Komatsu 102 Series Diesel Engine Service Repair Shop Manual - SEBM010021

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the 102 Series Komatsu Diesel Engine 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.


APPLICABLE MODELS :

4D102E-1
S4D102E-1
6D102E-1
S6D102E-1
SA6D102E-1
SAA4D102E-2
SAA6D102E-2

4D102E-1
PC60-7, PC60-7B, PC70-7
BR100J-1, BR100JG, RG-1

S4D102E-1
PC100-6, PC100-6EXCEL
PC120-6, PC120-6MIGHTY, PC120-6EXCEL
PC128UU-1, PC128US-1, PC128US-2
PC158US-2
D31E, S, Q, P-20, D31PL, PLL-20, D31P-20A
D37E-5, D37P-5A
WA120-3, WA120-3D

6D102E-1
D41A-6

S6D102E-1
PC200, 200LC-6, PC200, 200LC-6HYPER GX
PC200-6CUSTOM, EXCEL(BKC), PC210, 210LC-6MIGHTY
PC228USL-1, PC228USLC-2
BR200S-1, BR210JG-1
CD60RE-1
D41E, P-6
WA180-3, WA180-3 (For EU), WA180PT-3
WA250-3, WA250L-3 (For USA), WA250PT-3
GD405A-3, GD521A-1E
JV100WA-2, JV100WP-2

SA60102E-1
PC220, 220LC-6, PC220-6EXCEL
PC250HD-1, PC250, 250LC-6
BR250RG-1, BR350JG-1
WA300L-3 (For USA), WA320-3, WA320-3 CUSTOM
DCA-125SSK

SAA4D102E-2
D31EX-21, D31PX-21
D37EX-21, D37PX-21
D39EX-21, D39PX-21
PC160LC-7

SAA6D102E-2
PC200-7, PC200LC-7, PC228US-3, PC228USLC-3, PC270-7,
PC308USLC-3, PC220-7, PC220LC-7
BR120T-1, BR380JG-1
WA150-5
WA200-5
WA250-5, WA250PT-5
WA320-5
GD555-3A, GD555-3C


TABLE OF CONTENTS :

01 GENERAL
11 STRUCTURE AND FUNCTION
12 TESTING AND ADJUSTING
13 DISASSEMBLY AND ASSEMBLY
14 MAINTENANCE STANDARD
15 REPAIR AND REPLACEMENT OF PARTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM010021
Total Pages : 977


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.

This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, maintenance manual, operating manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

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Komatsu 102 Series Diesel Engine OEM Manual PDF Download

