Komatsuengine(no series)

Komatsu 6D102-1-Z(S/N 30707205-UP)

Maintenance schedule, common problems & OEM parts breakdown

The 6D102-1-Z is a mid-range industrial diesel in Komatsu's 6D102 family: water-cooled, inline six-cylinder, roughly 5.9-liter displacement with a 102 mm bore. The S/N 30707205-UP break covers the mechanically governed, non-electronic build of that engine as factory power in Komatsu's D41A-6 crawler dozer, early 830-series motor graders, the WA180-3L and WA250-3L wheel loaders, and the 150A/150FA rough-terrain crane chassis. Rated output runs from roughly 82 hp on the dozer up toward 150 hp on the grader depending on host machine and governed speed - varies by configuration/series. Host machine operating weights span from about 9.3 metric tons (20,500 lb) on the smaller wheel loader to around 12.6 metric tons (27,800 lb) on the grader. These platforms date from the late 1980s through the late 1990s, spanning Komatsu's Dash-6 dozer generation and the Galion/Komatsu-Dresser crane and grader lines the company folded in through its joint venture with Dresser Industries. In shared chassis like the 150A/150FA crane, Komatsu offered this mechanical engine alongside a turbocharged, electronically governed S6D102E-1 option, so buyers could choose mechanical simplicity over electronic injection control.

Komatsu moved its 830-series grader to the larger 6D114E-1 engine in the 830B and 830C updates, and its dozer and wheel loader lines shifted toward turbocharged, electronically governed 6D102E and later SAA6D102E variants as emissions rules tightened through the 1990s and 2000s. That leaves the 6D102-1-Z as a late mechanical-generation engine: no electronic injection control, no aftertreatment, and a block and injection architecture simple enough to rebuild in the field. Because it was fitted across dozers, graders, wheel loaders, and cranes rather than a single model line, used cylinder heads, injection components, and long blocks stay in wider circulation than a single-application engine would support. For shops keeping D41A-6 dozers, early 830 graders, WA180-3L/WA250-3L loaders, or 150A/150FA cranes running past their original service life, that cross-application parts base is the main reason this engine still has a working presence in the used and rebuild market.

Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.

Komatsu 6D102-1-Z(S/N 30707205-UP) specifications

Engine

Model / seriesKomatsu 102-series diesel, factory code 6D102-1-Z / S6D102E-1-Z, S/N 30707205-UP production break
Cylinders / configuration6-cylinder, inline, 4-stroke, water-cooled, direct injection, all-speed mechanical governor
Bore x stroke102 mm x 120 mm (4.02 in x 4.72 in)
Displacement5.88 L (359 cu in)
Gross/net power (this serial break, industrial/lift-truck tune)approx. 71 kW (95 HP) at 2400 rpm net flywheel output
Power noteOther 6D102 family builds (naturally aspirated and turbocharged, used in excavators, dozers and wheel loaders) are rated from roughly 82 kW (110 HP) to 157 kW (210 HP) depending on tune - varies by configuration/series, verify rating against the nameplate for this exact serial
Compression ratioapprox. 16.5:1 (published for the 102-series family; not separately confirmed for this exact serial break)
Emissions tierMechanical diesel predating EPA/EU nonroad emissions tiers - no certified tier documented for this serial range

Weights

Engine dry weightapprox. 466 kg (1,025 lb) bare long block; complete accessorized builds for some fitments run up to approx. 560 kg (1,235 lb) - varies by configuration

Dimensions

Engine assembly (L x W x H)approx. 1,067 x 711 x 894 mm (42 x 28 x 35 in) for the standard build; some accessorized/turbo fitments list up to approx. 1,250 x 800 x 1,280 mm - varies by configuration

Performance

Rated speedapprox. 2400 rpm at rated output for the industrial/lift-truck tune
Peak torqueapprox. 340 lb-ft (461 Nm) in the low-speed range (roughly 1300-1600 rpm) - torque figures vary across published sources for this engine family, treat as approximate
Fuel systemDirect injection with all-speed mechanical governor

Service capacities (summary)

Engine oil (pan) capacityapprox. 22.8 L (24.1 qt / 6 US gal)
Coolant capacityapprox. 30 L (7.9 US gal) - figure sourced from a shared 102-series fitment; host-machine cooling circuit volume may differ
Fuel tankNot documented for the engine itself - fuel tank capacity is a host-machine (chassis) spec and was not confirmed for this exact serial break

Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.

