Caterpillar S4S Diesel Engine 180396 & Up 99729-87120 (Preview)
1Introduction.pdf
COVER
INTRODUCTION
How to use this manual
Safety Cautions
GENERAL CONTENTS
2General
GENERAL
1. External view
2. System flow diagrams
2.1 Fuel system – flow diagram
2.2 Lubrication system – flow diagram
2.3 Cooling system – flow diagram
2.4 Inlet and exhaust system – flow diagram
3. Engine serial number location
4. Main specifications
5. Tips on disassembling and reassembling
5.1 Disassembling
5.2 Reassembling
3Service Data
SERVICE DATA
1. Maintenance service data
1.1 General
1.2 Basic engine
1.3 Fuel system
1.4 Lubrication system
1.5 Cooling system
1.6 Inlet and exhaust system
1.7 Electrical system
2. Tightening torque table
2.1 Major bolt tightening torque
2.1.1 Basic engine
2.1.2 Fuel system
2.1.3 Lubrication system
2.1.4 Cooling system
2.1.5 Inlet and exhaust systems
2.1.6 Electrical system
2.2 Standard bolt and nut tightening torque
2.3 Standard eyebolt tightening torque
2.4 Standard union nut tightening torque
2.5 High-pressure fuel injection pipe tightening torque
4Service Tools
SERVICE TOOLS
1. Special tool
5Determination of Overhaul
DETERMINATION OF OVERHAUL
1. Determining overhaul timing
2. Testing compression pressure
6Disassembly of Basic Engine
DISASSEMBLY OF BASIC ENGINE
1. Disassembling and inspecting cylinder head and valve mechanism
1.1 Removing rocker shaft assembly
1.2 Disassembling rocker shaft assembly
1.3 Removing cylinder head bolt
1.4 Removing cylinder head assembly
1.5 Removing valve and valve spring
1.6 Removing valve stem seal
2. Disassembling and inspecting flywheel
2.1 Removing flywheel
2.2 Removing oil seal case
2.3 Removing rear plate
3. Disassembling and inspecting damper, gear case, timing gear and camshaft
3.1 Removing crankshaft pulley and damper
3.2 Removing cover
3.3 Removing timing gear case
3.4 Measuring timing gear backlash
3.5 Measuring idler gear and camshaft gear end play
3.6 Removing fuel injection pump
3.7 Removing oil pan
3.8 Removing oil strainer
3.9 Removing oil pump gear
3.10 Removing idler gear
3.11 Removing PTO drive gear
3.12 Removing camshaft
3.13 Separating camshaft gear
3.14 Installing camshaft gear and thrust plate
3.15 Removing front plate
3.16 Removing oil pump
4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
4.1 Removing connecting rod cap
4.2 Removing carbon deposits from the upper part of cylinder liner
4.3 Pulling out piston
4.4 Removing piston ring
4.5 Removing piston pin and piston
4.6 Removing main bearing cap
4.7 Removing crankshaft
4.8 Removing tappet
7Inspection and Repair of Basic Engine
INSPECTION AND REPAIR OF BASIC ENGINE
1. Inspecting and repairing cylinder head and valve mechanism
1.1 Measuring clearance between rocker bushing and rocker shaft
1.2 Measuring valve stem outside diameter and valve guide inside diameter
1.3 Replacing valve guide
1.4 Inspecting valve face
1.5 Refacing valve face
1.6 Refacing valve seat
1.7 Replacing valve seat
1.8 Lapping valve and valve seat
1.9 Measuring perpendicularity and free length of valve spring
1.10 Measuring distortion of the bottom surface of the cylinder head
1.11 Measuring push rod runout
1.12 Removing combustion jet
2. Inspecting and repairing flywheel
2.1 Measuring flatness of flywheel
2.2 Measuring flywheel face and radial runouts
2.3 Inspecting ring gear
2.4 Replacing ring gear
2.4.1 Removing ring gear
2.4.2 Installing ring gear
3. Inspecting and repairing timing gear and camshaft
3.1 Measuring timing gear backlash
3.2 Measuring idler gear and camshaft gear end play
3.3 Measuring cam lift
3.4 Measuring camshaft runout
3.5 Measuring camshaft journal outside diameter
3.6 Measuring idler bushing inside diameter and idler shaft outside diameter
3.7 Replacing idler shaft
3.8 Measuring clearance between tappet and tappet guide hole
3.9 Inspecting tappet
3.9.1 Contact surface of camshaft
3.9.2 Contact surface of pushrod
3.10 Inspecting V-belt groove wear
4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase
4.1 Measuring crankcase top surface distortion
4.2 Measuring cylinder inside diameter
4.3 Measuring piston outside diameter
4.4 Measuring piston ring end gap
