Komatsu 102 Series Diesel Engine Shop Manual SEBM010025 – PDF DOWNLOAD

Komatsu 102 Series Diesel Engine Shop Manual SEBM010025 – PDF DOWNLOAD

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Komatsu 102 Series Diesel Engine Shop Manual SEBM010025 – PDF DOWNLOAD

Language : English
Pages : 1012
Downloadable : Yes
File Type : PDF
Size: 34.9 MB

DESCRIPTION:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010025 – PDF DOWNLOAD

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.• Always wear safety glasses when hitting parts with a hammer.• Always wear safety glasses when grinding parts with a grinder, etc.3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

• 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
• 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
• 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
• 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu 102 Series Diesel Engine Shop Manual SEBM010025 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 33
APPLICABLE MACHINE 34
SPECIFICATIONS 36
GENERAL ASSEMBLY DRAWING 56
ENGINE PERFORMANCE CURVE 78
WEIGHT TABLE 121
11 STRUCTURE AND FUNCTION 123
GENERAL STRUCTURE 124
INTAKE AND EXHAUST DEVICES 126
AIR CLEANER 136
TURBOCHARGER 137
CYLINDER HEAD 142
CYLINDER BLOCK 150
MAIN MOVING PARTS 156
TIMING GEAR PORTION 163
FRONT GEAR COVER 164
CAMSHAFT TIMING PIN 165
VALVE MECHANISM 166
OIL PAN 171
FLYWHEEL, FLYWHEEL HOUSING 174
LUBRICATION SYSTEM DIAGRAM 177
OIL PUMP 184
OIL FILTER, OIL COOLER 186
REGULATOR VALVE, SAFETY VALVE 190
FUEL SYSTEM DIAGRAM 191
FUEL INJECTION PUMP 200
TIMING LOCK PIN FOR FUEL INJECTION PUMP 204
FUEL FILTER 205
FUEL INJECTION NOZZLE 206
FUEL CUT SOLENOID 207
COOLING SYSTEM DIAGRAM 209
WATER PUMP 213
THERMOSTAT 214
FAN DRIVE 215
AIR COMPRESSOR 220
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM 222
ALTERNATOR 224
STARTING MOTOR 233
STARTING AID 237
12 TESTING AND ADJUSTING 239
SPECIAL TOOL LIST 241
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM 241
SPECIAL TOOLS FOR ENGINE 242
SPECIAL TOOLS FOR FUEL SYSTEM 244
SPECIAL TOOLS FOR COMPONENTS 245
SPECIAL TOOLS FOR ELECTRICAL COMPONENTS 246
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST 247
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM 249
CLEAN AIR 249
TESTING INTAKE RESISTANCE 249
DAMAGE CAUSED BY UNFILTERED AIR 250
LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER) 250
LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER) 251
MEASURING PRESSURE OF TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER) 251
DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) 252
OIL CONSUMPTION AND OIL LEAKAGE 252
NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER) 253
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER) 254
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER) 255
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER) 256
TESTING AUTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER) 256