6D102-1-Z(S/N 30707205-UP) fluids & capacities

SystemCapacityRecommended fluid
Engine crankcase (with filter)approx. 19-24 L (5.0-6.3 US gal), varies by carrier machine oil pan/sump configurationKomatsu Genuine engine oil, viscosity by ambient temperature: SAE 10W below 0 C, SAE 10W-30 across -20 to 40 C, SAE 15W-40 above 0 C, SAE 30 in warm climates; API CD/CE/CF-4 performance level for this engine generation. Equivalent commercial diesel engine oil of matching viscosity/API class accepted if genuine oil unavailable.
Cooling systemapprox. 22-28 L (5.9-7.4 US gal), varies by carrier machine radiator/circuit sizeKomatsu Supercoolant AF-NAC, ethylene-glycol type all-season antifreeze/anti-corrosion coolant, supplied pre-diluted (30/65 or 50/50 with water); maintain year-round for freeze and corrosion protection regardless of climate.
Fuel tanknot fixed at engine level; set by carrier machine (ranges roughly 80-225 L depending on excavator, dozer, wheel loader, or crane installation)ASTM D975 No. 2-D diesel fuel (or equivalent), cetane number 45 or higher; switch to No. 1-D or a winter-grade blend in cold climates below 0 C to prevent fuel waxing.
Transmission / powertrain (torque converter, transmission or damper case)not documented for the bare engine; determined by the host machine's own drivetrain and its OMM (dozer transmission, wheel loader torque-converter transmission, or excavator swing/travel drives differ by carrier)Komatsu Genuine powertrain oil (TO series), viscosity selected by ambient temperature per the host machine's own fluid chart; not specified in the engine-only literature.
Final drives (each)not applicable to the engine itself; final drive capacity is set by the carrier machine (dozer/wheel loader) and its own OMMKomatsu Genuine final drive oil (TO or GO series gear oil) per the host machine's chart; varies by configuration/series.
Hydraulic system and tanknot applicable to the engine assembly; hydraulic tank and system volumes are set by the carrier machine (excavator, wheel loader, or crane) and its own OMMKomatsu Genuine hydraulic oil (HO series), viscosity selected by ambient temperature per host machine chart; not part of the engine's own fluid specification.
Axles / differentialsapplicable only on wheel-loader or crane carriers using this engine; not documented at engine levelKomatsu Genuine axle oil (AXO series, GL-5 type gear oil) per the host machine's own maintenance chart where axles are fitted.
Grease (spec only)not applicable (lubrication points and intervals are set by the carrier machine)Komatsu Genuine Grease G2-LI, lithium EP multipurpose grease, NLGI 2, effective roughly -20 C to +120 C; in extreme cold below -20 C use Komatsu Genuine Grease G0-LI (NLGI 0) low-temperature grease.

Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.

