Komatsu 12V140-1 Series Diesel Engine Shop Manual SEBM028318 – PDF DOWNLOAD

Komatsu 12V140-1 Series Diesel Engine Shop Manual SEBM028318 – PDF DOWNLOAD

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Komatsu 12V140-1 Series Diesel Engine Shop Manual SEBM028318 – PDF DOWNLOAD

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Pages : 471
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Komatsu 12V140-1 Series Diesel Engine Shop Manual SEBM028318 – PDF DOWNLOAD

The Komatsu 12V140-1 Series Diesel Engine Shop Manual is a comprehensive guide to servicing, maintaining, and repairing the Komatsu 12V140-1 diesel engine. This engine is commonly used in a variety of heavy equipment, including excavators, bulldozers, and other construction machinery.

The manual is published by Komatsu, a leading manufacturer of heavy equipment and diesel engines. It is designed to provide detailed information on the engine to qualified mechanics and technicians, enabling them to service and repair the engine to the highest standards.

The manual is divided into several sections, each of which provides specific information on different aspects of the engine. The sections include:

1. General information: This section provides an overview of the engine, including its specifications, features, and operating principles. It also includes information on safety precautions, tools, and equipment needed for maintenance and repair.
2. Inspection and adjustment: This section provides detailed instructions on how to inspect and adjust various components of the engine, including the cylinder head, valves, fuel system, and cooling system.
3. Engine disassembly and assembly: This section provides step-by-step instructions on how to disassemble and assemble the engine. It includes detailed diagrams and illustrations to help users understand each step of the process.
4. Troubleshooting: This section provides a comprehensive list of potential problems that may arise with the engine, along with diagnostic procedures to help identify and fix these issues.
5. Maintenance: This section provides information on the regular maintenance tasks that should be performed on the engine, including oil changes, filter replacements, and other routine tasks.
6. Reassembly and testing: This section provides detailed instructions on how to reassemble the engine after repairs have been made. It also includes information on how to test the engine to ensure that it is functioning properly.
7. Service data: This section provides detailed technical data on the engine, including torque specifications, compression pressures, and other important information.

The manual is written in clear, concise language and is filled with detailed diagrams and illustrations to help users understand each step of the process. It is an essential tool for anyone who works with Komatsu diesel engines and can help to ensure that the engine is maintained and repaired to the highest standards.

However, it should be noted that the manual is designed for use by qualified mechanics and technicians and should not be used by individuals without the appropriate training and experience. The manual is also specifically for the Komatsu 12V140-1 engine and should not be used as a reference for other engines in the Komatsu lineup.

TABLE OF CONTENTS:

Komatsu 12V140-1 Series Diesel Engine Shop Manual SEBM028318 – PDF DOWNLOAD

COVER…………………………………………………………………………………………………………………….. 1
CONTENTS………………………………………………………………………………………………………………….. 2
01 GENERAL………………………………………………………………………………………………………………… 27
APPLICABLE MACHINE……………………………………………………………………………………………………… 28
SPECIFICATIONS…………………………………………………………………………………………………………. 29
GENERAL ASSEMBLY DRAWING………………………………………………………………………………………………… 38
ENGINE PERFORMANCE CURVE………………………………………………………………………………………………… 51
WEIGHT TABLE…………………………………………………………………………………………………………… 64
11 STRUCTURE AND FUNCTION…………………………………………………………………………………………………… 66
GENERAL STRUCTRE……………………………………………………………………………………………………….. 67
INTAKE AND EXHAUST SYSTEM……………………………………………………………………………………………….. 69
AIR CLEANER………………………………………………………………………………………………………… 71
TURBOCHARGER……………………………………………………………………………………………………….. 72
AFTER-COOLER……………………………………………………………………………………………………….. 74
ENGINE BODY……………………………………………………………………………………………………………. 75
CYLINDER HEAD………………………………………………………………………………………………………. 75
CYLINDER BLOCK……………………………………………………………………………………………………… 79
MAIN REVOLVING SYSTEM……………………………………………………………………………………………….. 81
TIMING GEAR………………………………………………………………………………………………………… 83
VALVE SYSTEM……………………………………………………………………………………………………….. 87
FLYWHEEL AND FLYWHEEL HOUSING………………………………………………………………………………………… 91
LUBRICATION SYSTEM……………………………………………………………………………………………………… 92
LUBRICATION SYSTEM CHART…………………………………………………………………………………………….. 92
OIL PUMP…………………………………………………………………………………………………………… 94
MAIN RELIEF………………………………………………………………………………………………………… 95
OIL COOLER BY-PASS VALVE, REGULATOR VALVE……………………………………………………………………………… 96
OIL FILTER…………………………………………………………………………………………………………. 98
OIL COOLER………………………………………………………………………………………………………….102
FUEL SYSTEM ……………………………………………………………………………………………………………103
FUEL SYSTEM CHART……………………………………………………………………………………………………103
FUEL INJECTION PUMP………………………………………………………………………………………………….106
FUEL INJECTION NOZZLE………………………………………………………………………………………………..120
FUEL FILTER…………………………………………………………………………………………………………121
ENGINE STOP MOTOR……………………………………………………………………………………………………123
COOLING SYSTEM………………………………………………………………………………………………………….128
COLING SYSTEM SHART………………………………………………………………………………………………….128
WATER PUMP………………………………………………………………………………………………………….129
COOLING FAN…………………………………………………………………………………………………………130
THERMOSTAT………………………………………………………………………………………………………….136
CORROSION RESISTOR…………………………………………………………………………………………………..137
ACCESSORY………………………………………………………………………………………………………………138
AIR COMPRESSOR………………………………………………………………………………………………………138
EXHAUST BRAKE……………………………………………………………………………………………………….140
ELECTRICAL SYSTEM……………………………………………………………………………………………………….141
ALTERNATOR………………………………………………………………………………………………………….141
STARTING MOTOR………………………………………………………………………………………………………144
ELECTRICAL INTAKE AIR HEATER………………………………………………………………………………………….145
OIL PAN HEATER………………………………………………………………………………………………………146
COOLING WATER HEATER…………………………………………………………………………………………………147
12 TESTING AND ADJUSTING…………………………………………………………………………………………………….148
ENGINE BODY…………………………………………………………………………………………………………….149
ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………….149
MEASURING COMPRESSION PRESSURE………………………………………………………………………………………..150
MEASURING BLOW-BY……………………………………………………………………………………………………151
FUEL SYSTEM…………………………………………………………………………………………………………….152
TESTING AND ADJUSTMENT OF FUEL INJECTION TIMAING………………………………………………………………………..152
(WITH ZEXEL MECHANICAL GOVERNOR)…………………………………………………………………………………..152
(WITH ZEXEL ELECTRONICAL GOVERNOR)…………………………………………………………………………………155
TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH KOMATSU ELECTRONICAL GOVERNOR)………………………………………..158
ADJUSTING INJECTION PUMP GOVERNOR LINK…………………………………………………………………………………161
(WITH MECHANICAL GOVERNOR)………………………………………………………………………………………..161
(WITH ZECEL ELECTRONICAL GOVERNOR)…………………………………………………………………………………163