4.5 Measuring clearance between piston ring groove and piston ring
4.6 Measuring piston pin bore diameter and piston pin outside diameter
4.7 Measuring piston protrusion
4.8 Measuring clearance between connecting rod bearing and crankpin
4.9 Measuring clearance between connecting rod bushing and piston pin
4.10 Replacing connecting rod bushing
4.11 Inspecting connecting rod bend and twist
4.12 Inspecting connecting rod bearing
4.13 Measuring connecting rod end play
4.14 Weight difference of connecting rod assembly in one engine
4.15 Measuring crankshaft journal outside diameter
4.16 Measuring crankshaft crankpin outside diameter
4.17 Grinding crankshaft
4.18 Measuring crankshaft end play
4.19 Measuring crankshaft runout
4.20 Replacing crankshaft gear
4.20.1 Removing crankshaft gear
4.20.2 Installing crankshaft gear
4.21 Inspecting oil seal contact surface
4.22 Installing oil seal sleeve
4.23 Removing oil seal sleeve
4.24 Inspecting main bearing surface
4.25 Measuring clearance between main bearing and crankshaft journal
8Reassembly of Basic Engine
REASSEMBLY OF BASIC ENGINE
1. Reassembling piston, connecting rod, crankshaft and crankcase
1.1 Installing main bearing
1.2 Installing thrust plate
1.3 Installing tappet
1.4 Installing crankshaft
1.5 Installing main bearing caps
1.6 Inserting side seal
1.7 Installing main bearing cap bolt
1.8 Measuring crankshaft end play
1.9 Reassembling piston and connecting rod
1.10 Installing piston ring
1.11 Preparation for installing pistons
1.12 Installing connecting rod bolt and connecting rod bearing
1.13 Installing pistons
1.14 Installing connecting rod cap
2. Reassembling timing gear and camshaft
2.1 Installing oil pump
2.2 Installing front plate
2.3 Installing camshaft gear and thrust plate
2.4 Installing camshaft
2.5 Installing PTO drive gear
2.6 Installing idler gear
2.7 Installing oil pump gear
2.8 Installing fuel injection pump
2.9 Inspecting and adjusting timing gear after installation
2.9.1 Inspecting backlash and end play
2.10 Installing front oil seal
2.11 Installing timing gear case
2.12 Installing oil strainer
2.13 Installing oil pan
2.14 Installing cover
2.15 Installing crankshaft pulley
3. Reassembling flywheel
3.1 Installing rear plate
3.2 Installing oil seal
3.3 Installing flywheel
4. Reassembling cylinder head and valve mechanism
4.1 Cleaning cylinder head bottom surface
4.2 Installing valve stem seal
4.3 Installing valve and valve spring
4.4 Installing cylinder head assembly
4.5 Tightening cylinder head bolts
4.6 Inserting push rod
4.7 Reassembling rocker shaft assembly
4.8 Installing rocker shaft assembly
4.9 Determining top dead center of No.1 cylinder compression stroke
4.10 Adjusting valve clearance
4.11 Installing rocker cover
9Fuel System
FUEL SYSTEM
1. Removing fuel system
1.1 Removing fuel filter
1.2 Removing fuel injection pipe
1.3 Removing fuel injection pump
2. Disassembling, inspecting and reassembling fuel system
2.1 Disassembling and inspecting fuel filter
2.2 Changing fuel filter
2.3 Disassembling and inspecting fuel injection nozzle
2.4 Inspecting and adjusting fuel injection valve opening pressure
2.5 Inspecting fuel spray pattern of fuel injection nozzle
2.6 Cleaning and inspecting nozzle tip
2.7 Reassembling fuel injection nozzle
2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump
3. Installing fuel system
3.1 Installing fuel injection pump
3.2 Installing fuel injection pipe
3.3 Installing fuel filter
10Lubrication System
LUBRICATION SYSTEM
1. Removing lubrication system
1.1 Removing oil filter and relief valve
1.2 Removing oil pump, oil pan and oil strainer
2. Disassembling, inspecting and reassembling lubrication system
2.1 Disassembling and inspecting oil pump
2.2 Inspecting oil pump
2.2.1 Measuring clearance between outer rotor and inner rotor
2.2.2 Measuring end play of rotor and pump case
2.2.3 Measuring clearance between outer rotor and pump case
2.2.4 Measuring clearance between main shaft and pump case
2.2.5 Measuring clearance between main shaft and bushing
2.2.6 Installing oil pump bushing
2.3 Reassembling oil pump
2.4 Inspecting oil filter
2.5 Inspecting relief valve
3. Installing lubrication system