-

01 GENERAL
-APPLICABLE MACHINE
-SPECIFICATIONS
-GENERAL ASSEMBLY DARWING
-ENGINE PERFORMANCE CURVE
-WEIGHT TABLE

11 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

12 TESTING AND ADJUSTING
-SPECIAL TOOL LIST
--SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM
--SPECIAL TOOLS FOR ENGINE
--SPECIAL TOOLS FOR FUEL SYSTEM
--SPECIAL TOOLS FOR COMPONENTS
--SPECIAL TOOLS FOR ELECTRICAL COMPONENTS
--SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST
-TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM
--CLEAN AIR
--TESTING INTAKE RESISTANCE
--DAMAGE CAUSED BY UNFILTERED AIR
--LEAKAGE OF SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER)
--LEAKAGE OF EXHAUST AIR (ENGINE WITH TURBOCHARGER)
--MEASURING PRESSURE OF TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER)
--DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
--OIL CONSUMPTION AND OIL LEAKAGE
--NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)
-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
--VALVE MECHANISM AND CYLINDER HEAD
--TESTING AIR SYSTEM AND FUEL SYSTEM
--TESTING VALVE CLEARANCE
--TESTING COMPRESSION
--PISTON RING SEALING PERFORMANCE
--VALVE SEALING PERFORMANCE
--HEAD GASKET SEALIN PERFORMANCE
--VALVE SEAL WEAR
--PROTRUDING PORTION OF FUEL INJECTION NOZZLE
--FRONT GEAR HOUSING AND GEAR TRAIN
--VIBRATION DAMPER
--ROCKERLEVER, VALVESTEM, PUSH ROD, TAPPET, AND CAMSHAFT
--PISTON AND CONNECTING ROD
--CRANKSHAFT AND MAIN BEARING
--CYLINDER BLOCK
--FLYWHEEL HOUSING AND FLYWHEEL
-ADJUSTING VALVE CLEARANCE
--ADJUSTING 4-CYLINDER ENGINE
--ADJUSTING 6-CYLINDER ENGINE
-TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM
--OUTLINE
--HIGH PRESSURE
--REGULATOR VALVE
--LOW PRESSURE
--OIL LEVEL
--OIL FILTER
--OIL PRESSURE GAUGE
--OIL PAN SUCTION TUBE
--BEARING AND OIL PUMP
--UNSUITABLE OIL PUMP
--DILUTION OF OIL
--COOLING WATER IN OIL
--FUEL IN OIL
-FUEL INJECTION PUMP CALIBRATION DATA
-RUNNING IN STANDARD
-PERFORMANCE TEST CRITERIA
-TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (DIAPHRAGM TYPE)
--TESTING FEED PUMP
--TEST 1:TESTING OUTPUT PRESSURE
--TEST 2:TESTING FLOW
-TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (PISTON TYPE)
--TEST 1:TESTING OUTPUT PRESSURE
--TEST 2:TESTING FLOW
-TESTING AIR INSIDE FUEL SYSTEM
-TESTING WATER SEPARATOR,FUEL FILTER
-TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP (BOSCH VE, LUCAS CAV)
--DEFECTIVE ACTUATION OF GOVERNOR
--STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT
---LUCAS CAV ADJUSTMENT SCREW
---BOSCH VE ADJUSTMENT SCREW
--MANUAL SHUT-OFF LEVER
--TIMING PROPULSION ANGLE MECHANISM
--ELECTRICAL SHUT-OFF VALVE
--DELIVERY VALVE (LUCAS CAV)
-TESTING HIGH-PRESSURE FUEL PIPING
-TESTING FUEL INJECTION NOZZLE
-TESTING FUEL DRAIN PIPING
-BLEEDING AIR FROM FUEL SYSTEM
--BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER
--BLEEDING AIR FROM FUEL INJECTION PUMP
--BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT
-ADJUSTING FUEL INJECTION TIMING
--ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE
--ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV
-ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)
-REPLACING FUEL INJECTION NOZZLE
-TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM
--TROUBLESHOOTING
--RADIATOR CAP
--WATER PUMP
--RADIATOR, FAN, AND RADIATOR SHUTTER
--THERMOSTAT
--WATER TEMPERATURE GAUGE, FUEL GAUGE, OVERLOAD
-TESTING CARBON DEPOSIT IN AIR COMPRESSOR
-TESTING AIR LEAKAGE FROM AIR COMPRESSOR
-TESTING AIR GOVERNOR, UNLOADER VALVE
-TESTING BATTERY
-TESTING BATTERY TERMINAL CONNECTIONS
-TESTING STARTING CIRCUIT
--TESTING BATTERY RELAY
--TESTING STARTING SWITCH
--TESTING STARTING MOTOR AND MAGNETIC SWITCH
--TESTING DROP IN CRANKING SPEED
-TESTING ALTERNATOR
--ABNORMAL DISPLAY OF CHARGE LAMP
--ABNORMAL ACTUATION OF CHARGING SYSTEM
-TESTING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR
--TESTING OIL PRESSURE SWITCH
--TESTING WATER TEMPERATURE SENSOR
-TESTING WHITE SMOKE
--NORMAL AUTUATION OF INTAKE HEATER SYSTEM
-TESTING INTAKE HEATER
--TESTING PREHEATING CYCLE
-SIDE VIEW OF ENGINE
-OUTLINE OF ENGINE PERFORMANCE TEST
-BLOW-BY MEASUREMENT AND REPLACEMENT TABLE
-ENGINE DYNAMOMETER
--INSTALLING ENGINE
--PROCEDURE FOR RUNNING IN NEGINE
--ENGINE PERFORMANCE TEST
-ENGINE PAINTWORK
-TROUBLESHOOTING
--STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
--TROUBLESHOOTING OF ENGINE
---METHOD OF USING TROUBLESHOOTING CHARTS
---S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
---S-2 ENGINE DOES NOT START
----(1) ENGINE DOES NOT TURN
----(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
----(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
---S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
---S-4 ENGINE STOPS DURING OPERATIONS
---S-5 ENGINE DOES NOT ROTATE SMOOTHLY 9HUNTING)
---S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
---S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
---S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
---S-9 OIL BECOMES CONTAMINATED QUICKLY
---S-10 FUEL CONSUMPTION IS EXCESSIVE
---S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN
---S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
---S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
---S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
---S-15 ABNORMAL NOISE IS MADE
---S-16 VIBRATION IS EXCESSIVE

