Manual de Mantenimiento de Motor Mitsubishi S4S de Mini Cargador CAT

MAINTENANCE STANDARDS 1. Maintenance Standards Table ...................................................... 2 – 1 2. Tightening Torques .......................................................................... 2 – 6 2.1 Important Bolts and Nuts ................................................................ 2 – 6 2.2 Standard Bolts ................................................................................ 2 – 7 2.3 Standard Studs ............................................................................... 2 – 7 2.4 Standard Plugs ............................................................................... 2 – 7

3. Sealants and Lubricants Table ..................................................... 2 – 8 4. Maintenance Schedule ................................................................... 2 – 9

2

MAINTENANCE STANDARDS

1.

Maintenance Standards Table Unit: mm (in.)

Group

Inspection Point

Nominal Value

Maximum min−1, (no-load) Minimum min , (no-load)

General

3.2 (33) [469] at 300 min−1

2.8 (29) [413]

0.3 to 0.5 (3 to 5) [43 to 71] at 1500 min−1

0.15 (1.5) [21.3]

0.1 (1) [14.2] or more at idling

0.05 (0.5) [7]

Crankcase

Push belt in ward with thumb pressure {98 N (10 kgf) [22 lbf]} and measure deflection.

10 to 12 (0.4 to 0.5)

Warpage of gasket contact surface 94 (3.70)

0.05 (0.0020) or less

0.20 (0.0079)

94.000 to 94.035 (3.7008 to 3.7022)

94.200 (3.7087)

94.700 (3.7283)

(0.200) ([0.0079])

–0.09 (–0.035) as journal diameter which is 78 (3.07)

Circularity

0.01 (0.0004) or less

Cylindricity

0.015 (0.0006) or less

Clearance between bearing and journal

Both inlet and exhaust valves

BTDC 5°

V-belt deflection

Cylinder

(0.050 to 0.110) ([0.0020 to 0.0043])

Main bearing

Tappet bore

Camshaft bore

Oil temperature 70 to 90°C (158 to 194°F)

0.25 (0.0098)

Fuel injection timing

Inside diameter

Oil and water temp. 20 to 30°C (68 to 86°F)

BTDC 30° ABDC 50° BBDC 74° ATDC 30° ±3° (crank angle)

Inlet open Inlet close Exhaust open Exhaust close

Valve clearance (cold)

Crankcase

Remark

Adjust governor setting.

750±20

Compression pressure MPa (kgf/cm2) [psi]

Valve timing

Repair Service Limit Limit (Clearance) (Clearance)

2460±20

−1

Engine oil pressure MPa (kgf/cm2) [psi]

Assembly Standard (Standard Clearance)

Regrind if warpage is minor.

Width of thrust journals (Clearance between thrust and journal)

0.100 to 0.264 (0.0039 to 0.0104)

0.300 (0.0118)

Inside diameter

14.000 to 14.018 (0.5512 to 0.5519)

14.100 (0.5551)

Refinish cylinder to 0.25 (0.0098) or 0.50 (0.0197) oversize of normal value by honing and use the same oversize pistons and piston rings. If repair limit is reached, replace bearings. If is exceeded, regrind journals and use undersize bearings. Bearing undersizes: 0.25 (0.0098) 0.50 (0.0197) 0.75 (0.0295) Replace thrust plate.

Clearance between tappet and bore

(0.016 to 0.052) ([0.0006 to 0.0021])

(0.080) ([0.0031])

If it exceeds the repair limit, replace tappets.

Clearance between camshaft journal and bore

(0.070 to 0.110) ([0.0028 to 0.0043])

(0.15) ([0.0059])

If it exceeds the repair limit, refinish bores and install bushings, or replace camshaft.

