Mitsubishi Heavy Industries S4E2 Manuals

Manuals and User Guides for Mitsubishi Heavy Industries S4E2. We have 1 Mitsubishi Heavy Industries S4E2 manual available for free PDF download: Service Manual

Mitsubishi Heavy Industries S4E2 Service Manual

Mitsubishi Heavy Industries S4E2 Service Manual (485 pages)

Brand: Mitsubishi Heavy Industries | Category: Engine | Size: 8 MB

Table of Contents

Contents
1
Definition of Terms
3
Table of Contents
5
Table of Contents
7
General
7
General
8
Left-Hand Side View
8
S4E2 Diesel Engine - External Views
8
- Right-Hand Side View
  9
- S4E2 Diesel Engine - Sectional Views
  10
  - Transverse View
    10
  - Longitudinal View
    11
- Engine Model and Application Codes
  12
- Engine Serial Number Location
  12
2 Specifications

13
3 Tips on Disassembly and Reassembly

16
- Maintenance Standards
  17
- Maintenance Standards
  18
- Important Bolts and Nuts
  25
- Tightening Torque
  25
- General Bolts and Nuts
  26
- Sealants
  27
  - Special Tool List
    29
  - Special Tool List
    30
  - Overhaul Instructions
    33
  - Determining When to Overhaul the Engine
    34
  - Testing the Compression Pressure
    35
  - Adjustments, Bench Test, Performance Tests
    37
  - Adjustments, Bench Test, Performance Tests
    38
  - Valve Clearance
    38
  - Fuel System Priming
    39
  - Fuel Injection Timing Inspection and Adjustment
    40
    
    No-Load Minim Urn (Idling) Speed and Maximum Speed Setting Inspection and Adjustment
    42
    
    RSV-Type Governor
    42
  - Fan Drive Belt Inspection and Adjustment
    48
  - Bench Test
    49
  - Inspection after Starting up
    49
  - Inspection and Adjustment after Bench Test
    49
  - Performance Tests
    49
  - Standard Equipment
    49
  - Starting up
    49
  - Test Items
    49
  - Test Methods
    50
    
    Engine Accessory Removal and Installation
    51
    
    Engine Accessory Removal
    52
    
    Preparatory Steps
    52
    
    Engine Accessory Installation
    56
    
    Engine Proper
    57
  - Cylinder Head and Valve Mechanism
    58
  - Disassembly
    58
  - Engine Proper
    58
  - Inspection and Repair
    60
  - Reassembly
    60
    
    Valves, Valve Guides and Valve Seats
    61
    
    Valve Springs
    66
    
    Combustion Jets
    67
    
    Cylinder Head
    67
    
    Valve Push Rods
    67
    
    Reassembling Sequence
    68
    
    Reassembly
    68
  - Disassembly
    72
  - Flywheel, Timing Gears and Camshaft
    72
  - Camshaft and Camshaft Bushings
    75
  - Inspection and Repair
    75
    
    Tappets
    76
    
    Idler, Idler Bushing and Idler Shaft
    77
    
    Timing Gears
    77
    
    Flywheel and Ring Gear
    78
    
    Crankshaft Pulley
    79
  - Reassembly
    81
  - Disassembly
    84
    
    Piston, Connecting Rods, Crankshaft and Crankcase
    84
    
    Crankcase and Cylinder Sleeves
    86
  - Inspection and Repair
    86
    
    Pistons and Piston Rings
    89
    
    Crankshaft
    95
    
    Main Bearings
    98
  - Reassembly
    100
    
    Intake & Exhaust Systems
    105
    
    Description
    106
    
    Exhaust Manifold
    106
    
    Lubrication System
    107
  - Description
    108
  - Oil Pump
    109
  - Inspection and Repair
    110
  - Reassembly
    112
  - Disassembly and Inspection
    113
  - Inspection
    113
  - Oil Filter
    113
  - Relief Valve
    113
  - Cooling System
    115
  - Disassembly
    116
  - Water Pump
    116
  - Inspection
    117
  - Reassembly
    118
    
