Mitsubishi S12A2 Manuals

Manuals and User Guides for Mitsubishi S12A2. We have 1 Mitsubishi S12A2 manual available for free PDF download: Service Manual

Mitsubishi S12A2 Service Manual (355 pages)

Brand: Mitsubishi | Category: Engine | Size: 38 MB

Description Format
4
How to Use this Manual
4
Abbreviations and Standards
5
Terms Used in this Manual
5
Unit of Measurement
5
Fire and Explosion Precautions
6
Safety Cautions
6
Stay Away from Rotating and Moving Parts
7
Be Careful of Exhaust Gas Poisoning
8
Be Careful of Falling
8
Be Careful of Hearing Loss
8
Be Careful of Burns
9
Be Careful When Handling Fuel, Engine Oil or LLC
9
Be Careful with Battery
10
When Abnormality Occurs
10
Other Cautions
11
Cool down the Engine before Stop
12
Do Not Operate the Engine in an Overloaded Condition
12
Use Care to Protect Engine from Water
12
Warm-Up the Engine before Use
12
Be Careful of Engine Room Ventilation
13
Do Not Operate Starter for a Long Time
13
Do Not Touch High Pressure Fuel Jet
13
Do Not Turn off the Battery Switch During Operation
13
Warning Labels
14
Points on Disassembling and Assembling
15
General Contents
17
Table of Contents
19
General Information
19
Engine Front View - S12A2-PTA
21
Engine Rear View - S12A2-PTA
21
External View

21
Chapter 1 GENERAL

33
Contents of Plate and Label

37
- Name Plate
  37
- Caution Plate
  37
- Emissions Certification Label
  37
Specifications

38
- Service Data
  43
Chapter 2 SERVICE DATA

45
Chapter 5 DISASSEMBLY of BASIC ENGINE

83
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

83
Rear Mechanism - Disassemble and Inspect

88
Front Mechanism - Disassemble and Inspect

94
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

97
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

102
- Crankcase - Turn over (Upend)
  103
- Crankshaft End Play - Measure
  103
- Main Bearing Cap - Remove
  103
- Piston Cooling Nozzle - Remove
  103
- Crankshaft - Remove
  104
- Inspection and Repair of Basic Engine
  105
Chapter 6 INSPECTION and REPAIR of BASIC ENGINE

107
Cylinder Head and Valve Mechanism - Inspect and Repair

107
Rear Mechanism - Inspect and Repair

115
Front Mechanism - Inspect and Repair

118
- Pulley - Inspect
  118
- Piston - Inspect Visually
  119
Piston and Connecting Rod - Inspect and Repair

119
Crankcase and Crankshaft - Inspect and Repair

127
- Crankcase Top Surface Distortion - Measure
  127
- Inside Diameter of Main Bearing Housing Bore - Measure
  127
- Counterbore in Crankcase - Repair
  128
- Crankpin and Journal Outside Diameters - Measure
  128
- Cylinder Liner Fitting Bore in Crankcase - Inspect
  128
  - Crankpin and Crank Journal - Grind
    129
  - Rearmost Crank Main Journal Width - Grind
    130
  - Width of Crankpin and Rearmost Crank Main Journal - Measure
    130
  - Crankshaft Runout - Measure
    131
  - Crankshaft Gear - Inspect
    132
    
    Crankshaft Gear - Install
    132
    
    Crankshaft Gear - Remove
    132
  - Crankshaft Gear - Replace
    132
  - Oil Seal Slinger - Inspect
    133
  - Oil Seal Slinger - Install
    133
  - Oil Seal Slinger - Replace
    133
  - Main Bearing - Inspect
    134
  - Thickness of Main Bearing Shell - Measure
    134
  - Thrust Plate - Inspect
    134
  - Piston Cooling Nozzle - Inspect
    135
  - Thickness of Thrust Plate - Measure
    135
  - Oil Seal Slinger - Remove
    133
  - Assembly of Basic Engine
    137
Chapter 7 ASSEMBLY of BASIC ENGINE

139
- Crankcase - Turn over (Upend)
  139
- Upper Main Bearing - Install
  140
- Crankshaft - Install
  141
- Upper Thrust Plates - Install
  141
- Lower Main Bearing Shell and Lower Thrust Plate - Install
  141
- Main Bearing Cap - Install
  142
- Crankshaft End Play - Measure
  143
- Crankcase - Turn over
  143
Crankshaft and Main Bearing - Install

139
- Piston Cooling Nozzle - Install
  139
Cylinder Liner, Piston and Connecting Rod - Assemble

144
Front Mechanism - Assemble

154
- Front Oil Seal - Install
  154
- Crankshaft Pulley, Damper and Front Pulley - Install
  155
  - Damper Face and Radial Runout - Measuring
    155
  - Pointer - Install and Adjust
    155
Rear Mechanism - Assemble