13 DISASSEMBLY AND ASSEMBLY
-SPECIAL TOOL LIST
--SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY
--SPECIAL TOOLS FOR ENGINE
--SPECIAL TOOLS FOR FUEL SYSTEM
-OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
--OUTLINE
--DISASSEMBLY
--ASSEMBLY
-DISASSEMBLY OF ENGINE
--STEAM CLEANING OF ENGINE
--REMOVAL OF STARTING MOTOR
--WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER)
--INSTALLATION TO ENGINE STAND
--DRAINING OIL
--REMOVAL OF REAR LIFTING BRACKET
--REMOVEL OF BELT
--REMOVAL OF FAN PULLEY
--REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY
--REMOVAL OF BELT TENSIONER
--REMOVAL OF FAN HUB
--REMOVAL OF ALTERNATOR
--REMOVAL OF THERMOSTAT
--REMOVAL OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
--REMOVAL OF EXHAUST MANIFOLD
--REMOVAL OF FUEL FILTER
--REMOVAL OF FUEL FILTER HEAD
--REMOVAL OF FUEL PIPING
--REMOVAL OF DIPSTICK
--REMOVAL OF INTAKE MANIFOLD COVER
--REMOVAL OF AFTERCOOLER (ENGINE WITH AFTERCOOLER)
--REMOVAL OF CYLINDER HEAD COVER
--REMOVAL OF FUEL INJECTION NOZZLE
--REMOVAL OF ROCKER LEVER
--REMOVAL OF PUSH ROD
--REMOVAL OF CYLINDER HEAD
--REMOVAL OF FRONT COVER
--REMOVAL OF WATER PUMP
--REMOVAL OF FLYWHEEL
--REMOVAL OF FLYWHEEL HOUSING
--REMOVAL OF COMPONENTS (COMPRESSOR,HYDRAULIC PUMP,ETC.)
--REMOVAL OF FUEL INJECTION PUMP (BOSCH A,ZEXEL A)
--REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE)
--REMOVAL OF TAPPET COVER
--REMOVAL OF OIL FILLER
--REMOVAL OF OIL COOLER
--REMOVAL OF WATER INLET
--REMOVAL OF OIL PAN
--REMOVAL OF OIL PAN SUCTION TUBE
--REMOVAL OF REAR SEAL COVER
--REMOVAL OF CAMSHAFT
--REMOVAL OF TAPPET
--REMOVAL OF OIL PUMP
--REMOVAL OF TIMING PIN HOUSING
--REMOVAL OF GEAR HOUSING
--REMOVAL OF BALANCER (WHEN BALANCER IS INSTALLED)
--REMOVAL OF PISTON CONNECTING ROD
--REMOVAL OF CRANKSHAFT
--REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE
--REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND
-ASSEMBLY OF ENGINE
--PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK
--INSTALLATION OF TAPPET
--INSTALLATION OF CRANKSHAFT
--INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES
--INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY
--INSTALLATION OF GEAR HOUSING
--INSTALLATION OF OIL PUMP
--INSTALLATION OF CAMSHAFT
--INSTALLATION OF TIMING PIN
--INSTALLATION OF BALANCER
--INSTALLATION OF REAR OIL SEAL
--INSTALLATION OF OIL PAN SUCTION TUBE
--INSTALLATION OF OIL PAN
--INSTALLATION OF OIL COOLER
--INSTALLATION OF PIL FILLER PORT
--INSTALLATION OF FEED PUMP
--INSTALLATION OF TAPPET COVER
--INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A)
--INSTALLATION OF COMPONENTS (COMPRESSOR, HYDRAULIC PUMP, ETC.)
--INSTALLATION OF FLYWHEEL HOUSING
--INSTALLATION OF FLYWHEEL
--INSTALLATION OF WEATER PUMP
--INSTALLATION OF FRONT COVER
--INSTALLATION OF CYLINDER HEAD
--INSTALLATION OF PUSH ROD
--INSTALLATION OF ROCKER LEVER
--TIGHTENING OF CYLINDER HEAD
--ADJUSTING VALVE CLEARANCE
--INSTALLATION OF FUEL INJECTION NOZZLE
--INSTALLATION OF CYLINDER HEAD COVER
--INSTALLATION OF INTAKE MANIFOLD COVER
