)
Engine Testing (Engine Dynamometer)
Engine Testing (in Chassis)
Service Tools
-MOUNTING ADAPTATIONS
Engine Mounts
Engine Support Bracket, Front
Engine Support Bracket, Rear
Flywheel
Flywheel Housing
Flywheel Ring Gear
Service Tools
-MISCELLANEOUS
Cup Plug
Expansion Plug
Pipe Plug
Service Tools
-SPECIFICATIONS
Air Intake System
Air Intake System – Specifications
Air Intake System – Torque Values
Cam Followers/Tappets – Specifications
Cam Followers/Tappets – Torque Values
Capscrew Markings and Torque Values
Compressed Air System
Compressed Air System – Specifications
Compressed Air System – Torque Values
Cooling System
Cooling System – Specifications
Cooling System – Torque Values
Cummins/Fleetguard Filter Specifications
Cylinder Block – Specifications
Cylinder Block – Torque Values
Cylinder Head – Specifications
Cylinder Head – Torque Values
Drive Belt Tension
Drive Units – Specifications
Drive Units – Torque Values
Electrical Equipment – Torque Values
Electrical System
Engine Component Torque Values
Engine Testing
Engine Testing – Specifications
Exhaust System
Exhaust System – Specifications
Exhaust System – Torque Values
Fraction, Decimal, Millimeter Conversions
Fuel System
Fuel System – Specifications
Fuel System – Torque Values
General Engine
Injectors and Fuel Lines – Specifications
Injectors and Fuel Lines – Torque Values
Lubricating Oil System
Lubricating Oil System – Specifications
Lubricating Oil System – Torque Values
Mounting Adaptations – Specifications
Mounting Adaptations – Torque Values
Newton-Meter to Foot-Pound Conversions
Pipe Plug Torque Values
Rocker Levers – Specifications
Rocker Levers – Torque Values
Tap-Drill Chart – US Customary and Metric
Weights and Measures – Conversion Factors
COMPONENT MANUFACTURERS
SERVICE LITERATURE
INDEX
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