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER 257
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER) 259
MEASURING EXHAUST RESISTANCE 260
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER) 260
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE 261
VALVE MECHANISM AND CYLINDER HEAD 261
TESTING AIR SYSTEM AND FUEL SYSTEM 261
TESTING VALVE CLEARANCE 262
TESTING COMPRESSION 262
PISTON RING SEALING PERFORMANCE 262
VALVE SEALING PERFORMANCE 263
HEAD GASKET SEALIN PERFORMANCE 263
VALVE SEAL WEAR 264
PROTRUDING PORTION OF FUEL INJECTION NOZZLE 265
FRONT GEAR HOUSING AND GEAR TRAIN 266
VIBRATION DAMPER 266
ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT 267
PISTON AND CONNECTING ROD 268
CRANKSHAFT AND MAIN BEARING 270
CYLINDER BLOCK 271
FLYWHEEL HOUSING AND FLYWHEEL 272
ADJUSTING VALVE CLEARANCE 273
ADJUSTING 4-CYLINDER ENGINE 274
ADJUSTING 6-CYLINDER ENGINE 275
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM 276
OUTLINE 276
HIGH PRESSURE 276
REGULATOR VALVE 276
LOW PRESSURE 277
OIL LEVEL 277
OIL FILTER 277
OIL PRESSURE GAUGE 278
OIL PAN SUCTION TUBE 278
BEARING AND OIL PUMP 278
UNSUITABLE OIL PUMP 278
DILUTION OF OIL 279
COOLING WATER IN OIL 279
FUEL IN OIL 280
FUEL INJECTION PUMP CALIBRATION DATA 283
RUNNING IN STANDARD 341
PERFORMANCE TEST CRITERIA 348
TROUBLESHOOTINGDEFECTIVE ACTUATION OFFEED PUMP (DIAPHRAGM TYPE) 366
Testing feed pump 366
TEST 1: TESTING OUTPUT PRESSURE 366
TEST 2: TESTING FLOW 367
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE) 368
TEST 1: TESTING OUTPUT PRESSURE 369
TEST 2: TESTING FLOW 370
TESTING AIR INSIDE FUEL SYSTEM 373
TESTING WATER SEPARATOR,FUEL FILTER 374
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV) 376
DEFECTIVE ACTUATION OF GOVERNOR 377
STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT 377
LUCAS CAV ADJUSTMENT SCREW 377
BOSCH VE ADJUSTMENT SCREW 378
MANUAL SHUT-OFF LEVER 378
TIMING PROPULSION ANGLE MECHANISM 379
ELECTRICAL SHUT-OFF VALVE 379
DELIVERY VALVE (LUCAS CAV) 381
TESTING HIGH-PRESSURE FUEL PIPING 382
TESTING FUEL INJECTION NOZZLE 383
TESTING FUEL DRAIN PIPING 385
BLEEDING AIR FROM FUEL SYSTEM 385
BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER 386
BLEEDING AIR FROM FUEL INJECTION PUMP 386
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT 387
ADJUSTING FUEL INJECTION TIMING 387
ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE 390
ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV 391
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV) 392
REPLACING FUEL INJECTION NOZZLE 392
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM 396
TROUBLESHOOTING 396
RADIATOR CAP 398
WATER PUMP 399
RADIATOR, FAN, AND RADIATOR SHUTTER 400
THERMOSTAT 402
WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD 403
TESTING CARBON DEPOSIT IN AIR COMPRESSOR 404
TESTING AIR LEAKAGE FROM AIR COMPRESSOR 405
TESTING AIR GOVERNOR, UNLOADER VALVE 406
TESTING AIR GOVERNOR 407
TESTING BATTERY 409
TESTING BATTERY TERMINAL CONNECTIONS 410