    Workshop Theory
    119
    
    Oil Seals
    120
    
    Precautions for Disassembly and Reassembly
    120
    
    Bearings
    121
    
    O-Rings
    121
    
    Lock Plates
    122
    
    Split Pins and Spring Pins
    122
  - Inspection
    123
  - Thermostat
    123
  - Fan and Fan Belt
    124
  - Inspection
    124
    
    Introduction
    129
    
    Major Equipment Specifications
    129
    
    Fuel System
    131
    
    Cartridge Type Paper-Element Filter
    132
  - Description
    132
  - Disassembly and Inspection
    132
  - Fuel Filter
    132
  - Fuel System
    132
  - Disassembly
    133
  - Fuel Injection Nozzles
    133
  - Inspection and Adjustment
    133
  - Reassembly
    136
  - Disassembly
    137
  - Fuel Feed Pump
    137
  - Airtightness
    138
  - Inspection and Adjustment
    138
  - Disassembly
    139
  - Fuel Injection Pump
    139
  - Inspection
    141
  - Reassembly
    143
  - Testing and Adjustment
    145
  - Disassembly
    150
  - Governor - Disassembled View
    150
  - RSV Governor
    150
  - Governor - Sectional View
    152
  - Reassembly
    152
  - Testing and Adjustment
    153
  - Tightening Torque
    153
    
    Medium-Speed Control Adjustment
    154
    
    Setting the Full-Load Stopper
    154
    
    Angleich Control Adjustment
    155
    
    Low-Speed Control Adjustment
    155
    
    High-Speed Control Adjustment
    156
    
    Matching the Pump to the Engine
    158
    
    Maintenance Standards
    159
    
    Important Bolts and Nuts
    161
    
    Tightening Torque
    161
    
    Electrical System
    163
  - Disassembly
    164
  - Electrical System
    164
  - Starter
    164
  - Inspection and Repair
    165
  - Reassembly
    169
  - Inspection and Testing after Reassembly
    170
  - Alternator
    172
  - Disassembly
    172
  - Inspection and Repair
    172
  - Glow Plugs
    174
  - Inspection
    174
  - Reassembly
    174
  - Maintenance Standards
    175
  - Tightening Torque
    175
  - BD2G, BS3G Wiring Diagram
    177
  - Flywheel Clutch I
    183
  - Direct Drive Transmission
    185
  - Brake
    187
  - Steering Clutches and Final Drives
    188
  - Steering Valve
    190
  - Frame
    191
  - Front Idlers
    192
  - Hydraulic Adjuster Cylinders and Recoil Springs
    193
  - Track Carrier Rollers
    194
  - Track Rollers
    195
  - Tracks
    196
    
    Standard Model Track
    197
    
    Swamp Model/Super-Swamp Model/Ultra Super-Swamp Model Track
    197
    
    Hydraulic Pump
    198
    
    Control Valve
    199
  - Cylinders
    207
  - Power Angling/Tilt Blade (BD2G)
    213
  - Power Tilt Blade (BD2G)
    214
    
    Bucket and Linkage (BS3G)
    215
    
    Tightening Torque for Standard Bolts
    216
  - Operating Principle
    225
  - Direct-Drive (DO) Model
    226
  - General Description
    226
  - Operating Principle
    226
  - Flywheel Clutch
    229
  - Clutch Oil Line
    230
  - Direct-Drive (DD) Transmission
    231
  - Power Flow in Transmission
    232
  - Transmission Control
    233
  - Steering Clutches, Brakes and Final Drives
    234
  - Steering Clutch and Brake Controls
    235
    
    Steering Clutch Control Hydraulic Circuit
    236
    
    Carrier Rollers
    237
  - Undercarriage
    237
  - Testing and Adjustment
    241
  - Adjusting the Steering Clutches and Brakes
    242
  - Adjusting the Brake Pedal
    243
  - Adjusting the Clutch Pedal
    243
  - Adjusting the Clutch Brake
    244
  - Adjusting the Tracks
    244
  - Troubleshooting Guide
    245
  - Operating Principle
    263
  - General Description
    264
  - Power Train
    264
  - Damper
    269
  - Description
    270
  - DPS Transmission
    270
  - Hydraulic Control Circuit
    273
  - Transmission Control Valve
    275
    