Komatsu 6D102-1-Z(S/N 30707205-UP) maintenance schedule

Service intervalTasks
Every 10 h
  • Check engine oil level before starting and top up as needed
  • Check coolant level at the sub-tank, not the radiator cap, when cold
  • Check air cleaner restriction indicator and empty the dust cup
  • Walk-around check for fuel, oil, and coolant leaks around the block and manifold
  • Check fan belt tension and condition
  • Drain water and sediment from the fuel tank and water separator
Every 250 h
  • Change engine oil and replace the oil filter element
  • Replace the fuel filter cartridge
  • Check battery electrolyte level and clean terminals
  • Grease all chassis and undercarriage or driveline pivot points per the host machine's grease chart
  • Check alternator and starter mounting bolt torque
  • Inspect exhaust manifold and turbo mounting hardware for looseness
Every 500 h
  • Replace the fuel pre-filter or water separator element
  • Check and adjust fan belt tension
  • Test coolant condition and additive concentration
  • Check alternator charging output
  • Inspect and grease driveshaft or PTO u-joints on grader and crane applications
  • Check engine mounting bolts for torque
Every 1,000 h
  • Adjust valve clearance for the first time on a new or rebuilt engine
  • Replace the hydraulic oil filter on the host machine
  • Check fuel injection nozzle spray pattern and opening pressure
  • Check turbocharger shaft end play where a turbocharged build is fitted
  • Replace transmission or torque converter oil filter
  • Inspect engine mounts and vibration damper condition
Every 2,000 h
  • Adjust valve clearance again and at every 2000-hour interval thereafter
  • Replace or test coolant and corrosion resistor element
  • Inspect turbocharger housing and compressor wheel for play or fouling
  • Check fuel injection pump timing
  • Replace fuel injection nozzles showing wear or poor spray pattern
  • Check crankshaft pulley and vibration damper for cracking or delamination
Every 4,000 h
  • Flush the cooling system and refill with fresh coolant to specification
  • Pull and bench-test or overhaul the fuel injection pump
  • Inspect cylinder head for valve seat recession and guide wear
  • Replace the water pump if seal weep or bearing play is present
  • Check block-to-liner fit and cylinder bore wear ahead of any top overhaul

Servicing the 6D102-1-Z(S/N 30707205-UP) beyond the schedule

Predictive Maintenance & Fluid Analysis

Sample engine oil at every 250-hour change on the 6D102-1-Z and trend wear metals from the cast-iron liners and wet cylinder sleeves; rising iron or copper points to ring or bearing wear before it reaches the crank. On host machines still running conventional coolant rather than long-life fill, check silicate depletion at each interval since this engine predates long-life coolant as a factory standard. On the 830-series grader and 150A/150FA crane, trend hydraulic pump drive coupling wear alongside oil analysis - shared PTO loads on these builds can mask early engine bearing wear.

Corrective & Common Repairs

Common failures on this mechanically governed 6D102-1-Z trace to the injection pump linkage and governor springs sticking with age, producing surging at idle - free and clean the linkage before condemning the pump. Fan belt and water pump bearing wear shows up often on the D41A-6 and WA180-3L/WA250-3L given constant dusty duty; check belt tension every 50 hours. Exhaust manifold cracking appears on graders and cranes doing sustained high-load work. Fuel filter housings on these older builds tend to weep at the gasket - reseat rather than over-torque.

Overhaul & Rebuild Points

Cylinder liners are the key wear item at overhaul; measure bore taper and ovality against shop manual limits before choosing between honing and liner replacement. Check crankshaft main and rod journal wear alongside valve seat recession, since these mechanical-injection blocks were tuned for older diesel fuel rather than modern low-sulfur blends. On D41A-6 and WA-series applications, inspect the flywheel housing and PTO drive gear train for wear from the torque converter or transmission side before reassembly. Parts pulled from later electronically governed 6D102E variants need dimensional verification, not assumed fit.

Seasonal & Environment Servicing

In cold climates, D41A-6 and WA180-3L/WA250-3L owners should switch to a lower-viscosity winter-grade engine oil and confirm coolant freeze protection before first frost, since this mechanical engine has no electronic cold-start assist to fall back on. In hot, dusty grader and crane duty, shorten air cleaner service intervals and check the pre-cleaner more often than the standard 250-hour chart calls for. Store idle machines with a full, treated fuel tank to limit condensation inside the mechanical injection pump, a known issue on units sitting between seasonal grading or lifting contracts.

6D102-1-Z(S/N 30707205-UP) common service parts

Part numberPart
6732-21-5530Cartridge, Engine Oil FilterCheck fitment →
6736-61-5170Head, Lube Oil FilterCheck fitment →
6735-61-2150Gasket, Filter HeadCheck fitment →
6735-61-2260Head, FilterCheck fitment →
6736-61-5180Adapter, Filter HeadCheck fitment →

Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.