2-1

MAINTENANCE STANDARDS

Unit: mm (in.) Group

Inspection Point

Cylinder head

Warpage of gasket contact surface Compressed thickness of gasket Diameter of valve stem

Valve and Clearance valve guide between guide and stem

Inlet valve

Valve seat

0.05 (0.0020) or less 1.2 (0.05)

(0.065 to 0.095) ([0.0026 to 0.0037])

(0.150) ([0.0059])

Exhaust valve

(0.080 to 0.115) ([0.0032 to 0.0045])

(0.200) ([0.0079])

Inlet valve

0.4 (0.016)

Exhaust valve

0.5 (0.020) 1.4 (0.055)

1.8 (0.071)

2.13 (0.0839)

Up to 1.83 (0.0720) by refacing

Valve margin Valve sinkage

Squareness of ends with respect to center line

19 (0.75)

147 (15) [33]

19.010 to 19.030 (0.7484 to 0.7492) 18.980 to 19.000 (0.7472 to 0.7480) (0.010 to 0.050) ([0.0004 to 0.0020])

(0.070) ([0.0028])

Deflection

0.3 (0.012) or less

Deflection

0.02 (0.0008) or less

0.05 (0.0020)

1/2 of dial indicator reading

Journal diameter

78 (3.07)

77.955 to 77.970 (3.0691 to 3.0697)

77.850 (3.0650)

Crankpin diameter

58 (2.28)

57.955 to 57.970 (2.2817 to 2.2823)

57.800 (2.2756)

Center to center distance between journal and crankpin

60 (2.36)

±0.04 (±0.0016)

Parallelism between journal and crankpin

Valve seat angle

43 (1.69)

Clearance between bushing and shaft

Crankshaft

Seat width

47.60 (1.87)

176 to 196 (1.8 to 20) [40 to 44]

Set force N (kgf) [lbf]

Diameter of rocker shaft

±0.14 (±0.0055)

1.5° or less

Set length

Inside diameter of rocker bushing

±0.1 (±0.004)

1.0 (0.039)

48.85 (1.92)

Squareness

Main moving parts

13.9 to 14.1 (0.5472 to 0.5551)

30°

Free length

Valve pushrod

±0.05 (±0.002)

Inlet valve

14 (0.55)

Remark Regrind if warpage is minor.

7.850 (0.3091)

8 (0.31)

Valve margin

Rocker arm

0.20 (0.0079)

7.920 to 7.940 (0.3118 to 0.3126)

Exhaust valve

Width

Valve spring

Repair Service Limit Limit (Clearance) (Clearance)

7.900 (0.3110)

Angle Valve sinkage

Assembly Standard (Standard Clearance)

7.940 to 7.955 (0.3126 to 0.3132)

Height to top of valve guide

Cylinder head

Nominal Value

Runout : 0.01 (0.004) or less (over crankpin length)

2-2

77.100 (3.0354)

MAINTENANCE STANDARDS

Unit: mm (in.) Group

Inspection Point

Nominal Value

Circularity of journal and crankpin

0.01 (0.0004) or less

Taper of journal and crankpin

Crankshaft

Fillet radius of journal and crankpin

Piston

Outside diameter (at skirt)

End play (Width of shaft thrust journal)

3 (0.12)

3.1 (1.22)

Standard 0.25 (0.0098) oversize

94 (3.70)

0.50 (0.0197) oversize

Connecting rod

Clearance Clearance between between ends groove and ring

Main moving parts

(0.100 to 0.264) ([0.0039 to 0.0104])

If thrust plate clearance exceeds the repair limit, replace thrust plates. If it is exceeded, use oversize thrust plates. Thrust plate oversizes: 0.15 (0.0059) 0.30 (0.0118)

(0.300) ([0.0118])

93.955 to 93.985 (3.6990 to 3.7002)

93.770 (3.6917)

94.205 to 94.235 (3.7089 to 3.7100)

94.020 (3.7016)

94.455 to 94.485 (3.7187 to 3.7199)

94.270 (3.7114) Check bearing clearance. (0.200) ([0.0079])

No.2 ring

(0.045 to 0.085) ([0.0018 to 0.0034])

(0.150) ([0.0059])

Oil ring

(0.020 to 0.060) ([0.0010 to 0.0026])

(0.150) ([0.0059])

No.1 ring Oil ring

0.30 to 0.50 (0.0118 to 0.0197)

No.2 ring

0.50 to 0.70 (0.0196 to 0.0275)

1.50 (0.0591)

29.994 to 30.000 (1.1809 to 1.1811)