TESTING STARTING CIRCUIT 410
TESTING BATTERY RELAY 410
TESTING STARTING SWITCH 412
TESTING STARTING MOTOR AND MAGNETIC SWITCH 413
TESTING DROP IN CRANKING SPEED 415
TESTING ALTERNATOR 416
ABNORMAL DISPLAY OF CHARGE LAMP 417
ABNORMAL ACTUATION OF CHARGING SYSTEM 418
TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR 419
TESTING OIL PRESSURE SWITCH 419
TESTING WATER TEMPERATURE SENSOR 420
TESTING WHITE SMOKE 421
NORMAL AUTUATION OF INTAKE HEATER SYSTEM 421
TESTING INTAKE HEATER 422
TESTING PREHEATING CYCLE 423
SIDE VIEW OF ENGINE 424
OUTLINE OF ENGINE PERFORMANCE TEST 426
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE 427
ENGINE DYNAMOMETER 428
INSTALLING ENGINE 428
PROCEDURE FOR RUNNING IN NEGINE 435
ENGINE PERFORMANCE TEST 438
ENGINE PAINTWORK 440
TROUBLESHOOTING 443
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 444
TROUBLESHOOTING OF ENGINE 465
METHOD OF USING TROUBLESHOOTING CHARTS 466
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 470
S-2 ENGINE DOES NOT START 472
(1) ENGINE DOES NOT TURN 472
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 473
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 474
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 475
S-4 ENGINE STOPS DURING OPERATIONS 476
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING) 477
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 478
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 479
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 480
S-9 OIL BECOMES CONTAMINATED QUICKLY 481
S-10 FUEL CONSUMPTION IS EXCESSIVE 482
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN 483
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 484
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 485
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 486
S-15 ABNORMAL NOISE IS MADE 487
S-16 VIBRATION IS EXCESSIVE 488
13 DISASSEMBLY AND ASSEMBLY 489
SPECIAL TOOL LIST 494
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY 494
SPECIAL TOOLS FOR ENGINE 496
SPECIAL TOOLS FOR FUEL SYSTEM 498
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE 500
OUTLINE 500
DISASSEMBLY 500
ASSEMBLY 500
DISASSEMBLY OF ENGINE 501
STEAM CLEANING OF ENGINE 501
WEIGHT OF ENGINE (REFERENCEVALUE NOT INCLUDING AUXILIARIESSUCH AS MUFFLER) 501
INSTALLATION TO ENGINE STAND 501
DRAINING OIL 502
REMOVAL OF REAR LIFTINGBRACKET 502
REMOVAL OF BELT 502
REMOVAL OF FAN PULLEY 503
REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY 503
REMOVAL OF BELT TENSIONER 503
REMOVAL OF FAN HUB 504
REMOVAL OF ALTERNATOR 504
REMOVAL OF THERMOSTAT 505
REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) 505
REMOVAL OF EXHAUST MANIFOLD 507
REMOVAL OF FUEL FILTER 507
REMOVAL OF FUEL FILTER HEAD 508
REMOVAL OF FUEL PIPING 508
REMOVAL OF DIPSTICK 510
REMOVAL OF INTAKE MANIFOLD COVER 510
REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER) 511
REMOVAL OF CYLINDER HEAD COVER 511
REMOVAL OF FUEL INJECTION NOZZLE 511
REMOVAL OF ROCKER LEVER 512