156
- Idler Shaft - Install
  156
- Rear Plate - Install
  156
- Camshaft Gear - Install
  157
  - Idler Gear End Play - Measuring
    159
  - Timing Gear Backlash - Measuring
    160
  - Timing Gear Case - Install
    160
  - Flywheel - Install
    161
  - Rear Oil Seal - Install
    161
  - Flywheel Face and Radial Runout - Measuring
    161
  - Pickup - Install (Electronic Governor Spec)
    162
Cylinder Head and Valve Mechanism - Assemble

163
- Cylinder Head - Assemble
  163
- Fuel System
  173
Chapter 8 FUEL SYSTEM

175
Fuel System - Remove and Inspect

175
Fuel System - Disassemble, Inspect and Assemble

186
- Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble
  186
- Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble
  187
Fuel System - Install

205
- Rubber - Install
  204
- Fuel Injection Pump - Install
  205
  - Assembling Position of Fuel Injection Pump Coupling
    207
  - Checking before Installing Fuel Injection Pump
    207
  - Drive Coupling - Install
    207
  - Pointer and Line Mark - Align
    207
  - Coupling Distance - Adjust
    208
  - Couplings and Plates - Assemble (Diagram)
    208
  - Engine Oil - Refill (Diagram)
    208
  - Fuel Injection Pump - Installation
    208
  - Control Link Lever - Install
    209
  - Control Shaft - Install
    209
  - Fuel Control Link - Install
    209
    
    Fuel Control Link - Install and Adjust
    210
    
    Left-Bank Linkage - Overall View
    210
    
    Fixed-Length Control Links of Right and Left Banks
    211
    
    Left Bank Variable-Length Control Link
    211
    
    Right-Bank Linkage - Overall View
    211
    
    Fuel Control Link - Installation and Adjustment
    213
    
    Right and Left-Bank Control Links - Diagram
    214
    
    Stopper - Install
    215
  - Stop Solenoid - Install
    216
  - Stop Solenoid (RUN on Type) - Adjust
    216
  - Solenoid Function - Verify
    217
  - Stop Solenoid (RUN off Type) - Adjust
    217
  - Lubrication System
    219
Chapter 9 LUBRICATION SYSTEM

221
Lubrication System - Remove and Inspect

221
Lubrication System - Disassemble, Inspect and Assemble

231
Lubrication System - Install

241
- Backlash When Installing Oil Pump - Adjust
  241
- Oil Pan - Install
  241
- Oil Pump, Oil Strainer and Oil Pan - Install
  241
- Cooling System
  243
Chapter 10 COOLING SYSTEM

245
Cooling System - Remove and Inspect

245
Cooling System - Disassemble, Inspect and Assemble

257
- Tension Pulley - Disassemble and Inspect (Water Pump Side)
  257
  - Inner Ball Bearing - Insert
    258
  - Outer Ball Bearing - Insert
    258
  - Tension Pulley - Assemble
    258
  - Tension Pulley - Insert
    258
  - Bolt - Tighten
    259
  - Snap Ring - Install
    259
  - Thrust Plate - Install
    259
  - Tension Pulley - Disassemble and Inspect (Water Pump Side for Air Cooler)
    260
    
    Spacer and Bolt - Install
    261
    
    Tension Pulley - Assembling
    261
  - Tension Pulley - Disassemble and Inspect (Water Pump Side PTA2 Spec)
    263
    
    Tension Pulley - Inspect
    263
    
    Tension Pulley Assembling
    264
  - Tension Pulley - Disassemble and Inspect (Fan Side PTA2 Spec)
    265
    
    Tension Pulley Inspecting
    265
    
    Tension Pulley Assembling Steps
    266
  - Thermostat - Disassemble and Inspect
    267
  - Thermostat - Inspect
    268
  - Thermostat Motion Diagram
    268
  - Heat Exchanger - Disassemble and Inspect
    269
  - Heat Exchanger Element - Clean
    269
  - Water Pump - Disassemble and Inspect
    270
    
    Impeller - Remove
    271
    
    Water Pump Mounted on Engine - Inspect
    271
    
    Water Pump Pulley - Remove
    271
    
    Water Pump Shaft - Remove
    271
  - Water Pump - Inspect
    272
  - Water Pump - Assemble
    273
    
    Ball Bearing - Install
    274
    
    Oil Seal - Install
    274
    
    Outer Oil Seal - Install
    274
    
    Unit Seal (Stationary Side) - Install
    274
  - Water Pump for Air Cooler Cooling - Disassemble and Inspect
    275
    
    Impeller Removal
    276
    
    Water Pump for Air Cooler Cooling - Disassembling and Inspection
    276
    
    Water Pump Shaft Removal
    276
    
    Water Pump for Air Cooler Cooling - Inspect
    277
  - Water Pump for Air Cooler Cooling - Assemble
    278
    