PROCEFURE FOR ADJUSTING ENGINE STOP MOTOR CABLE (APPLICABLE FOR MODELSUSING ENGINE STOP MOTOR)……………………………….165
METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR………………………………………………………………..166
ADJUSTING FUEL INJECTION PRESSURE……………………………………………………………………………………..167
FUEL INJECTION PUMP CALIBRATION DATA…………………………………………………………………………………..168
ADJUSTMENT OF ELECTRONICAL GOVERNOR MADE BY KOMATSU……………………………………………………………………..192
HANDLING OF THROTTLE BOX……………………………………………………………………………………………..209
HANDLING OF XEP CHECKER………………………………………………………………………………………………219
COOLING SYSTEM………………………………………………………………………………………………………….224
CHECKING AND ADJUSTING V-BELT TENSION………………………………………………………………………………….224
PERFORMANCE TEST………………………………………………………………………………………………………..226
RUNNING IN STANDARD………………………………………………………………………………………………….226
PERFORMANCE TEST CRITERIA…………………………………………………………………………………………….230
TESING AND ADJUSTING TOOL LIST………………………………………………………………………………………..240
TESTING AND ADJUSTING DATA……………………………………………………………………………………………241
TROUBLESHOOTING…………………………………………………………………………………………………………252
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………………………………..254
METHOD OF USING TROUBLESHOOTING CHART………………………………………………………………………………….255
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH ELECTRONICAL GOVERNOR)…………………………………..259
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH MECHANICAL GOVERNOR)…………………………………….260
S-2 EGINE DOES NOT START……………………………………………………………………………………………..261
① ENGINE DOES NOT TURN……………………………………………………………………………………………261
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH ELECTRONICAL GOVERNOR) …………………….262
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH MECHANICAL GOVERNOR)……………………….263
③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) …………………………………………….264
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…………………………………………………………………265
S-4 ENGINE STOPS DURING OPERATIONS (WITH MECHANICAL GOVERNOR)…………………………………………………………….267
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) (WITH ELECTRONICAL GOVERNOR)………………………………………………….268
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) (WITH MECHANICAL GOVERNOR)…………………………………………………..269
S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH ELECTRONICAL GOVERNOR)…………………………………………………………..270
S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH MECHANICAL GOVERNOR)…………………………………………………………….271
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH ELECTRONICAL GOVERNOR)……………………………………………..272
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH MECHANICAL GOVERNOR)……………………………………………….273
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)………………………………………………………………..274
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………………………………………………..275
S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH ELECTRONICAL GOVERNOR) ………………………………………………………….276
S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH MECHANICAL GOVERNOR)…………………………………………………………….277
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN……………………………………………….278
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)………………………………………………………………….279
S-13 OIL LEVEL RISES…………………………………………………………………………………………………280
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)……………………………………………………………………281
S-15 ABNORMAL NOISE IS MADE…………………………………………………………………………………………..282
S-16 VIBRATION IS EXCESSIVE…………………………………………………………………………………………..283
S-17 DIAGNOSIS OF ELECTRONICAL GOVERNOR BY DIAGNOSIS DISPLAY (ELECTRONICAL GOVERNOR MADE BY ZEXEL)……………………………284
1. CONTROLLER SYSTEM ABNORMALITY…………………………………………………………………………………..287
2. GOVERNOR SERVO SYSTEM ABNORMALITY……………………………………………………………………………….287
3. RACK SENSOR SYSTEM ABORMALITY…………………………………………………………………………………..289
4. OVERRUN ABNORMALITY……………………………………………………………………………………………291
5. 1ST SPEED SENSOR ABNORMALITY……………………………………………………………………………………292
6. 2ND SPEED SENSOR ABNORMALITY……………………………………………………………………………………292