Clearance between pin and piston

0.000 to 0.016 (0.000 to 0.006)

0.050 (0.0019)

Clearance between pin and bushing

(0.020 to 0.051) ([0.0008 to 0.0020])

(0.080) ([0.0032])

Inside diameter of bushing

30 (1.18)

Clearance between crankpin and connecting rod bearing

Flatness Face runout

30.020 to 30.045 (1.1819 to 1.1829) 0.05/100 (0.0019/3.94) or less

Bend and twist

End play Flywheel

±0.2 (±0.008)

(0.07 to 0.11) ([0.0028 to 0.0043])

30 (1.18)

Remark

0.03 (0.0012)

No.1 ring

Diameter Piston pin

Repair Service Limit Limit (Clearance) (Clearance)

0.05 to 0.45 (0.0020 to 0.0177)

Protrusion

Piston ring

Assembly Standard (Standard Clearance)

33 (1.30)

(0.030 to 0.090) ([0.0012 to 0.0035])

(0.200) ([0.0079])

If service limit is exceeded, replace bearing or regrind pin and use undersize bearing.

(0.15 to 0.35) ([0.0059 to 0.0138])

(0.50) ([0.020])

Replace connecting rod.

0.15 (0.0059) or less

2-3

0.50 (0.020)

MAINTENANCE STANDARDS

Unit: mm (in.) Group

Nominal Value

Inspection Point

Assembly Standard (Standard Clearance) 0.02 (0.0008) or less

Cam lift C Journal diameter

Timing gear

Camshaft

Deflection A= 46.916 − 0.3 [1.8471 +− 0.004 0.012 ]

Exhaust valve

46.880 − 0.3 [1.8457 +− 0.004 0.012 ]

6.720 (0.2646)

6.220 (0.2450)

No.1, 2

54 (2.13)

53.94 to 53.96 (2.1236 to 2.1244)

53.90 (2.1220)

No.3

53 (2.09)

52.94 to 52.96 (2.0842 to 2.0850)

52.90 (2.0827)

5 (0.20)

(0.10 to 0.25) ([0.0039 to 0.0098])

(0.30) ([0.0118])

(0.009 to 0.050) ([0.0004 to 0.0020])

0.100 (0.0040) (0.35) ([0.0138])

+ 0.1

A=

End play

4.5 (1.17)

(0.05 to 0.20) ([0.0020 to 0.0079])

Fit (interference) of bushing in crankcase bore

3.5 (1.17)

(0.021T to 0.076T) ([0.0008T to 0.0030T]) 0.05 to 0.15 (0.0012 to 0.0071)

Backlash

Injection nozzle

Fuel system

Valve opening pressure MPa (kgf/cm2) [psi]

Spray cone angle

Oil tightness of needle valve seat

Starter (12 V–2.2 kW)

Electrical system

Diameter of commutator

11.77 (120) [1706]

31 (3.2) [7.0]

D1

Replace thrust plates. Replace bushing. Replace thrust plates.

Replace gears.

Test by means of hand tester, using diesel fuel, at 20°C (68°F). If discharge pattern is bad even after nozzle is washed in clean diesel fuel, replace nozzle tip.

32 (1.26)

Spring force, N (kgf) [lbf]

D2

Make shim adjustment. Pressure varies by 1 (10) [142] per 0.1 mm (0.004 in.) thickness of shim.

11.77 to 12.75 (120 to 130) [1707 to 1849]

Seat shall hold a test pressure 2 MPa (20 kgf/cm2) [284 psi] lower than valve opening pressure for 10 seconds.

18 (0.71)

Pinion clearance

0.25 (0.0098)

0°

Length

Remark Straighten by cold working or replace.