REMOVAL OF PUSH ROD 513
REMOVAL OF CYLINDER HEAD 513
REMOVAL OF FRONT COVER 513
REMOVAL OF WATER PUMP 514
REMOVAL OF FLYWHEEL 514
REMOVAL OF FLYWHEEL HOUSING 515
REMOVAL OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC ) 515
REMOVAL OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) 515
REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE) 518
REMOVAL OF FEED PUMP (FUEL INJECTION TYPE) 518
REMOVAL OF TAPPET COVER 518
REMOVAL OF OIL FILLER 518
REMOVAL OF COOLANT HEATER (IF APPLICABLE) 519
REMOVAL OF OIL COOLER 519
REMOVAL OF WATER INLET 519
REMOVAL OF OIL PAN HEATER (IF APPLICABLE) 520
REMOVAL OF OIL PAN 520
REMOVAL OF OIL PAN SUCTIONTUBE 520
REMOVAL OF REAR SEAL COVER 522
REMOVAL OF CAMSHAFT 522
REMOVAL OF TAPPET 524
REMOVAL OF OIL PUMP 524
REMOVAL OF TIMING PIN HOUSING 525
REMOVAL OF GEAR HOUSING 525
REMOVAL OF BALANCER (WHEN BALANCER IS INSTALLED) 526
REMOVAL OF PISTON CONNECTING ROD 528
REMOVAL OF CRANKSHAFT 530
REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE 532
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND 532
ASSEMBLY OF ENGINE 533
PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK 533
INSTALLATION OF TAPPET 533
INSTALLATION OF CRANKSHAFT 534
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES 538
INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY 538
INSTALLATION OF GEAR HOUSING 542
INSTALLATION OF OIL PUMP 543
INSTALLATION OF CAMSHAFT 544
INSTALLATION OF TIMING PIN 547
INSTALLATION OF BALANCER 550
INSTALLATION OF REAR OIL SEAL 554
INSTALLATION OF OIL PAN SUCTION TUBE 555
INSTALLATION OF OIL PAN 556
INSTALLATION OF OIL PANHEATER (IF APPLICABLE) 557
INSTALLATION OF OIL COOLER 557
INSTALLATION OF COOLANTHEATER (IF APPLICABLE) 558
INSTALLATION OF OIL FILLERPORT 558
INSTALLATION OF FEED PUMP 560
INSTALLATION OF FEED PUMP (FUEL INJECTION TYPE) 560
INSTALLATION OF TAPPET COVER 560
INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A) 563
INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC ) 568
INSTALLATION OF FLYWHEEL HOUSING 568
INSTALLATION OF FLYWHEEL 569
INSTALLATION OF WEATER PUMP 570
INSTALLATION OF FRONT COVER 570
INSTALLATION OF CYLINDER HEAD 572
INSTALLATION OF PUSH ROD 573
INSTALLATION OF ROCKER LEVER 573
TIGHTENING OF CYLINDER HEAD 575
ADJUSTING VALVE CLEARANCE 577
INSTALLATION OF FUEL INJECTION NOZZLE 579
INSTALLATION OF CYLINDER HEAD COVER 580
INSTALLATION OF INTAKE MANIFOLD COVER 580
INSTALLATION OF FUEL FILTER HEAD 582
INSTALLATION OF EXHAUST MANIFOLD 583
INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) 584
INSTALLATION OF THERMOSTAT 587
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER 588
INSTALLATION OF FAN HUB 588
INSTALLATION OF BELT TENSIONER 588
INSTALLATION OF WATER INLET 589
INSTALLATION OF ALTERNATOR 589
INSTALLATION OF BELT 590
INSTALLATION OF OIL FILTER 591
REMOVAL OF ENGINE FROM ENGINE STAND 591
INSTALLATION OF STARTING MOTOR 591
INTAKE GROUP 592
DISASSEMBLY AND ASSEMBLY DRAWING 592
OUTLINE 594
REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER) 595
REMOVAL 595
INSTALLATION 596
CLEANING AND INSPECTION 598
REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER) 600
REMOVAL 600
CLEANING 600
INSTALLATION 601
CLEANING AND INSPECTION 602
ASSEMBLY 602
REPLACEMENT OF INTAKE CONNECTOR 603
REMOVAL AND INSTALLATION 603
AIR CONNECTOR 603
CLEANING 603
INSPECTION 603
REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET 603
REMOVAL 604
CLEANING 604
INSTALLATION 604
AIR CROSSOVER TUBE 605
CLEANING 605
INSPECTION 605
EXHAUST GROUP 606
DISASSEMBLY AND ASSEMBLY DRAWING 606
OUTLINE OF EXHAUST MANIFOLD 607
REPLACEMENT OF EXHAUST MANIFOLD, GASKET 608
REMOVAL 608
CLEANING AND INSPECTION 608
INSTALLATION 608
REPLACEMENT OF EXHAUST MANIFOLD 609
CLEANING 609
INSTALLATION 610
INSPECTION 610
REPLACEMENT OF TURBOCHARGER 611
REMOVAL 611
INSTALLATION 612
TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER) 615
REPLACEMENT 615
CYLINDER BLOCK GROUP 616
DISASSEMBLY AND ASSEMBLY DRAWING 616
OUTLINE OF CYLINDER BLOCKGROUP 619
OUTLINE OF CAMSHAFT 619
OUTLINE OF CRANKSHAFT 619
OUTLINE OF CYLINDER BLOCK 619
OUTLINE OF OIL SEAL 619
REPLACEMENT OF FRONT OILSEAL 620
REMOVAL 620
CLEANING AND INSPECTION 621
INSTALLATION 621
REPLACEMENT OF REAR OIL SEAL 623
OUTLINE OF PISTON 625
OUTLINE OF VIBRATION DAMPER 625
CHECK LIST FOR CYLINDER BLOCK GROUP 626
CYLINDER BLOCK 627
INSPECTION BEFORE DISASSEMBLY 627
DISASSEMBLY OF CYLINDER BLOCK 627
CLEANING OF CYLINDER BLOCK 629
INSPECTION OF CYLINDER BLOCK 632
REMOVAL OF GLAZE FROM CYLINDER BORE 634
DISASSEMBLY 634
INSPECTION 635
REMOVAL OF GLAZE 635
CLEANING 638
ASSEMBLY 639
REMOVAL OF GLAZE FROM CYLINDER BLOCK 640
REPLACEMENT OF PLUG 643
REMOVAL 643
CLEANING AND INSPECTION 643
INSTALLATION 644
REPLACEMENT OF CAP 644
REMOVAL 644
CLEANING 645
INSTALLATION 645
INSTALLATION OF CAP AND PLUG 648
INSTALLATION OF CAMSHAFT CUP 650
INSTALLATION OF CAMSHAFT BUSHING 651
REPLACEMENT OF DIPSTICK TUBE 652
STORING CYLINDER BLOCK 653
CRANKSHAFT 653
REPLACEMENT OF MAIN BEARING 654
CLEANING OF CRANKSHAFT 661
INSTALLATION OF CRANKSHAFT 661
REPLACEMENT OF CRANKSHAFT GEAR 662
REPLACEMENT OF CAMSHAFT AND TAPPET 664
REMOVAL OF CAMSHAFT 664
REMOVAL OF TAPPET 665
INSPECTION OF TAPPET 667
STANDARDS FOR PITTING WHEN REUSING 669
STANDARD FOR DETERIORATION (BREAKAGE) OF TIP 670
INSPECTION OF CAMSHAFT BORE 673
REPLACEMENT OF CAMSHAFT BUSHING 673
INSTALLATION OF TAPPET 674
INSTALLATION OF CAMSHAFT 677
CLEANING OF CAMSHAFT 679
INSPECTION OF CAMSHAFT, GEAR 680
REPLACEMENT OF CAMSHAFT, GEAR 682
CLEANING AND INSPECTION 683
INSTALLATION 684
REPLACEMENT OF TIMING PIN 686
REPLACEMENT OF GEAR HOUSING, GASKET 687
REMOVAL 687
CLEANING AND INSPECTION 688
INSTALLATION 689
REPLACEMENT OF CAMSHAFT GEAR 697
REMOVAL 697
INSTALLATION (SHRINK-FITTING METHOD) 698
INSTALLATION (METHOD USING SPECIAL TOOL) 699
INSTALLATION OF CAMSHAFTMOUNTING BOLTS 701
REPLACEMENT OFVIBRATION DAMPER, CRANKSHAFT PULLEY 702
REMOVAL 702
INSPECTION OF RUBBER DAMPER 702
INSTALLATION 703