6D102-1-Z(S/N 30707205-UP) fault codes & troubleshooting

CodeMeaningLikely causeWhat to do
E02PC-EPC (pump controller, electronic proportional control) system faultOpen, shorted, or corroded harness or connector at the EPC solenoid on the hydraulic pump, or a failed pump controllerStop and inspect EPC solenoid wiring and connectors for damage or corrosion before ordering a controller; report the code to the dealer if it repeats
E03Swing (rotary) parking brake system faultFaulty parking brake switch, solenoid, or wiring in the swing brake release circuitStop the machine, check the parking brake switch and its wiring, and report the code to the dealer before moving the machine again
E05Governor motor system faultFaulty electric governor motor, worn or disconnected linkage, or bad feedback signal on the mechanical injection pump's speed controlInspect the governor motor and linkage for binding, disconnection, or wiring damage; confirm motor power and feedback signal before replacing the motor
E101Fault history record abnormal (monitor/controller memory fault)Internal memory or backup power fault in the machine monitor/controllerHave a technician check monitor backup power and verify stored fault history; replace the controller if the fault persists
E102Clock data abnormalMonitor internal clock or backup battery failureReset the clock; if it will not hold the correct time, replace the monitor backup battery or the panel itself
E103Buzzer output short-circuited (buzzer drive harness contacting the 24V line)Shorted alarm buzzer or damaged wiring in the buzzer circuitCheck the buzzer and its harness for a short, repair the wiring, or replace the buzzer
E104Air filter cloggedDirty or blocked air filter elementInspect and clean or replace the air filter element
E108Coolant (water) temperature above roughly 105 C (221 F)Low coolant level, blocked radiator core, slipping or broken fan belt, or a faulty coolant temperature sensorStop the engine safely, let it cool, then check coolant level, radiator, fan, and belt before restarting

Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.

6D102-1-Z(S/N 30707205-UP) attachments & work tools

Model type clarification

6D102-1-Z (S/N 30707205-UP) is an engine designation, not a machine model. Attachment and work-tool compatibility is set by the chassis the engine is installed in, not by the engine itself, so treat the rows below as class-level guidance rather than a factory attachment list for this exact serial range.

Host machine class

Engines in the 6D102 family, including this naturally aspirated -1-Z build, power Komatsu compact-to-midsize hydraulic excavators in roughly the 12-20 tonne class and related industrial power units. Confirm the exact host chassis and serial break with a dealer before ordering attachments, since the same engine family also appears with turbocharged and electronically governed variants on different size classes.

General purpose buckets

For this excavator size class, standard digging buckets run roughly 0.4-0.9 cubic meter (0.5-1.2 cu yd) struck capacity, with narrower ditching/trenching buckets and skeleton (screening) buckets offered as size options. Bucket width and tooth pattern vary by application (general purpose, rock, or clean-up).

Hydraulic breakers

Hydraulic breakers sized for this class typically fall in the 0.9-1.8 tonne operating-weight range and require a dedicated one-way (single-acting) auxiliary hydraulic circuit routed to the arm end. Breaker output is matched to the excavator's pump flow and relief-pressure setting; oversized breakers risk piston damage or reduced impact rate.

Quick couplers

Both mechanical pin-grabber couplers and hydraulic (single- or fully automatic double-locking) quick couplers are offered for this machine class, letting the operator swap buckets, breakers, and grapples without leaving the cab on hydraulic versions. Coupler pin spacing and pin diameter must match the stick and bucket linkage of the host excavator.

Grapples and thumbs

Hydraulic thumbs pivot off the bucket pin and are used with the standard bucket for handling debris, pipe, or brush; demolition/sorting grapples mount in place of the bucket. Both need their own single-acting auxiliary circuit and, on some installations, a reinforced arm-end bracket.

Compaction and vibratory attachments

Plate compactors for trench backfill in this class are driven off a high-flow one-way auxiliary circuit; flow and relief settings must be matched to the compactor manufacturer's chart to avoid overheating the attachment's hydraulic motor.