6.184 (0.2435)

Clearance between shaft and bushing

Brush

0.05 (0.0020)

6.684 (0.2632)

End play

Idler gear

+ 0.1

Inlet valve

Repair Service Limit Limit (Clearance) (Clearance)

31.8 to 32.2 (1.25 to 1.27)

Wash or replace nozzle tip. 31.4 (1.24) 11 (0.43)

26 to 36 (2.7 to 3.7) [5.8 to 8.1]

15 (1.5) [3.4]

0.5 to 2.0 (0.020 to 0.079) No-load characteristics Voltage, V

Current, A

Speed, min−1

11

130 or less

3800 or more

2-4

MAINTENANCE STANDARDS

Unit: mm (in.) Inspection Point Alternator (12 V–50 A)

Electrical system

Group

Nominal Value

18.5 (0.73)

Brush height Resistance in slip rings

Oil pump

Lubrication system

(0.20 to 0.30) ([0.0012 to 0.0018])

Diameter of main shaft (case side)

16 (0.63)

15.985 to 16.000 (0.6293 to 0.6299)

Diameter of main shaft (oil pump bushing side)

14 (0.55)

13.957 to 13.975 (0.5495 to 0.5502)

Remark

5 (0.20) at 20°C (68°F) 0.50 [0.0197]

Replace oil pump assembly.

Clearance between main shaft and case

(0.032 to 0.074) ([0.0013 to 0.0029])

(0.15) ([0.0059])

Replace pump assembly.

Clearance between main shaft and oil pump bushing

(0.025 to 0.111) ([0.0010 to 0.0044])

(0.200) ([0.0079])

Replace pump assembly.

Clearance between outer and inner rotors

(0.13 to 0.15) ([0.0051 to 0.0059])

(0.20) ([0.0079])

Replace shaft assembly.

Clearance between rotors and cover

(0.04 to 0.09) ([0.0016 to 0.0035])

(0.15) ([0.0059])

Replace shaft assembly.

Relief valve

Valve opening pressure, MPa (kgf/cm2) [psi] Inner rotor bore

Thermostat

Repair Service Limit Limit (Clearance) (Clearance)

2.7 to 3.2 ohm

Clearance between outer rotor and case

Cooling system

Assembly Standard (Standard Clearance)

0.35±0.05 (3.5±0.5) [50±7] 16 (0.63)

(15.95 to 15.968) ([0.6279 to 0.6286])

Temp. at which valve starts opening

76.5±2°C (170±3.6°F)

Temp. at which valve lift is more than 8 (0.3)

90°C (194°F)

2-5

Mainshaft shrinkage fit

MAINTENANCE STANDARDS

2.

Tightening Torques

2.1 Important Bolts and Nuts Thread Dia. × Pitch (M-thread)

Width across flats mm (in.)

N·m

kgf·m

lbf·ft

Cylinder head bolt

M12 × 1.75

19

113 to 123

11.5 to 12.5

83 to 90

Cylinder head plug

M16 × 1.5

14

39.2 to 49.0

4.0 to 5.0

28.9 to 36.2

Rocker cover

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.23 to 9.40

Rocker shaft brackets (long)

M8 × 1.25

12

10.0 to 20.0

1.0 to 2.0

7.23 to 14.5

M14 × 2

22

98 to 108

10.0 to 11.0

72 to 80

Connecting rod caps nut

M10 × 1.0

14

49.0 to 59.0

5.0 to 6.0

36.2 to 43.4

Flywheel

M12 × 1.25

17

78.5 to 88.3

8.0 to 9.0

57.9 to 65.1

Camshaft thrust plate

M8 × l.25

12

10.0 to 13.0

1.0 to 1.3

7.23 to 9.40

Front plate

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.23 to 9.40

Timing gear case cover

M8 × 1.25

12

17.0 to 20.0

1.7 to 2.0

12.3 to 14.5

Crankshaft pulley

M30 × 1.5

46

480 to 500

49 to 51

354 to 369

Idler gear thrust plate

M10 × 1.25

14

29.0 to 39.0

3.0 to 4.0

21.7 to 28.9

Oil pan

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.25 to 9.40

Rear plate

M10 × 1.25

14

54.0 to 65.7

5.5 to 6.7

39.8 to 48.5

Fuel injection pump delivery valve holders

M14 × 1.5

14

44.0 to 54.0

4.5 to 5.5

32.5 to 39.8

Fuel injection pump gear nut

M12 × 1.75

19

58.8 to 68.6

6.0 to 7.0

43.4 to 50.6

Fuel injection pump gear (in–line, swirl chamber type) (in–line, direct injection type)