INSPECTION OF VISCOUSDAMPER 703
VIBRATION DAMPER (RUBBER TYPE) 707
PISTON, PIN, CONNECTING ROD 709
REPLACEMENT OF PISTON AND RING 709
REMOVAL OF PISTON CONNECTING ROD 710
DISASSEMBLY OF PISTON CONNECTING ROD 712
CLEANING OF PISTON,PIN,CONNECTING ROD 712
INSPECTION OF PISTON 713
INSPECTION OF PISTON PIN 714
ASSEMBLY OF PISTON CONNECTING ROD 715
INSPECTION OF PISTON RING GAP 716
INSTALLATION OF PISTON RING 717
INSTALLATION OF PISTON CONNECTING ROD 718
REPLACEMENT OF CONNECTING ROD 722
REMOVAL 722
CLEANING AND INSPECTION 723
INSTALLATION 725
REPLACEMENT OF CONNECTING ROD BEARING 726
REMOVAL 726
CLEANING AND INSPECTION 728
INSTALLATION 729
DISASSEMBLY OF PISTON CONNECTING ROD 732
CLEANING OF PISTON, PIN, CONNECTING ROD 733
INSPECTION OF PISTON 734
INSPECTION OF PISTON PIN 735
INSPECTION OF CONNECTING ROD 735
INSPECTION OF CONNECTING ROD BEARING CLEARANCE 735
ASSEMBLY OF PISTON CONNECTING ROD 736
INSPECTION OF PISTON RING END GAP 737
INSTALLATION OF PISTON RING 738
BALANCER 739
DISASSEMBLY 739
ASSEMBLY 742
GEAR COVER 749
REPLACEMENT OF GEAR COVER 749
REMOVAL 749
CLEANING AND INSPECTION 750
INSTALLATION 750
INSTALLATION OF GEAR COVER 752
INSPECTION OF GEAR HOUSING AND TIMING PIN 754
DISASSEMBLY OF GEAR HOUSING 754
REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD 755
REPLACEMENT OF ENGINE NAME PLATE 755
CYLINDER HEAD 758
DISASSEMBLY AND ASSEMBLY DRAWING 758
OUTLINE 760
REPLACEMENT OF CYLINDER HEAD 761
REMOVAL 761
INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD 764
DISASSEMBLY OF CYLINDER HEAD 765
CLEANING OF CYLINDER HEAD 766
INSPECTION OF VALVE 768
INSPECTION OF VALVE GUIDE 769
INSPECTION OF CYLINDER DECK 769
INSPECTION OF VALVE SEAT 770
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING 770
REPLACEMENT OF VALVE SPRING 771
ASSEMBLY OF CYLINDER HEAD 771
INSTALLATION OF CYLINDER HEAD 772
ADJUSTING VALVE CLEARANCE 776
INSTALLATION OF THERMOSTAT 777
INSTALLATION OF FAN HUB 777
INSTALLATION OF BELT TENSIONER 778
INSTALLATION OF ALTERNATOR 778
INSTALLATION OF DRIVE BELT 779
INSPECTION BEFORE DISASSEMBLY 779
DISASSEMBLY OF CYLINDER HEAD 780
CLEANING OF CYLINDER HEAD 781
INSPECTION OF VALVE 783
INSPECTION OF VALVE GUIDE 784
INSPECTION OF CYLINDER HEAD COMBUSTION DECK 784
INSPECTION OF VALVE SEAT 785
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING 785
REPLACEMENT OF VALVE SPRING 786
REPLACEMENT OF CAP 786
POLISHING VALVE 788
POLISHING VALVE SEAT 789
CALCULATING GRINDING DEPTH AND MEASURING DEPTH OF VALVE 790
ASSEMBLY OF CYLINDER HEAD 794
ROCKER LEVER 796
DISASSEMBLY AND ASSEMBLY DRAWING 796
OUTLINE 798
REPLACEMENT OF ROCKER LEVER AND PUSH ROD 799
REMOVAL 799
DISASSEMBLY OF ROCKER LEVER 800
CLEANING OF ROCKER LEVER 801
INSPECTION OF ROCKER LEVER 801
ASSEMBLY OF ROCKER LEVER 802
INSTALLATION OF ROCKER LEVER 803
DISASSEMBLY OF ROCKER LEVER 805
CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT 806
INSPECTION OF ROCKER LEVER 806
INSPECTION OF ROCKER LEVER SHAFT 807
ASSEMBLY OF ROCKER LEVER 807