--INSTALLATION OF FUEL FILTER HEAD
--INSTALLATION OF EXHAUST MANIFOLD
--INSTALLATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
--INSTALLATION OF THERMOSTAT
--INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER
--INSTALLATION OF FAN HUB
--INSTALLATION OF BELT TENSIONER
--INSTALLATION OF WATER INLET
--INSTALLATION OF ALTERNATOR
--INSTALLATION OF BELT
--INSTALLATION OF OIL FILTER
--REMOVAL OF ENGINE FROM ENGINE STAND
--INSTALLATION OF STARTING MOTOR
-INTAKE GROUP
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE
-REPLACEMENT OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)
--REMOVAL
--INSTALLATION
--CLEANING AND INSPECTION
-REPLACEMENT OF AFTERCOOLER, GASKET (ENGINE WITH AFTERCOOLER)
--REMOVAL
--CLEANING
--INSTALLATION
--CLEANING AND INSPECTION
--ASSEMBLY
-REPLACEMENT OF INTAKE CONNECTOR
--REMOVAL AND INSTALLATION
-AIR CONNECTOR
--CLEANING
--INSPECTION
-REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET
--REMOVAL
--CLEANING
--INSTALLATION
-AIR CROSSOVER TUBE
--CLEANING
--INSPECTION
-EXHAUST GROUP
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE OF EXHAUST MANIFOLD
-REPLACEMENT OF EXHAUST MANIFOLD, GASKET
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
-REPLACEMENT OF EXHAUST MANIFOLD
--REMOVAL
--CLEANING
--INSTALLATION
--INSPECTION
-REPLACEMENT OF TURBOCHARGER
--REMOVAL
--INSTALLATION
-TURBOCHARGER MOUNTING STUD (ENGINE WITH TURBOCHARGER)
--REPLACEMENT
-CYLINDER BLOCK GROUP
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE OF CYLINDER BLOCK GROUP
--OUTLINE OF CAMSHAFT
--OUTLINE OF CRANKSHAFT
--OUTLINE OF CYLINDER BLOCK
--OUTLINE OF OIL SEAL
-REPLACEMENT OF FRONT OIL SEAL
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
-REPLACEMENT OF REAR OIL SEAL
--OUTLINE OF PISTON
--OUTLINE OF VIBRATION DAMPER
--CHECK LIST FOR CYLINDER BLOCK GROUP
-CYLINDER BLOCK
--INSPECTION BEFORE DISASSEMBLY
--DISASSEMBLY OF CYLINDER BLOCK
--CLEANING OF CYLINDER BLOCK
--INSPECTION OF CYLINDER BLOCK
-REMOVAL OF GLAZE FROM CYLINDER BORE
--DISASSEMBLY
--INSPECTION
--REMOVAL OF GLAZE
--CLEANING
--ASSEMBLY
--REMOVAL OF GLAZE FROM CYLINDER BLOCK
-REPLACEMENT OF PLUG
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
-REPLACEMENT OF CAP
--REMOVAL
--CLEANING
--INSTALLATION
-INSTALLATION OF CAP AND PLUG
--INSTALLATION OF CAMSHAFT CUP
--INSTALLATION OF CAMSHAFT BUSHING
--REPLACEMENT OF DIPSTICK TUBE
--STORING CYLINDER BLOCK
-CRANKSHAFT
--REPLACEMENT OF MAIN BEARING
--CLEANING OF CRANKSHAFT
--INSTALLATION OF CRANKSHAFT
--REPLACEMENT OF CRANKSHAFT GEAR
--REPLACEMENT OF CAMSHAFT AND TAPPET
--REMOVAL OF CAMSHAFT
--REMOVAL OF TAPPET
--INSPECTION OF TAPPET
--STANDARDS FOR PITTING WHEN REUSING
--STANDARD FOR DETERIORATION (BREAKAGE) OF TIP
--INSPECTION OF CAMSHAFT BORE
--REPLACEMENT OF CAMSHAFT BUSHING
---INSTALLATION OF TAPPET
---INSTALLATION OF CAMSHAFT
--CLEANING OF CAMSHAFT
---INSPECTION OF CAMSHAFT,GEAR
--REPLACEMENT OF CAMSHAFT,GEAR
---CLEANING AND INSPECTION
---INSTALLATION
-REPLACEMENT OF TIMING PIN
-REPLACEMENT OF GEAR HOUSING, GASKET