7. LOW IDLING SPEED CONTROL DIAL ABNORMALITY………………………………………………………………………..293
8. DROOP CONTROL DIAL ABNORMALITY………………………………………………………………………………….294
9. DIAGNOSIS LAMP FAILS TO MAKE INDICATION………………………………………………………………………….295
10. NORMAIL INDICATION……………………………………………………………………………………………296
11. MEMORY CLEAR CANNOT BE ACHIEVED BY PRESSING THE MEMORY CLEAR SWITCH (WHEN FAILURE INDICATION IS MADE BY DIAGNOSIS LAMP)….301
13 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………….302
GENERAL DISASSEMBLY……………………………………………………………………………………………………..303
1. WASHING………………………………………………………………………………………………………….304
2. SETTING ENGINE STAND………………………………………………………………………………………………304
3. ENGINE COOLING WATER AND ENGINE OIL…………………………………………………………………………………305
4. FILTER…………………………………………………………………………………………………………..305
5. MUFFLER ASSERMBLY…………………………………………………………………………………………………305
6. FAN……………………………………………………………………………………………………………..305
7. FAN BELT…………………………………………………………………………………………………………306
8. FAN PULLEY ASSEMBLY……………………………………………………………………………………………….306
9. LNTAKE CONNECTOR………………………………………………………………………………………………….306
10. EXHAUST BRAKE ASSEMBLY……………………………………………………………………………………………306
11. TURBOCHARGER ASSEMBLY…………………………………………………………………………………………….307
12. INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY………………………………………………………………………………307
13. EXHAUST MANIFOLD ASSEMBLY…………………………………………………………………………………………308
14. FUEL INJECTION PIPE,SPIL TUBE……………………………………………………………………………………..308
15. FUEL INJECTION PUMP ASSEMBLY………………………………………………………………………………………309
16. WATER PUMP ASSEBLY……………………………………………………………………………………………….310
17. BREATHER………………………………………………………………………………………………………..310
18. AIR COMPRESSOR…………………………………………………………………………………………………..310
19. OIL COOLER ASSEMBLY………………………………………………………………………………………………311
20. OIL FILLER, OIL LEVEL GAUGE……………………………………………………………………………………….311
21. HEAD COVER………………………………………………………………………………………………………312
22. NOZZZLE HOLDER, CONNECTION………………………………………………………………………………………..312
23. ROCKER ARM………………………………………………………………………………………………………313
24. PUSH ROD………………………………………………………………………………………………………..313
25. CROSSHEAD……………………………………………………………………………………………………….313
26. ROCKER ARM HOUSING……………………………………………………………………………………………….313
27. CYLINDER HEAR ASSEMBLY……………………………………………………………………………………………313
28. CAM FOLLOWER ASSEMBLY…………………………………………………………………………………………….314
29. THERMOSTAT HOUSING……………………………………………………………………………………………….314
30. ASSESSORY DRIVE ASSEMBLY………………………………………………………………………………………….315
31. DAMPER, CRANKSHAFT PULLEY ASSEMBLY…………………………………………………………………………………315
32. OIL PAN…………………………………………………………………………………………………………316
33. MAN RELIEF VALVE, SUCTION TUBE…………………………………………………………………………………….316
34. FRONT SUPPOR…………………………………………………………………………………………………….316
35. FLYWHEEL………………………………………………………………………………………………………..316
36. FLYWHEEL HOUSING, REAR SEAL……………………………………………………………………………………….317
37. GEAR CASE COVER, FRONT SEAL……………………………………………………………………………………….317
38. IDLER GEAR (LARGE)……………………………………………………………………………………………….317
39. INJECTION PUMP DRIVE GEAR…………………………………………………………………………………………317
40. INJECTION PUMP DRIVE CASE ASSEMLY………………………………………………………………………………….318
41. OIL PUMP ASSEMBLY………………………………………………………………………………………………..318
42. IDLER GEAR (SMALL)……………………………………………………………………………………………….318
43. CAMSHAFT ASSEMBLY………………………………………………………………………………………………..319
44. TIMING GEAR CASE…………………………………………………………………………………………………319
45. PISTON COOLING NOZZLE…………………………………………………………………………………………….319
46. PISTON AND CONNECTING ROD ASSEMBLY…………………………………………………………………………………319
47. CRANKSHAFT………………………………………………………………………………………………………321
48. CYLINDER LINER…………………………………………………………………………………………………..322
WASHING………………………………………………………………………………………………………………..323
WASHING CYLINDER BLOCK……………………………………………………………………………………………….324
WASHING CRANKSHFT……………………………………………………………………………………………………326
WASHING CONNECTING ROD……………………………………………………………………………………………….326
MEASURING AND INSPECTING PARTS……………………………………………………………………………………………327
