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Manuals and User Guides for Mitsubishi Heavy Industries SL Series. We have
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Mitsubishi Heavy Industries SL Series manual available for free PDF download: Service Manual
Mitsubishi Heavy Industries SL Series Service Manual (200 pages)
Brand:
Mitsubishi Heavy Industries
| Category:
Engine
| Size: 5.59 MB
Table of Contents
General Contents
15
Table of Contents
15
General
17
External View
18
External View of S3L and S3L2
18
External View of S4L and S4L2
19
System Flow Diagrams
20
Fuel System - Flow Diagram
20
Lubrication System - Flow Diagram
20
Cooling System - Flow Diagram
21
Inlet and Exhaust System - Flow Diagram
21
Engine Serial Number Location
22
Specifications
23
Tips on Disassembling and Reassembling
26
Disassembling
26
Reassembling
26
Service Data
27
1 Maintenance Service Data
28
Basic Engine
28
General
28
Cooling System
31
Fuel System
31
Inlet and Exhaust System
31
Lubrication System
31
Electrical System
32
Basic Engines
33
Fuel System
33
Major Bolt Tightening Torque
33
2 Tightening Torque Table
33
Cooling System
34
Electrical System
34
Inlet and Exhaust Systems
34
Lubrication System
34
Standard Bolt and Nut Tightening Torque
35
Standard Eyebolt Tightening Torque
36
Standard Union Nut Tightening Torque
36
Service Tools
37
Determination of Overhaul
41
Determining Overhaul Timing
42
Disassembly of Basic Engine
45
Disassembly of Basic Engine
46
1 Disassembling and Inspecting Cylinder Head and Valve Mechanism5-2
46
Disassembling Rocker Shaft Assembly
47
Removing Cylinder Head Bolt
47
Removing Rocker Shaft Assembly
47
Removing Cylinder Head Assembly
48
Removing Valve Stem Seal
48
Removing Valves and Valve Spring
48
2 Disassembling and Inspecting Flywheel
49
Removing Flywheel
50
Removing Flywheel Housing
50
Removing Rear Plate
50
Removing Oil Seal Case
51
3 Disassembling and Inspecting Gear Case, Timing Gear and Camshaft
52
Removing Tappet
53
Removing Crankshaft Pulley
53
Removing Timing Gear Case
53
Measuring Timing Gear Backlash
54
Removing Idler Gear
54
Removing Camshaft
54
Removing Fuel Injection Pump Camshaft
55
Removing Oil Pump
55
Removing Front Plate
55
4 Disassembling and Inspecting Cylinder Block, Crankshaft, Piston and Oil Pan
56
Removing Oil Pan
57
Removing Oil Strainer
57
Removing Connecting Rod Cap
57
Pulling out Piston
57
Measuring Crankshaft End Play
58
Removing Main Bearing Cap
58
Removing Crankshaft
58
Removing Piston Pin
59
Inspection and Repair of Basic Engine
61
1 Inspecting and Repairing Cylinder Head and Valve Mechanism
62
Measuring Distortion of the Bottom Surface of the Cylinder Head
62
Measuring Clearance between Rocker Arm and Rocker Shaft
62
Measuring Perpendicularity and Free Length of Valve Spring
62
Measuring Push Rod Runout
63
Measuring Valve Stem Outside Diameter and Valve Guide Inside Diameter
63
Replacing Valve Guide
63
Inspecting Valve Face
64
Refacing Valve Face
64
Refacing Valve Seat
65
Lapping Valve and Valve Seat
65
Removing Combustion Jet
66
2 Inspecting and Repairing Flywheel
67
Measuring Flatness of Flywheel
67
Inspecting Ring Gear
67
Replacing Ring Gear
67
Removing Ring Gear
67
Installing Ring Gear
67
3 Inspecting and Repairing Gear Case, Timing Gear and Camshaft
68
Measuring Timing Gear Backlash
68
Measuring Clearance between Idler Gear and Idler Shaft
68
Replacing Idler Shaft
68
Measuring Clearance between Camshaft Journal and Bushing
69
Replacing Camshaft Bushing
69
Removing Camshaft Bushing
69
Driving in Camshaft Bushing
69
Measuring Cam Lift
70
Measuring Cam Height of Fuel Injection Pump Camshaft
70
Inspecting Tappet
70
Measuring Clearance between Tappet and Tappet Guide Hole
70
4 Inspecting and Repairing Cylinder Block, Crankshaft and Piston
71
Measuring Cylinder Inside Diameter
71
Measuring Piston Outside Diameter
71
Measuring Piston Ring Groove
72
Measuring Piston Ring End Gap
72
Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter
73
Inspecting Connecting Rod Bend and Twist6-13
73
Measuring Connecting Rod End Play
74
Measuring Clearance between Connecting Rod Bearing and Crankpin
75
Measuring Clearance between Main Bearing and Crankshaft Journal
76
Measuring Crankshaft Runout
77
Replacing Crankshaft Gear
77
Removing Crankshaft Gear
77
Installing Crankshaft Gear
77
Measuring Distortion Cylinder Block Top Surface
78
Reassembly of Basic Engine
79
1 Reassembling Cylinder Block, Crankshaft, Piston and Oil Pan
80
Installing Main Bearing
80
Installing Crankshaft
80
Installing Main Bearing Cap
81
Inserting Side Seal
81
Installing Main Bearing Cap Bolt
82
Measuring Crankshaft End Play
82
Reassembling Piston and Connecting Rod
83
Installing Piston Ring
84
Installing Piston and Connecting Rod
84
Installing Connecting Rod Cap
85
Installing Oil Strainer
85
Installing Oil Pan
86
2 Reassembling Flywheel, Timing Gear and Camshaft
87
Installing Front Plate
87
Installing Oil Pump
87
Rotating Crankshaft
87
Installing Fuel Injection Pump Camshaft
87
Installing Camshaft
88
Installing Idler Gear
88
Installing Timing Gear Case
88
Installing Crankshaft Pulley
89
Installing PTO Gear
89
Installing Tappet
89
Installing Oil Seal Case
89
Installing Rear Plate
90
Installing Flywheel Housing
90
Installing Flywheel
90
3 Reassembling Cylinder Head and Valve Mechanism
91
Cleaning Cylinder Head Bottom Surface
91
Installing Valve Stem Seal
91
Installing Valve Spring
91
Installing Valve Lock
91
Installing Cylinder Head Gasket
92
Installing Cylinder Head Assembly
92
Tightening Cylinder Head Bolts
92
Inserting Push Rod
92
Reassembling Rocker Shaft Assembly
93
Installing Rocker Shaft Assembly
93
Adjusting Valve Clearance
93
Installing Rocker Cover
93
Fuel System
95
1 Removing Fuel System
96
Removing Fuel Injection Pipe
97
Removing Fuel Injection Nozzle
97
Removing Governor Assembly
97
Removing Governor Weights
97
Removing Fuel Injection Pump
98
2 Disassembling, Inspecting and Reassembling Fuel System
99
Fuel Injection Nozzle
99
Disassembling and Inspecting Fuel Injection Nozzle
99
Reassembling Fuel Injection Nozzle
101
Fuel Injection Pump
102
Inspecting Fuel Injection Pump on Engine
102
Disassembling and Inspecting Fuel Injection Pump
102
Governor
108
Disassembling and Inspecting Governor
108
Inspecting Fuel Pump
110
Fuel Filter
111
Disassembling, Inspecting and Reassembling Fuel Filter
111
3 Installing Fuel System
112
Installing Fuel Injection Pump
113
Installing Governor Weights
113
Installing Sliding Sleeve
113
Installing Governor Assembly
114
Installing Fuel Injection Nozzle
114
Installing Fuel Pipes
114
Lubrication System
115
1 Removing Lubrication System
116
Removing Oil Filter
117
Removing Relief Valve
117
Removing Oil Pressure Switch
117
2 Disassembling, Inspecting and Reassembling Lubrication System
118
Inspecting the Oil Pump
118
Inspecting Relief Valve
118
Inspecting Oil Pressure Switch
119
3 Installing Lubrication System
120
Installing Oil Pressure Switch
121
Installing Relief Valve
121
Installing Oil Filter
121
Cooling System
123
1 Removing Cooling System
124
2 Disassembling, Inspecting and Reassembling Cooling System
125
Disassembling and Inspecting Thermostat10-3
125
Inspecting Thermostat
125
Inspecting Thermoswitch
126
Inspecting Thermostat
126
Inspecting Water Pump for Smooth Rotation10-4
126
3 Installing Cooling System
127
Inlet and Exhaust Systems
129
1 Removing Inlet and Exhaust Systems
130
Removing Intake Cover and Exhaust Manifold
130
2 Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems
131
Inspecting Intake Cover and Exhaust Manifold
131
Measuring Distortion of Inlet and Exhaust Manifold
131
3 Installing Inlet and Exhaust Systems
132
Installing Intake Cover and Exhaust Manifold
132
Electrical System
133
1 Removing Electrical System
134
Removing Starter
134
Inspection before Removing Alternator
135
Inspecting Alternator Operation
135
Handling Precaution
135