TAPPETS AND PUSH RODS 809
DISASSEMBLY AND ASSEMBLY DRAWING 809
OUTLINE 810
CLEANING OF PUSH ROD 811
INSPECTION OF PUSH ROD 811
INSTALLATION OF PUSH ROD 811
INSPECTION OF TAPPET 812
ENGINE MOUNT GROUP 814
OUTLINE OF FLYWHEEL HOUSING 814
OUTLINE OF FLYWHEEL, RING GEAR 814
OUTLINE OF FRONT SUPPORT 814
FLYWHEEL, RING GEAR 815
INSPECTION OF FLYWHEEL, RING GEAR 815
REPLACEMENT OF FLYWHEEL, RING GEAR 815
FLYWHEEL HOUSING 817
REPLACEMENT OF REAR OIL SEAL 817
REMOVAL 817
CLEANING AND INSPECTION 819
INSTALLATION 819
REPLACEMENT OF FLYWHEEL HOUSING 822
REMOVAL 822
CLEANING AND INSPECTION 823
INSTALLATION (DRY CLUTCH SPECIFICATION) 824
INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING 825
INSPECTION OF FACE RUNOUT OF FLTWHEEL HOUSING 827
INSTALLATION (WET CLUTCH SPECIFICATION) 828
INSPECTION 830
INSTALLATION 831
FRONT SUPPORT 832
CLEANING AND INSPECTION 832
REMOVAL OF ENGINE 833
INSPECTION OF ENGINE MOUNT 835
INSTALLATION OF ENGINE 836
OIL PAN AND SUCTION TUBE 840
DISASSEMBLY AND ASSEMBLY DRAWING 840
REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET 841
CLEANING AND INSPECTION 843
REGULATOR VALVE 844
REPLACEMENT OF REGULATOR VALVE, SPRING 844
DISASSEMBLY 844
CLEANING AND INSPECTION 844
OIL FILTER BYPASS VALVE 847
REPLACEMENT 847
OIL COOLER 848
DISASSEMBLY AND ASSEMBLY DRAWING 848
REPLACEMENT OF OIL COOLER CORE, GASKET 849
CLEANING 851
INSPECTION 852
OIL PUMP 853
DISASSEMBLY AND ASSEMBLY DRAWING 853
REPLACEMENT OF OIL PUMP 854
CLEANING AND INSPECTION 855
INSTALLATION OF OIL PUMP 858
INSPECTION 859
FUEL INJECTION PUMP GROUP 863
DISASSEMBLY AND ASSEMBLY DRAWING 863
FUEL INJECTION NOZZLE GROUP 864
DISASSEMBLY AND ASSEMBLY DRAWING 864
FUEL INJECTION NOZZLE 865
DISASSEMBLY 865
CLEANING AND INSPECTION 866
ASSEMBLY 868
FEED PUMP (CYLINDER BLOCK MOUNT TYPE) 871
REPLACEMENT OF FEED PUMP (DIAPHRAGM TYPE) 871
REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE) 873
REMOVAL 873
CLEANING 874
ASSEMBLY 874
INSTALLATION 875
CLEANING AND INSPECTION 875
REPLACEMENT OF FUEL FILTER 878
FUEL PIPING 880
REPLACEMENT OF HIGH-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV) 880
REPLACEMENT OF FUEL SUPPLY PIPING (BOSCH VE, LUCAS CAV) 881
CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING 883
REPLACEMENT OF FUEL RETURN PIPING (BOSCH VE, LUCAS CAV) 884
CLEANING AND INSPECTION OF FUEL DRAIN PIPING 886
REPLACEMENT OF LOW-PRES-SURE FUEL PIPING (BOSCH VE, LUCAS CAV) 886
CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING 887
REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE (BOSCH VE) 888
WATER PUMP 889
DISASSEMBLY AND ASSEMBLY DRAWING 889
REPLACEMENT OF WATER PUMP 890
INSPECTION 891
FAN HUB 891
REPLACEMENT OF FAN PULLEY 891
REPLACEMENT OF FAN HUB 892
INSPECTION 892
DISASSEMBLY 893
ASSEMBLY 894
BELT TENSIONER 896
DISASSEMBLY AND ASSEMBLY DRAWING 896
REPLACEMENT OF BELT 897
REPLACEMENT OF BELT TENSIONER 897
INSPECTION 897
THERMOSTAT 898
DISASSEMBLY AND ASSEMBLY DRAWING 898
REPLACEMENT OF THERMOSTAT 899
INSPECTION 900