M12 × 1.75 M14 × 1.5

19 22

58.8 to 68.6 83.4 to 98.0

6.0 to 7.0 8.5 to 10.0

43.4 to 50.6 61.5 to 72.3

Fuel return pipe nuts

M10 × 1.25

17

20.6 to 24.5

2.1 to 2.5

15.2 to 18.1

Fuel return pipe flare nut

M10 × 1.25

14

17.7 to 21.6

1.8 to 0.22

13.0 to 15.9

Fuel injection pump overflow valve

M12 × 1.0

17

20.0 to 29.0

2.0 to 3.0

14.5 to 21.7

Fuel injection pipe nuts

M12 × 1.5

17

26.5 to 32.4

2.7 to 3.3

19.5 to 23.9

Oil pump gear

M10 × 1.25

14

28.0 to 38.0

2.9 to 3.9

21.0 to 28.2

Oil pan drain plug

M14 × 1.5

17

34.0 to 44.0

3.5 to 4.5

25.3 to 32.5

Oil pressure relief valve

M22 × 1.5

27

44.1 to 53.9

4.5 to 5.5

32.5 to 39.8

l/4–18NPTF

14

35.3 to 43.1

3.6 to 4.4

26.0 to 31.8

Thermostat

M16 × 1.5

19

20.6 to 24.5

2.1 to 2.5

15.2 to 18.1

Exhaust manifold (bolt only) (with spacer)

M8 × 1.25

12

27.5 to 33.3

2.8 to 3.4

20.3 to 24.6

Starter terminal B

M8 × 1.25

12

9.81 to 11.8

1.0 to 1.2

7.23 to 8.68

Alternator pulley

M16 × 1.5

24

98 to 137

Description

Main bearing caps

Coolant drain plug

2-6

Tightening Torque

10.0 to 14.0 72.3 to 101.3

MAINTENANCE STANDARDS

Thread Dia. × Pitch (M-thread)

Width across flats mm (in.)

N·m

kgf·m

lbf·ft

M10 × 1.25

12

15.0 to 20.0

1.5 to 2.0

10.8 to 14.5

Glow plug (terminal)

M4 × 0.7

7

1.0 to 1.5

0.10 to 0.15

0.72 to 1.08

Nozzles tip retaining nut (to engine)

M20 × 1.5

21

53.0 to 64.7

5.4 to 6.6

39.1 to 47.7

Thermostat case

M8 × 1.25

12

17.0 to 20.0

1.7 to 2.0

12.3 to 14.5

Description Glow plug (body)

Tightening Torque

2.2 Standard Bolts Torque Thread Diameter (mm)

4T

7T

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

M6

2.94 to 4.90

0.3 to 0.5

2.17 to 3.62

7.85 to 9.80

0.8 to 1.0

5.79 to 7.23

M8

9.80 to 12.7

1.0 to 1.3

7.23 to 9.40

14.7 to 21.6

1.5 to 2.2

10.8 to 15.9

M10

17.7 to 24.5

1.8 to 2.5

13.0 to 18.1

29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

M12

29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

53.9 to 73.5

5.5 to 7.5

39.8 to 54.2

2.3 Standard Studs Torque (tap end) Thread Diameter (mm)

For driving in aluminum materials

For driving in ferrous materials

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

M8

4.90 to 5.90

0.50 to 0.60

3.62 to 4.34

11.8 to 13.7

1.2 to 1.4

8.68 to 10.1

M10

12.7 to 14.7

1.3 to 1.5

9.40 to 10.8

21.6 to 25.5

2.2 to 2.6

15.9 to 18.8

2.4 Standard Plugs Torque Thread Diameter

For aluminum materials

For ferrous materials

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

NPTF 1/16

4.90 to 7.85

0.5 to 0.8

3.62 to 5.79

7.85 to 11.8

0.8 to 1.2

5.79 to 8.68

PT 1/8

7.85 to 11.8

0.8 to 1.2

5.79 to 8.68

14.7 to 21.6

1.5 to 2.2

10.8 to 15.9

PT 1/4, NPTF 1/4

19.6 to 29.4

2.0 to 3.0

14.5 to 21.7

34.3 to 44.1

3.5 to 4.5

25.3 to 32.5

––

––

––

53.9 to 73.5

5.5 to 7.5

39.8 to 54.2

PT 3/8

Remarks: 1. The torque values shown above are for the bolts with spring washers. 2. Do not apply any oil to the bolt threads.