Inspecting Regulated Voltage (IC Regulator Integral Type)
136
Inspecting Output (a Built-In IC Regulator Type)
136
Removing Alternator
137
Removing Stop Solenoid
138
Removing Glow Plug
139
2 Disassembling, Inspecting and Reassembling Electrical System
140
Inspection before Disassembling Starter
140
No Load Test
140
Disassembling and Inspecting Starter
141
M008T70471A (12V-2.0Kw), M008T81071A (24V-3.2Kw)
141
M001T68281(12V-1.7Kw)
142
Preparation before Disassembling
143
Removing Pinion Set
143
Removing Magnetic Switch
143
Removing Rear Bracket
144
Removing Brush Holder and Brush Assembly
144
Removing Armature and Yoke
144
Removing Overrunning Clutch
145
Removing Gear Shaft
145
Inspecting and Repairing Starter
146
Inspecting Brushes for Wear
146
Measuring Brush Spring Load
146
Inspecting Brush Holder for Insulation
146
Measuring Commutator Radial Runout
147
Measuring Commutator Outside Diameter12-15
147
Measuring Undercut Depth
147
Checking Armature Coil
148
Inspecting Rear Bracket
148
Inspecting Overrunning Clutch
149
Inspecting Continuity of Yoke Assembly
149
Inspecting Insulation between Yoke Body and Brush
149
Inspecting Pinion
150
Inspecting Front Bracket
150
Inspecting Gears of Starter
150
Inspecting Continuity of Magnetic Switch
150
(Between M Terminal and Case)
150
Inspecting Insulation of Magnetic Switch
150
(Between M Terminal and B Terminal)
150
Reassembling Starter
151
Applying Grease
152
Installing Pinion
152
Installing Gear Shaft
153
Installing Yoke and Armature
153
Installing Brush Holder and Brush Assembly
154
Installing Rear Bracket
154
Installing Magnetic Switch
154
Inspecting Pinion Clearance
155
Disassembling, Inspecting and Reassembling Alternator (12V-50A)
156
Separating Front Bracket from Stator
157
Removing Pulley
157
Removing Stator
157
Inspecting Rectifier
158
Inspecting Rotor
158
Inspecting Stator
159
Inspecting Brushes for Wear
159
Replacing Brushes
160
Reassembling Alternator
160
Inspecting Glow Plug
161
3 Installing Electrical System
162
Installing Glow Plug
162
Installing Stop Solenoid
163
Installing Stop Solenoid (ETR Type)
164
Procedure for Installing Stop Solenoid (ETR Type)
164
Verification after Reassembling (ETR Type)
164
Installing Stop Solenoid (ETS Type)
165
Procedure for Installing Stop Solenoid (ETS Type)
165
Verification after Reassembly (ETS Type)12-34
166
Installing Alternator
167
Installing Starter
168
Adjustment and Operation
169
1 Inspection and Adjustment of Engine
170
Inspecting Valve Clearance
170
Inspecting Fuel Injection Timing
171
Adjusting Fuel Injection Timing
172
Inspecting and Adjusting Low Idle Speed and High Idle Speed
173
Preparation
173
Adjusting Low Idle Speed
173
Adjusting High Idle Speed
173
Bleeding Fuel System
174
Bleeding Air from Fuel Filter
174
Bleeding Air from Fuel Injection Pump
174
Adjusting V-Belt Tension
175
2 Break-In Operation
176
Starting up
176
Inspecting Engine Condition after Starting up
176
Break-In Operation Time
176
Inspection and Adjustment after Break-In Operation
176
3 Performance Test (JIS Standard)
177
Engine Equipment Condition
177
Test Items and Purposes
177
Operation Load Test
177
Continuous Load Test
177
Low Idle Test
177
Engine Output Adjustment
177
Standard Atmospheric Conditions
177
Calculation of Corrected Power
178
Troubleshooting
179
Troubleshooting
180
Before Troubleshooting
180
Check Items before Troubleshooting
181
Problem: Starting Trouble
181
Starting Trouble
181
Check Items before Troubleshooting
182
Knocking
182
Problem: Knocking
182
Check Items before Troubleshooting
183
Overheating
183
Problem: Overheating
183
Check Items before Troubleshooting
184
Excessive Black Smoke
184
Problem: Excessive Black Smoke
184
Check Items before Troubleshooting
185
Idling Malfunction
185
Problem: Unstable Idling
185
Check Items before Troublshooting
186
Low Output
186
Problem: Low Output
186
Engine Inspection Sheet
187
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