3.1 Installing oil pump, oil pan and oil strainer
3.2 Installing oil filter and relief valve
11Cooling System
COOLING SYSTEM
1. Removing cooling system
1.1 Removing cooling fan, fan pulley and V-belt
1.2 Removing thermostat
1.3 Removing water pump
2. Disassembling, inspecting and reassembling cooling system
2.1 Disassembling and inspecting thermostat
2.2 Inspecting thermostat
2.3 Disassembling water pump
2.4 Inspecting water pump
3. Installing cooling system
3.1 Installing water pump
3.2 Installing thermostat
3.3 Installing cooling fan, fan pulley and V-belt
12Inlet and Exhaust Systems
INLET AND EXHAUST SYSTEMS
1. Removing turbocharger, inlet and exhaust system
1.1 Removing inlet manifold
1.2 Removing exhaust manifold
2. Disassembling, inspecting and reassembling inlet and exhaust systems
2.1 Measuring exhaust manifold distortion
3. Installing inlet and exhaust systems
3.1 Installing exhaust manifold
3.2 Installing inlet manifold
13Electrical System
ELECTRICAL SYSTEM
1. Removing electrical system
1.1 Removing starter
1.2 Inspection before removing alternator
1.2.1 Inspecting alternator operation
1.2.2 Handling precaution
1.3 Removing alternator
1.4 Removing glow plug
2. Disassembling, inspecting and reassembling electrical system
2.1 Inspection before disassembling starter
2.1.1 Inspecting magnetic switch
2.1.2 No load test
2.2 Disassembling and inspecting starter
2.2.1 Removing pinion set
2.2.2 Removing magnetic switch
2.2.3 Removing rear bracket
2.2.4 Removing armature and yoke
2.2.5 Removing overrunning clutch
2.3 Inspecting and repairing starter
2.3.1 Inspecting brushes for wear
2.3.2 Measuring brush spring load
2.3.3 Inspecting brush holder for insulation
2.3.4 Measuring commutator radial runout
2.3.5 Measuring commutator outside diameter
2.3.6 Measuring undercut depth
2.3.7 Inspecting armature coil
2.3.8 Inspecting field coil
2.3.9 Inspecting rear bracket
2.3.10 Inspecting overrunning clutch
2.3.11 Inspecting front bracket
2.3.12 Inspecting gears of starter
2.3.13 Inspecting magnet switch
2.4 Installing starter
2.4.1 Installing gear shaft
2.5 Disassembling and inspecting alternator
2.5.1 Separating front bracket from stator
2.5.2 Removing pulley
2.5.3 Removing rear bearing
2.5.4 Removing front bearing
2.5.5 Removing stator
2.5.6 Removing regulator assembly
2.5.7 Removing rectifier assembly
2.6 Inspecting and repairing alternator
2.6.1 Inspecting rectifier
2.6.2 Inspecting armature
2.6.3 Inspecting stator
2.6.4 Inspecting brushes for wear
2.6.5 Replacing brushes
2.7 Reassembling alternator
2.7.1 Installing rectifier assembly and regulator assembly
2.7.2 Installing stator
2.7.3 Installing front bearing
2.7.4 Installing rear bearing
2.7.5 Installing pulley
2.7.6 Assembling stator and front bracket
2.8 Inspecting glow plug
2.8.1 Continuity test of glow plug
2.8.2 Heating test of glow plug
2.9 Inspecting magnet valve (stop solenoid)
2.9.1 Continuity test of magnet valve (stop solenoid)
2.9.2 Inspecting magnet valve (stop solenoid) operation
2.10 Installing magnet valve (stop solenoid)
3. Installing electrical system
3.1 Installing glow plug
3.2 Installing alternator
3.3 Installing starter
14Adjustment and Operation
ADJUSTMENT AND OPERATION
1. Adjusting engine
1.1 Inspecting and adjusting valve clearance
1.1.1 Inspecting valve clearance
1.1.2 Adjusting valve clearances
1.2 Draining fuel system
1.2.1 Draining fuel filter
1.3 Bleeding fuel system
1.3.1 Bleeding fuel filter
1.4 Inspecting and adjusting fuel injection timing
1.4.1 Adjusting fuel injection timing
1.5 Inspecting V-belt and adjusting V-belt tension
1.6 Inspecting V-belt
1.7 Adjusting V-belt tension
2. Break-in operation
2.1 Starting up
2.2 Inspecting engine condition after starting up
2.3 Break-in operation time
2.4 Inspection and adjustment after break-in operation
3. Performance test (JIS standard)
3.1 Engine equipment condition
3.2 Test items and purposes
3.2.1 Operation load test
3.2.2 Continuous load test
3.2.3 Low idle test
3.3 Other inspections
3.4 Engine output adjustment
3.4.1 Standard atmospheric conditions:
3.4.2 Calculation of corrected power
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