MEASURING PARTS……………………………………………………………………………………………………..328
MEASURING CURVATURE OF CRANKSHAFT………………………………………………………………………………….328
MEASURING OUTSIDE DIAMETER OF JOURNAL………………………………………………………………………………328
MEASURING OUT-OF-ROUNDNESS OF JOURNAL………………………………………………………………………………328
MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL……………………………………………………………329
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE……………………………………………………………………….330
MEASURING MAIN BERING BORE………………………………………………………………………………………..330
MEASURING CUVATURE OF CAMSHAFT…………………………………………………………………………………….331
MEASURING OUTSIDE DIAMETER OF JOURNAL………………………………………………………………………………331
MEASURING HELGHT OF CAM…………………………………………………………………………………………..331
MEASURING PISTON RING GROOVE………………………………………………………………………………………332
MEASURING OUTSIDE DIAMETER OF PISTON……………………………………………………………………………….332
MEASURING LENGTH OF CONNECTING ROD…………………………………………………………………………………333
MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD……………………………………………………………..333
MEASUING INSIDE DIAMENTER AT BIG END OF CONNECTING ROD……………………………………………………………….333
MEASURING SURVATURE, TWISTING OF CONNECTING ROD……………………………………………………………………..334
STANDARD PRESSURE FOR PARTS PRESSURE TESTING………………………………………………………………………..335
GENERAL ASSEMBLY………………………………………………………………………………………………………..336
1. CYLINDER LINER……………………………………………………………………………………………………339
2. CRANKSHAFT……………………………………………………………………………………………………….342
3. PISTON, CONNECTING ROD ASSEMBLY…………………………………………………………………………………….345
4. PISTON COOLING NOZZLE……………………………………………………………………………………………..351
5. GEAR CASE ……………………………………………………………………………………………………….352
6. CAMSHAFT ASSEMBLY…………………………………………………………………………………………………352
7. IDLER GEAR (SMALL)………………………………………………………………………………………………..352
8. OIL PUMP ASSEMBLY…………………………………………………………………………………………………353
9. INJECTION PUMP DRIVE CASE………………………………………………………………………………………….353
10. INJECION PUMP DRIVE GEAR………………………………………………………………………………………….354
11. IDIER GEAR (LARGE) (RIGHT BANK)……………………………………………………………………………………354
12. IDIER GGEAR (LARGE) (LEFT BANK)……………………………………………………………………………………355
13. MEASURING BACKLASH OF GEAR………………………………………………………………………………………..355
14. GEAR CASE COVER………………………………………………………………………………………………….357
15. FRONT OIL SEAL, SLEEVE……………………………………………………………………………………………357
16. FLYWHEEL HOUSING…………………………………………………………………………………………………360
17. REAR OIL SEAL, SLEEVE…………………………………………………………………………………………….360
18. FLYWHEEL………………………………………………………………………………………………………..363
19. FRONT SUPPORT……………………………………………………………………………………………………364
20. MAIN RELIEF VALVE, SUCTION PIPE……………………………………………………………………………………365
21. OIL PAN ………………………………………………………………………………………………………..365
22. DAMPER, CRANKSHAFT PULLEY ASSEMBLY…………………………………………………………………………………365
23. ACCESSORY DRIVE ASSEMBLY………………………………………………………………………………………….366
24. THERMOSTAT HOUSING……………………………………………………………………………………………….367
25. CAM FOLLOWER ASSEMBLY…………………………………………………………………………………………….367
26. CYLINDER HEAD ASSEMBLY……………………………………………………………………………………………367
27. ROCKER ARM HOUSING……………………………………………………………………………………………….370
28. CROSSHEAD……………………………………………………………………………………………………….370
29. PUSH ROD………………………………………………………………………………………………………..370
30. ROCKER ARM………………………………………………………………………………………………………370
31. NOZZLE HOLDER, CONNECTION…………………………………………………………………………………………372
32. ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………372
33. HEAD COVER, TURBOCHARGER LUBRICATION TUBE…………………………………………………………………………..373
34. OIL LEVEL GAUGE,OIL FILLER………………………………………………………………………………………..373
35. OIL COOLER ASSEMBLY………………………………………………………………………………………………373
36. AIR COMPRESSOR…………………………………………………………………………………………………..373
37. BREATHER………………………………………………………………………………………………………..374
38. WATER PUMP ASSEMBLY………………………………………………………………………………………………375
39. FUEL INJECTION PUMP ASSEMBLY………………………………………………………………………………………375
40. FUEL INJECTION PIPES, SPILL TUBE…………………………………………………………………………………..377