Augers and two-way attachments

Earth augers and other bidirectional attachments require a two-way (double-acting) auxiliary hydraulic circuit with in-cab flow/direction control, as opposed to the simpler one-way circuit used for breakers and compactors. Not all base machines in this class come pre-piped for two-way service; a dealer-installed kit is often needed.

Auxiliary hydraulic arrangement

Factory or dealer-fit auxiliary hydraulic kits for this excavator class add a second pump circuit and control valving to the boom or arm end, with a selector for one-way versus two-way operation depending on the tool fitted. Piping routes along the arm with protective guarding where it passes near the bucket cylinder.

Guarding and factory options

For breaker and demolition duty, common factory or dealer options include arm/boom heel guards, reinforced cylinder guards, and an upgraded cab guard (falling-object protection) rated for the tool class in use. These are typically ordered as a package with the attachment rather than fitted standalone.

All 6D102-1-Z(S/N 30707205-UP) assemblies by section

Every catalogued assembly group for the Komatsu 6D102-1-Z(S/N 30707205-UP). Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.

Engine
Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Air Intake Connection And Exhaust Manifold
67***60Bolt, Mounting (M8x1.25x25)12
67***30Bolt, Mounting (M10x1.50x65)12
67***10Gasket,Exhaust Manifold6
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Alternator (40a) (Inner Parts)
20***10Cover1
20***20Bearing1
20***30Plate1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Alternator Mounting (40a)
12***60Brace1
12***80Fan1
12***30Pulley1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Camfollower Cover
67***20Hose1
67***20Bolt, Flange (M8-1.25x20)4
67***90Seal4
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Camshaft And Tappet
67***20Support, Camshaft Thrust1
67***60Bolt (M8x1.25x22)2
67***80Key, Plain Woodruff (4.0mm)1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Crankshaft
67***30Metal1
67***50Gear, Crankshaft1
67***10Metal,Lower7
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Cylinder Block
67***10Plug, Pipe (1/2-14 Npt)1
67***30Plug, Pipe (1/8 Nptf)2
67***90Nozzle, Piston Cooling6
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Cylinder Head
67***10Bolt, Mounting (M12x1.75x70)6
67***20Bolt, Mounting (M12x1.75x120)14
67***10Plug, Pipe (1/2-14 Npt)5
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Damper
67***20Bolt (M12x1.25x36)4
67***10Damper1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Engine Hanger
67***20Bolt (M12x1.75x30)2
67***10Bracket, Lifting1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Fan Drive
67***70Bolt, Mounting (M8-1.25x40)4
67***20Support Ass'Y,Fan1
67***10Hub, Fan1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Flywheel Housing
67***20Plug, Pipe (3/4 Nptf)1
67***10Seal,Oil (K2)1
67***30Plate, Cover1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Front Cover
67***40Pin, Timing1
67***50Ring, Retaining1
67***60Screw, Round Head (M5-0.80x17)2
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Fuel Injection Piping And Spill Pipe
07***12Gasket,(Without Air Compressor Type) (K1)2
67***60Bolt, Mounting (M8x1.25x25)2
67***90Valve, Check (M8x1.25x17.5)1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Fuel Injection Pump Mounting
67***10Nut, Hex Flange (M8-1.25)3
67***20Bolt, Flange (M8-1.25x20)3
67***30Stud3
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Fuel Shut Off Valve
67***10Solenoid,(For Bosch Injection Pump)1
67***10Solenoid,(For Cav Injection Pump)1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Fuel Transfer Pump
12***70Tube1
67***60Bolt2
67***40Elbow1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Head Cover
67***30Bolt (M8x1.25x25)6
67***10Gasket, Valve Cover6
67***10Cover,Head1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Injection Nozzle
67***50Seal, Rectangular Ring1
67***30Seal, Banjo Connector (6.2 mm)1
67***00Injector,Kit6
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Kit
07***12Gasket,Mechanical Pump Piping2
67***10Gasket,Exhaust Manifold6
67***20Seal, Rectangular Ring1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Oil Filler (Without Oil Filler)
67***60Plug, Expansion (Not Used With Side Oil Fill)1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Oil Filter And Oil Cooler
67***30Plug, Pipe (1/8 Nptf)1
67***40Bolt, (M8x1.25x35)14
67***40Plug Ass'Y1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Oil Level Gauge
Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Oil Pan
Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Oil Pump
67***10Oil Pump Ass'Y1
67***20Bolt (M8x1.25x30)4
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Piston
67***00Rod, Engine Connecting6
67***10Rod1
67***30Bushing1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Rocker Arm
67***40Bolt6
67***10Rod, Push12
67***20Bracket1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Starting Motor Mounting (4.5kw)
67***10Gasket1
67***20Bolt, Mounting (M10x1.50x35)3
67***10Seal1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Tension Pulley
12***10Bracket1
67***60Bolt, Mounting (M8-1.25x25)1
67***10Tensioner, Belt1
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Thermostat And Thermostat Housing
67***10Thermostat1
67***40Bolt, (M8x1.25x35)1
67***50Bolt2
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Water Inlet Connection
67***10Plug, Pipe (1/2-14 Npt)1
67***20Plug, Pipe (3/4 Nptf)1
67***20Bolt (M10-1.50x75)3
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Komatsu : 6d102-1-Z(S/N 30707205-Up) : Engine : Water Pump
67***60Bolt (M8x1.25x22)2
67***00Pump,Water1
67***00Water Pump Ass'Y1
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Frequently asked questions