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
--REPOSITIONING OF TIMING PIN
-REPLACEMENT OF CAMSHAFT GEAR
--REMOVAL
--INSTALLATION (SHRINK-FITTING METHOD)
--INSTALLATION (METHOD USING SPECIAL TOOL)
--INSTALLATION OF CAMSHAFT MOUNTING BOLTS
-REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
--REMOVAL
--INSPECTION OF RUBBER DAMPER
--INSTALLATION
--INSPECTION OF VISCOUS DAMPER
--VIBRATION DAMPER (RUBBER TYPE)
--CLEANING AND INSPECTION
-PISTON,PIN,CONNECTING ROD
--REPLACEMENT OF PISTON AND RING
--REMOVAL OF PISTON CONNECTING ROD
--DISASSEMBLY OF PISTON CONNECTING ROD
--CLEANING OF PISTON,PIN,CONNECTING ROD
--INSPECTION OF PISTON
--INSPECTION OF PISTON PIN
--ASSEMBLY OF PISTON CONNECTING ROD
--INSPECTION OF PISTON RING GAP
--INSTALLATION OF PISTON RING
--INSTALLATION OF PISTON CONNECTING ROD
-REPLACEMENT OF CONNECTING ROD
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
-REPLACEMENT OF CONNECTING ROD BEARING
--REMOVAL
--CLEANING AND INSPECTION
--INSTALLATION
--DISASSEMBLY OF PISTON CONNECTING ROD
--CLEANING OF PISTON, PIN, CONNECTING ROD
--INSPECTION OF PISTON
--INSPECTION OF PISTON PIN
--INSPECTION OF CONNECTING ROD
--INSPECTION OF CONNECTING ROD BEARING CLEARANCE
--ASSEMBLY OF PISTON CONNECTING ROD
--INSPECTION OF PISTON RING END GAP
--INSTALLATION OF PISTON RING
-BALANCER
--DISASSEMBLY
--ASSEMBLY
-GEAR COVER
--REPLACEMENT OF GEAR COVER
---REMOVAL
---CLEANING AND INSPECTION
---INSTALLATION
---INSTALLATION OF GEAR COVER
---INSPECTION OF GEAR HOUSING AND TIMING PIN
---DISASSEMBLY OF GEAR HOUSING
---REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD
---REPLACEMENT OF ENGINE NAME PLATE
-CYLINDER HEAD
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE
--REPLACEMENT OF CYLINDER HEAD
---REMOVAL
---INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD
---DISASSEMBLY OF CYLINDER HEAD
---CLEANING OF CYLINDER HEAD
---INSPECTION OF VALVE
---INSPECTION OF VALVE GUIDE
---INSPECTION OF CYLINDER DECK
---INSPECTION OF VALVE SEAT
---STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING
---REPLACEMENT OF VALVE SPRING
---ASSEMBLY OF CYLINDER HEAD
---ADJUSTING VALVE CLEARANCE
---INSTALLATION OF BELT TENSIONER
---INSTALLATION OF ALTERNATOR
---INSTALLATION OF DRIVE BELT
---INSPECTION BEFORE DISASSEMBLY
---DISASSEMBLY OF CYLINDER HEAD
---CLEANING OF CYLINDER HEAD
---INSPECTION OF VALVE
---INSPECTION OF VALVE GUIDE
---INSPECTION OF CYLINDER HEAD COMBUSTION DECK
---INSPECTION OF VALVE SEAT
---STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING
---REPLACEMENT OF VALVE SPRING
---REPLACEMENT OF CAP
---POLISHING VALVE
---POLISHING VALVE SEAT
-ROCKER LEVER
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE
--REPLACEMENT OF ROCKER LEVER AND PUSH ROD
---REMOVAL
--DISASSEMBLY OF ROCKER LEVER
--CLEANING OF ROCKER LEVER
--INSPECTION OF ROCKER LEVER
--ASSEMBLY OF ROCKER LEVER
--INSTALLATION OF ROCKER LEVER
--DISASSEMBLY OF ROCKER LEVER
--CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT
--INSPECTION OF ROCKER LEVER
--INSPECTION OF ROCKER LEVER SHAFT
--ASSEMBLY OF ROCKER LEVER