41. EXHAUST MANIFOLD ASSEMBLY…………………………………………………………………………………………377
42. INTAKE MANIFOLD, AFTER-COOLER ASSEMBLY……………………………………………………………………………..378
43. TURBOCHARGER ASSEMBLY…………………………………………………………………………………………….379
44. EXHAUST BRAKE ASSEMBLY……………………………………………………………………………………………379
45. INTAKE CONNECTOR…………………………………………………………………………………………………380
46. FAN PULLEY ASSEMBLY………………………………………………………………………………………………380
47. FAN BELT………………………………………………………………………………………………………..380
48. FAN…………………………………………………………………………………………………………….380
49. MUFFLER ASSEMBLY…………………………………………………………………………………………………381
50. FILTER………………………………………………………………………………………………………….381
51. SETTING ON ENGINE STAND…………………………………………………………………………………………..381
52. ALTERNATOR ASSEMBLY………………………………………………………………………………………………381
53. STARTING MOTOR ASSEMBLY…………………………………………………………………………………………..382
14 MAINTENANCE STANDIRD……………………………………………………………………………………………………..383
INTAKE AND EXHAUST SYSTEM………………………………………………………………………………………………..384
TRBOCHARGER…………………………………………………………………………………………………………384
ENGINE BODY…………………………………………………………………………………………………………….386
CYLINDER HEAD……………………………………………………………………………………………………….386
VALVE, VALVE SPRING AND VALVE GUIDE …………………………………………………………………………………..387
ROCKER ARM AND SHAFT…………………………………………………………………………………………………389
CROSSHEAD AND GUIDE………………………………………………………………………………………………….390
CYLINDER BLOCK………………………………………………………………………………………………………391
CYLINDER LINER………………………………………………………………………………………………………393
CRANKSHAFT………………………………………………………………………………………………………….394
CAMSHAFT……………………………………………………………………………………………………………396
CAM FOLLOWER AND PUSH ROD…………………………………………………………………………………………….397
TIMING GEAR…………………………………………………………………………………………………………398
PISTON, PISTON RING AND PISTON PIN…………………………………………………………………………………….400
CONNECTING ROD………………………………………………………………………………………………………402
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………………………………………………404
LUBRICATION SYSTEM………………………………………………………………………………………………………405
OIL PUMP …………………………………………………………………………………………………………..405
MAIN RELIEF VALVE……………………………………………………………………………………………………409
OIL COOLER BY-PASS VALVE, REGULATOR VALVE………………………………………………………………………………410
COOLING SYSTEM………………………………………………………………………………………………………….412
WATER PUMP………………………………………………………………………………………………………….412
THRMOSTAT…………………………………………………………………………………………………………..413
15 REPAIR AND REPLACEMENT OF PARTS……………………………………………………………………………………………414
TABLE OF SPECIAL TOOLS…………………………………………………………………………………………………..415
TESTING ANF INSPECTING CYINDER HEAD……………………………………………………………………………………….417
GRINDING CYLINDER HEAD MOUNTING FACE………………………………………………………………………………………420
REPLACING VALVE SEAT…………………………………………………………………………………………………….421
PRESSURE TEST OF CYLONDER HEAD……………………………………………………………………………………………426
REPLACING VALVE GUIDE……………………………………………………………………………………………………427
REPLACING CROSSHEAD GUIDE………………………………………………………………………………………………..428
GRINDING VALVE………………………………………………………………………………………………………….429
TESTING AND INSPECTING CYLINDER BLOCK……………………………………………………………………………………..430
CORRECTING CYLINDRE BLOCK TOP SURFACE, COUNTERBORE………………………………………………………………………….434
REPLACING MAIN BEARING CAP……………………………………………………………………………………………….442
REPLACING CAM BUSHING……………………………………………………………………………………………………444
TESTING AND INSPECTING CRANKSHAFT…………………………………………………………………………………………446
CORRECTING SURFACE ROUGHESS OF CRANKSHAFT JOURNAL PORTION……………………………………………………………………448
GRINDING CRANKSHAFT……………………………………………………………………………………………………..453
CORRECTING FRONT SEAL CONTACT SURFCE………………………………………………………………………………………462
CORRECTING REAR SEAL CONTACT SURFACE………………………………………………………………………………………464
TESTING AND INSPECTING CONNECTING ROD……………………………………………………………………………………..466
REPLACING CONNECTING ROD SMALL END BUSHING…………………………………………………………………………………468
REPLACING CRANKSHAFT GEAR………………………………………………………………………………………………..469
REPLACING CAMSHAFT GEAR………………………………………………………………………………………………….470
REPLACING FLYWHEEL RING GEAR……………………………………………………………………………………………..471