What engine is the Komatsu 6D102-1-Z(S/N 30707205-UP)?

It is a water-cooled, inline six-cylinder diesel in Komatsu's 6D102 family, roughly 5.9-liter displacement with a 102 mm bore. This serial-number break is the mechanically governed, non-electronic build used as factory power in the Komatsu D41A-6 crawler dozer, early 830-series motor grader, WA180-3L and WA250-3L wheel loaders, and the 150A/150FA rough-terrain crane.

What is the operating weight of machines using the 6D102-1-Z(S/N 30707205-UP)?

There is no single weight since the engine spans several machine classes - it varies by configuration/series. The WA180-3L wheel loader runs around 9.3 metric tons (about 20,500 lb), the D41A-6 dozer around 10.5 to 11.3 metric tons, and the 830-series grader around 12.6 metric tons (about 27,800 lb).

What replaced the 6D102-1-Z(S/N 30707205-UP)?

There is no single successor because replacement depended on the host machine. Komatsu moved the 830-series grader to the larger 6D114E-1 engine in the 830B/830C update, while its dozer and wheel loader lines transitioned to turbocharged, electronically governed 6D102E and later SAA6D102E variants as those platforms were refreshed. The 150A/150FA crane chassis was discontinued rather than re-engined.

What 6D102-1-Z(S/N 30707205-UP) owners discuss

What family does the 6D102-1-Z (S/N 30707205-UP) actually belong to, and which machines run it?
It's a direct-injection, turbocharged inline-six of 5.9 L (360 cu in) displacement, with 102 mm x 120 mm (4.02 in x 4.72 in) bore and stroke and a 16.5:1 compression ratio. It shares its basic block architecture with the Cummins 6BT 5.9 - long-time mechanics often refer to this family as "the Komatsu Cummins." The -1-Z designation is the earlier, mechanically governed generation: inline Bosch-type injection pump with an electric fuel shutoff solenoid, no engine ECU. It shows up broadly across Komatsu's -6 era lineup - PC200-6/PC220-6 family crawler excavators, WA180-3/WA250-3 wheel loaders, D41-6 dozers, plus rollers and graders through Komatsu's industrial power line. It predates the later electronically governed SAA6D102E-1/-2 used in -7 and -8 series machines - don't cross-shop parts, torque figures, or ratings between the two families without checking which side of that serial break you're on.
What powertrain or hydraulic behaviors do owners commonly flag on this engine and its hosts?
The most repeated comment is a light oil weep down the side of the block, usually around the pan rail/rear main area. Plenty of owners describe it as normal character for this engine rather than a fault, as long as it stays a weep and not a drip and oil level holds between services. On crawler excavator hosts, a hydraulic system that feels weak or slow more often traces back to relief-valve or main pump wear than to the engine - check main relief pressure before condemning anything upstream. On wheel loader hosts, watch for torque converter charge pressure drifting below spec as the charge pump and converter wear in; it shows up as sluggish response or needing more throttle than the machine used to need for the same task.
What undercarriage or driveline wear patterns are typical for the machines this engine powers?
On the crawler hosts (excavators and dozers), track tension is the single biggest lever on undercarriage life. Even a small over-tightening from correct sag accelerates wear at the bushing-to-sprocket-tooth contact and at the idler, while excess sag lets the chain slap and wears the same components from the other direction. Daily sag checks, and re-adjusting whenever ground or material conditions change, are standard practice among long-term owners. On wheel loader hosts, the early warning for charge pump or torque converter wear is metal or friction material showing up at the transmission suction screen and filters during scheduled service, well before the machine shows an obvious loss of power.
What engine-specific quirks come up repeatedly for this 102-series family?