-TAPPETS AND PUSH RODS
--DISASSEMBLY AND ASSEMBLY DRAWING
--OUTLINE
--CLEANING OF PUSH ROD
--INSPECTION OF PUSH ROD
--INSTALLATION OF PUSH ROD
--INSPECTION OF TAPPET
-ENGINE MOUNT GROUP
--OUTLINE OF FLYWHEEL HOUSING
--OUTLINE OF FLYWHEEL, RING GEAR
--OUTLINE OF FRONT SUPPORT
-FLYWHEEL, RING GEAR
--INSPECTION OF FLYWHEEL, RING GEAR
--REPLACEMENT OF FLYWHEEL, RING GEAR
-FLYWHEEL HOUSING
--REPLACEMENT OF REAR OIL SEAL
---REMOVAL
---CLEANING AND INSPECTION
---INSTALLATION
--REPLACEMENT OF FLYWHEEL HOUSING
---REMOVAL
---CLEANING AND INSPECTION
---INSTALLATION (DRY CLUTCH SPECIFICATION)
---INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING
---INSPECTION OF FACE RUNOUT OF FLTWHEEL HOUSING
---INSTALLATION (WET CLUTCH SPECIFICATION)
---INSPECTION
---INSTALLATION
-FRONT SUPPORT
--CLEANING AND INSPECTION
-REMOVAL OF ENGINE
-INSPECTION OF ENGINE MOUNT
-INSTALLATION OF ENGINE
-OIL PAN AND SUCTION TUBE
--DISASSEMBLY AND ASSEMBLY DRAWING
-REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET
--CLEANING AND INSPECTION
-REGULATOR VALVE
--REPLACEMENT OF REGULATOR VALVE, SPRING
---DISASSEMBLY
--CLEANING AND INSPECTION
-OIL FILTER BYPASS VALVE
--REPLACEMENT
-OIL COOLER
--DISASSEMBLY AND ASSEMBLY DRAWING
--REPLACEMENT OF OIL COOLER CORE, GASKET
--CLEANING
--INSPECTION
-OIL PUMP
--DISASSEMBLY AND ASSEMBLY DRAWING
--REPLACEMENT OF OIL PUMP
--CLEANING AND INSPECTION
--INSTALLATION OF OIL PUMP
--INSPECTION
-FUEL INJECTION PUMP GROUP
--DISASSEMBLY AND ASSEMBLY DRAWING
-FUEL INJECTION NOZZLE GROUP
--FUEL INJECTION NOZZLE
---DISASSEMBLY
--CLEANING AND INSPECTION
---ASSEMBLY
-FEED PUMP (CYLINDER BLOCK MOUNT TYPE)
--REPLACEMENT OF FEED PUMP (DIAPHRAGM TYPE)
-REPLACEMENT, ASSEMBLY OF FEED PUMP (PISTON TYPE)
--CLEANING
--ASSEMBLY
--INSTALLATION
-REPLACEMENT OF FUEL FILTER
-FUEL PIPING
--REPLACEMENT OF HIGH-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV)
--REPLACEMENT OF FUEL SUPPLY PIPING (BOSCH VE, LUCAS CAV)
--CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING
--REPLACEMENT OF FUEL RETURN PIPING (BOSCH VE, LUCAS CAV)
--CLEANING AND INSPECTION OF FUEL DRAIN PIPING
--REPLACEMENT OF LOW-PRES-SURE FUEL PIPING (BOSCH VE, LUCAS CAV)
--CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING
--REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE (BOSCH VE)
-WATER PUMP
--DISASSEMBLY AND ASSEMBLY DRAWING
--REPLACEMENT OF WATER PUMP
--INSPECTION
-FAN HUB
--REPLACEMENT OF FAN PULLEY
--REPLACEMENT OF FAN HUB
--INSPECTION
--DISASSEMBLY
--ASSEMBLY
-BELT TENSIONER
--DISASSEMBLY AND ASSEMBLY DRAWING
--REPLACEMENT OF BELT
--REPLACEMENT OF BELT TENSIONER
--INSPECTION
-THERMOSTAT
--DISASSEMBLY AND ASSEMBLY DRAWING
--REPLACEMENT OF THERMOSTAT
--INSPECTION
-FAN
-COOLANT
-ACCESSORY DRIVE ADAPTER
--DISASSEMBLY AND ASSEMBLY DRAWING
--CLEANING
--INSPECTION
--DISASSEMBLY
--ASSEMBLY
-DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD
--CLEANING
--INSPECTION
--ASSEMBLY
--REPLACEMENT OF AIR COMPRESSOR
--REMOVAL
--INSPECTION
--INSTALLATION
-ALTERNATOR
--INSPECTION
-STARTING MOTOR
--INSPECTION