    Pre Filling of 1St-Speed Clutch Piston Chamber
    277
    
    Pre Filling of Forward Clutch Piston Chamber
    278
    
    Modulation Action
    279
    
    Completion of Shifting
    280
    
    Inching Action
    281
  - Testing and Adjustment
    285
  - DPS Transmission
    286
    
    Testing the Clutches for Slippage
    286
    
    If Transmission Shifts Hard
    287
    
    Trouble Diagnosis by Oil Pressure Readings
    287
    
    If Shock Is Felt When Shifted
    288
    
    Iftime Lag in Shifting Is Excessive
    288
    
    If Inching Pedal Malfunctions
    289
    
    If Oil Pressures Are High
    290
    
    If Output Power Is Not Enough
    290
    
    If Transmission Overheats
    290
    
    Testing the Control Valve
    291
    
    Bench Test Criteria for Transmission Oil Pump
    292
  - Adjusting the Inching Pedal
    293
  - Adjusting the Transmission Control Lever
    293
  - Troubleshooting Guide
    294
  - Maintenance Standards
    299
  - DPS Transmission
    300
  - Transmission Control Valve
    302
  - Disassembly and Reassembly
    305
    
    B Reverse Clutch Group
    311
    
    C Forward Clutch Group and 3Rd-Speed Clutch Group
    312
    
    2Nd-Speed Clutch Group
    313
    
    1St-Speed Clutch Group and Cover Group
    314
    
    Forward Clutch Group and 3Rd-Speed Clutch Group
    318
    
    Reverse Clutch Group
    319
    
    Transmission Case and Flange· Group
    320
  - Transmission Control Valve
    323
  - Transfer
    325
  - Bevel Gear
    327
    
    Pinion Adjustment
    327
    
    Tips for Reassem Bly
    327
  - Damper
    328
  - Operating Principle
    339
    
    BD2G-PAT Hydraulic Circuit Diagram
    340
    
    BD2G-PT Hydraulic Circuit Diagram
    340
  - General Description
    340
  - BS3G Hydraulic Circuit Diagram
    341
  - 3-Section Control Valve (BD2G-PAT)
    342
    
    Control Valve Sections
    343
    
    Lift Valve Plunger Section
    343
    
    Tilt/Angling Valve Plunger Section
    343
  - 2-Section Control Valve (BD2G-PT)
    347
  - Main Relief Valve
    357
  - Safety Valve
    359
  - Testing and Adjustment
    361
  - BD2G Tractor
    362
  - Testing Cylinder Rods for Drift
    362
  - Testing Lift Cylinders for Blade Holding Ability (BD2G-PAT, PT)
    363
  - BS3G Tractor Shovel
    365
  - Testing Cylinder Rods for Drift
    365
  - Testing Cylinders for Actuating Speed
    367
  - Adjusting Main Relief Valve
    369
  - Adjusting Safety Valve
    369
  - Troubleshooting Guide
    370
    
    Blade (BD2G)
    371
    
    Shovel (BS3G)
    371
  - Engine Dismounting and Mounting
    381
    
    Mounting
    385
    
    Tips for Mounting
    385
  - Flywheel Clutch
    387
  - Direct-Drive (D D) Transmissi on
    397
  - C Shift Fork Group, D Countershaft Group and E Bevel Gear Shaft Group
    401
  - Steering Clutches and Brakes
    406
    
    Steering Clutch & Brake Assembly
    410
    
    Bevel Gear Assembly
    414
  - Steering Valve
    418
  - Final Drives
    420
  - Final Drives
    422
  - Undercarriage
    424
  - Front Idlers
    425
  - Recoil Springs and Hydraulic Adjuster Cylinders
    427
  - Track Rollers
    431
  - Tracks
    434
  - Track Carrier Rollers
    437
  - Special Tools
    440
  - Hydraulic Pump
    449
  - Control Valve
    453
  - Power Angling/Tiit Blade
    462
  - Power Tilt Blade
    464
  - Bucket and Linkage
    466
  - Hydraulic Cylinders
    468
    
    Ring Nut Type
    470
    
    Gland Screw Type
    471
    
    Gland Screw Type Cylinder
    473
  - Special Tools
    480
- Ring Nut Type Cylinder
  473

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