Shops that rebuild these heads note a known tendency to crack between the valve seats when localized overheating goes unaddressed - keeping the cooling system flushed and the thermostat and coolant level in spec is the standard preventive advice, and rebuilders favor reinforced replacement head castings for better thermal fatigue resistance. Main bearing, connecting rod, and head bolts follow a staged torque-plus-angle procedure rather than a single torque value - reusing old head bolts or skipping the angle step is a common cause of repeat head gasket failures reported after a rebuild. Exhaust manifold and turbo joint leaks are also worth checking on any tired example - a leak here shows up as weak low-speed response that seems to recover some at higher rpm, which gets mistaken for turbo failure when it's really lost exhaust energy at the manifold joint.
How does cold starting and fuel delivery behave on this generation, and what wears out?
This generation doesn't use glow plugs. Cold-start performance rides on an intake air heater (a grid-style heating element with its own relay) that warms incoming air before and during cranking. A tired heater element or a failed relay is the classic explanation for a hard cold start that isn't a compression or injector problem, and it's worth checking before chasing anything more expensive. At higher hours, injector and injection-pump wear - rough idle, increased smoke, harder starting even when warm - is the expected fuel-system wear item; some shops place this around 4,000-plus hours, though it varies a lot with fuel quality and duty cycle, so treat any single number as a rough guide rather than a rule.
What electrical or sensor issues are common on machines from this era?
This is a pre-ECU generation, so there's no engine fault-code system to lean on for diagnosis - troubleshooting here is old-school point-to-point. The two most repeated culprits behind gauge, monitor, or charging complaints are a corroded or loose cab-to-frame ground strap (the cab sits on isolation mounts and is deliberately grounded back to the frame with a separate wire, so a bad connection there can mimic all sorts of unrelated electrical faults) and a corroded oil pressure switch connector or a chafed harness run back toward the block. Some early monitor/gauge panels from this era are also known for LCD degradation after years of sun exposure, which reads as a dead or unreadable display rather than an actual sensor failure. Any oil pressure or charging warning should still be treated as real until proven otherwise - have your dealer verify before dismissing it as "just the gauge."
What should a buyer check on a used machine fitted with this engine and serial range?
Start with a true cold start - excessive cranking points to a weak intake air heater/relay or worn injectors/pump rather than anything more serious, but don't ignore it. Watch exhaust color through startup and under load: some white smoke on a cold morning clearing quickly is normal, but persistent white suggests unburned fuel (injectors, intake heater, or air restriction), blue suggests oil being burned past rings or valve seals, and black points to a fuel or air delivery problem. Pull the dipstick and the coolant - a milky, mayonnaise-like oil or oil in the coolant is a head gasket or cracked head until proven otherwise, tying back to the cracking pattern this family is known for. Check the pan rail and rear main for a light weep versus an active drip, confirm the undercarriage or (on loader configurations) the torque converter charge pressure and transmission screens are within spec for the hour meter shown, and confirm the engine data plate serial actually falls in the 30707205-UP range so parts and torque specs pulled for the machine match the engine actually installed. Compression, head gasket condition, and torque converter charge pressure are not things to guess at from a walk-around - have your dealer verify these before you commit to a price.

Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.

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