14 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

15 REPAIR AND REPLACEMENT OF PARTS
-OUTLINE
--REPAIR GUIDELINE
--WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT
--INSPECTION
--TO ENSURE SAFETY,FOLLOW ALL INSTRUCTIONS IN MANUAL
--FOLLOW WASHING METHODS GIVEN IN MANUAL
--FOLLOW INSPECTION METHODS GIVEN IN MANUAL
-REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT
-METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS
--REPAIR PROCEDURE
-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
--REPLACING VALVE SEAT
-METHOD OF GRINDING VALVE
--CHECKING TENSION OF VALVE SPRING
-ASSEMBLY OF CYLINDER HEAD
-PROCEDURE FOR REPAIRING CYLINDER BLOCK
--REPAIR TOOLS
--COMBUSTION DECK
--CAM BORE
--OUTLINE OF REPAIR OF CYLINDER BORE
--CYLINDER BORE
--INSTALLATION OF REPAIR SLEEVE
-PROCEDURE FOR REPAIRING CRANKSHAFT
--REPAIR TOOLS
--OUTLINE OF GRINDING CRANKSHAFT
--REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL
--REGRINDING CRANKSHAFT JOURNAL RADIUS
--SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL
--REGRINDING CRANKSHAFT ROD JOURNAL RADIUS
--OPTIONAL PROCEDURE
-PROCEDURE FOR REPAIRING CONNECTING ROD
--INSTALLATION OF PIN BORE BUSHING
--MACHINING OF CONNECTING ROD BUSHING
--INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD
--TESTING ALIGNMENT OF CONNECTING ROD
--INSPECTION OF TWISTING OF CONNECTING ROD
--REPLACING VALVE SEAT INSERT
--PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS

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