    Ball Bearing - Installation
    279
    
    Unit Seal - Install
    279
    
    Water Pump Shaft - Install
    279
  - Sea Water Pump - Disassemble and Inspect
    280
  - Outside Diameter and Inside Diameter of Bearing Fit - Inspect
    281
  - Sea Water Pump - Assemble
    282
    
    Bearing - Install
    283
    
    Cam - Install
    283
    
    Oil Seal - Installation
    283
    
    Unit Seal (Stationary Side) - Installation
    283
    
    Bushing - Install
    284
    
    Case - Install
    284
    
    Shaft and Bearing - Install
    284
    
    Snap Ring - Installation
    284
    
    Cover - Install
    285
    
    Impeller - Install
    285
  - Fan Drive Assembly - Disassemble and Inspect
    286
  - Fan Drive - Inspect
    287
  - Oil Seal Sleeve - Inspect
    288
  - Oil Seal Sleeve - Install
    288
  - Oil Seal Sleeve - Replace
    288
  - Fan Drive - Assemble
    289
  - Oil Seal Sleeve - Remove
    288
  - Inner Ball Bearing Inserting
    290
  - Oil Seal Installation
    290
  - Outer Ball Bearing Inserting
    290
  - Fan - Assemble
    291
  - Fan Installation Direction
    291
Cooling System - Install

292
- Fan Pulley - Lock
  291
- Tension Pulley - Install
  292
- Water Outlet Pipe - Install
  292
- Water Pipe (Air Cooler) - Install
  292
- Inlet and Exhaust Systems
  293
Chapter 11 INLET and EXHAUST SYSTEMS

295
Inlet and Exhaust Systems - Remove and Inspect

295
Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

303
Inlet and Exhaust Systems - Install

308
- Air Cooler - Inspect for Leakage
  307
- Exhaust Manifold - Install
  308
  - Exhaust Manifold Coupling - Tighten
    308
  - Air Start System
    309
Air Start System - Remove and Inspect

311
Chapter 12 AIR START SYSTEM

311
Air Start System - Disassemble, Inspect and Assemble

314
- Starter Valve - Disassemble and Inspect
  314
- Starter Valve - Inspect
  315
Air Start System - Install

319
- Adjustment and Operation
  321
Chapter 13 ADJUSTMENT and OPERATION

323
Engine - Adjust

323
- Valve Bridge and Adjusting Screw - Check
  323
- Fuel System - Bleed Air
  323
Break-In Operation

330
Engine-Test and Adjustment

332
- Inspection While the Engine Is Running
  331
- Alarm Action and Emergency Stop Tests
  332
- Emission Gas Test
  332
- Engine Performance Test
  332
- Maximum Fuel Injection Volume - Set
  332
  - Sealing after Tests and Adjustments Are Completed
    333
  - Tamper Proof - Install
    333
  - Tamper Proof - Remove
    333
  - Engine Inspection Record Sheet (SA Series)
    335
  - Inspection Record Sheet
    336

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Mitsubishi S12A2 Manuals

Mitsubishi S12A2 Service Manual (355 pages)

Table of Contents

External View

Chapter 1 GENERAL

Contents of Plate and Label

Specifications

Chapter 2 SERVICE DATA

Chapter 5 DISASSEMBLY of BASIC ENGINE

Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Rear Mechanism - Disassemble and Inspect

Front Mechanism - Disassemble and Inspect

Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

Chapter 6 INSPECTION and REPAIR of BASIC ENGINE

Cylinder Head and Valve Mechanism - Inspect and Repair

Rear Mechanism - Inspect and Repair

Front Mechanism - Inspect and Repair

Piston and Connecting Rod - Inspect and Repair

Crankcase and Crankshaft - Inspect and Repair

Chapter 7 ASSEMBLY of BASIC ENGINE

Crankshaft and Main Bearing - Install

Cylinder Liner, Piston and Connecting Rod - Assemble

Front Mechanism - Assemble

Rear Mechanism - Assemble

Cylinder Head and Valve Mechanism - Assemble

Chapter 8 FUEL SYSTEM

Fuel System - Remove and Inspect

Fuel System - Disassemble, Inspect and Assemble

Fuel System - Install

Chapter 9 LUBRICATION SYSTEM

Lubrication System - Remove and Inspect

Lubrication System - Disassemble, Inspect and Assemble

Lubrication System - Install

Chapter 10 COOLING SYSTEM

Cooling System - Remove and Inspect

Cooling System - Disassemble, Inspect and Assemble

Cooling System - Install

Chapter 11 INLET and EXHAUST SYSTEMS

Inlet and Exhaust Systems - Remove and Inspect

Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

Inlet and Exhaust Systems - Install

Air Start System - Remove and Inspect

Chapter 12 AIR START SYSTEM

Air Start System - Disassemble, Inspect and Assemble

Air Start System - Install

Chapter 13 ADJUSTMENT and OPERATION

Engine - Adjust

Break-In Operation

Engine-Test and Adjustment

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