FAN 902
COOLANT 902
ACCESSORY DRIVE ADAPTER 904
DISASSEMBLY AND ASSEMBLY DRAWING 904
CLEANING 905
INSPECTION 905
DISASSEMBLY 905
ASSEMBLY 906
DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD 908
CLEANING 909
INSPECTION 910
ASSEMBLY 914
REPLACEMENT OF AIR COMPRESSOR 917
REMOVAL 917
INSPECTION 918
INSTALLATION 920
CLEANING AND INSPECTION 922
INSPECTION 922
ALTERNATOR 923
REPLACEMENT OF ALTERNATOR 923
INSPECTION 924
STARTING MOTOR 924
INSPECTION 924
14 MAINTENANCE STANDARD 927
TURBOCHARGER 928
EXHAUST MANIFOLD 930
CYLINDER HEAD 932
VALVE, VALVE GUIDE 934
LOCKER ARM SHAFT, PUSH ROD AND TAPPET 936
CYLINDER BLOCK 938
CYLINDER 940
CRANKSHAFT 942
CAMSHAFT 944
TIMING GEAR 948
PISTON, PISTON RING AND PISTON PIN 950
CONNECTING ROD 952
VIBRATION DAMPER 954
FLYWHEEL, FLYWHEEL HOUSING 956
FAN HUB 958
OIL PUMP 959
WATER PUMP, THERMOSTAT 960
FUEL INJECTION PUMP 961
FUEL INJECTION NOZZLE 962
15 REPAIR AND REPLACEMENT OF PARTS 965
OUTLINE 966
REPAIR GUIDELINE 966
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT 966
INSPECTION 966
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL 966
FOLLOW WASHING METHODS GIVEN IN MANUAL 966
FOLLOW INSPECTION METHODS GIVEN IN MANUAL 966
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT 967
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS 968
REPAIR PROCEDURE 968
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS 971
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS 972
PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK 973
INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK 973
INSPECTION AND INSTALLATION OF VALVE GUIDE 974
PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE 975
PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE 976
OUTLINE OF VALVE SEAT REPAIR 976
CALCULATING GRINDING DEPTH OF VALVE SEAT 977
METHOD OF GRINDING VALVE SEAT 977
METHOD OF INSTALLING VALVE SEAT 981
MACHINING EXHAUST VALVE INSET POCKET 981
REPLACING VALVE SEAT 984
METHOD OF GRINDING VALVE 985
CHECKING TENSION OF VALVE SPRING 986
ASSEMBLY OF CYLINDER HEAD 987
PROCEDURE FOR REPAIRING CYLINDER BLOCK 988
REPAIR TOOLS 988
COMBUSTION DECK 988
CAM BORE 989
OUTLINE OF REPAIR OF CYLINDER BORE 990
CYLINDER BORE 990
INSTALLATION OF REPAIR SLEEVE 992
PROCEDURE FOR REPAIRING CRANKSHAFT 996
REPAIR TOOLS 996
OUTLINE OF GRINDING CRANKSHAFT 996
REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL 997
REGRINDING CRANKSHAFT JOURNAL RADIUS 997
SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL 999
REGRINDING CRANKSHAFT ROD JOURNAL RADIUS 999
OPTIONAL PROCEDURE 1000
PROCEDURE FOR REPAIRING CONNECTING ROD 1001
INSTALLATION OF PIN BORE BUSHING 1003
MACHINING OF CONNECTING ROD BUSHING 1005
INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD 1006
TESTING ALIGNMENT OF CONNECTING ROD 1007
INSPECTION OF TWISTING OF CONNECTING ROD 1007
REPLACING VALVE SEAT INSERT 1008
PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS 1011

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