2-7

MAINTENANCE STANDARDS

3.

Sealants and Lubricants Table Apply to

Mating Parts

Sealant or Lubricant

How to Use

Oil pan

Crankcase

ThreeBond 1207C

Apply to seal.

Rear bearing cap seat on crankcase

Rear bearing cap

ThreeBond 1212

Apply to corners before installing cap.

Side seals

Crankcase rear bearing cap

ThreeBond 1212

Apply to side seals.

Cylinder head coolant hole plug

Cylinder head

ThreeBond 1386D

Apply to plug hole.

Crankcase coolant hole plug

Crankcase

ThreeBond 1386D

Apply to plug hole.

Crankcase oil hole plug

Crankcase

ThreeBond 1386D

Apply to plug hole.

Return oil hole plug hole

Crankcase

ThreeBond 1386D

Apply to plug hole.

Crankshaft threads

Crankshaft pulley nut

ThreeBond 1212

Apply to crankshaft thread before tightening nut.

Rear gasket

Crankcase and rear plate

ThreeBond 1212

Apply to both sides of rear gasket.

CAUTION When changing parts, be sure to use OEM designed parts. Unless OEM designed parts are used, the exhaust emission warranty will be voided. Modification to the fuel system can only be done under these circumstances: Fuel and exhaust system repairs must only be conducted by an authorized CAT lift truck dealer. Tampering or adjusting the fuel system components outside the manufacturer’s specs will void the warranty. The fuel injection pump must be replaced as an assembly.

2-8

MAINTENANCE STANDARDS

4.

Maintenance Schedule (3) Perform service on items at multiples of the original requirement. For example, at Every 200 service hours, also service those items listed under Every 50 service hours and Every 10 service hours.

(1) Use the service meter to determine servicing intervals. (2) The servicing intervals in the schedule are for an average operating conditions. Service the engine earlier than the scheduled intervals if necessary. (The intervals depends on application, operating conditions and fuel oil and lube oil used in the engine. Adjust the intervals to meet the actual operating conditions.)

Check, clean, wash or adjust. Change. S Rely on Cat lift truck dealer if necessary.

Daily/Weekly Inspection Interval No.

Item

1

Cooling fan

Check

2

Engine coolant

Check level

3

Battery electrolyte

Check level

4

Engine (exhaust, noise, vibration)

Check

5

Engine oil

Check level

6

Fuel

Check level

7

Fuel hose, pipes, joints

Check

8

V-Belt (fan and alternator)

Check tension

9

Air cleaner element

Clean

Notes: 1. 2. 3.

Action

Every day (10 hrs)

Remarks

Weekly (10 hrs)

Add distilled water as required. (Note 1)

(Note 2)

Not required if battery type is full maintenance free. In corrosive or abrasive environments, clean, lubricate, or change more frequently. When fuel with poor quality is used, check, drain, and change more frequently.

2-9

MAINTENANCE STANDARDS Maintenance Schedule

Yearly or every 2000 service hours

Action

Every 6 months or 1000 service hours

Item

Every 3 months or 500 service hours

Group

1st month or 200 hrs only after delivery of new truck

Interval

Remarks

Lubrication system

Engine oil

Change

S

Oil filter

Change

S

Engine body

Cylinder head bolt, manifold nut (bolts & nuts of engine exterior)

Check

Fuel system

Engine idle speed

Check

Injection nozzle

Check

S

Fuel filter

Change

S (Note 3)

Fuel hose

Change

Radiator fin

Check/Clean

Engine coolant

Change

Cooling system

Radiator cap, rubber hose

Replace in 2-4 years

Check

Intake & ex- Intake & exhaust valve clearance haust system Air cleaner element

Check

Electrical system

Battery electrolyte specific gravity

Check

(Note 1)

Alternator

Check

S

Starter

Check

S

Change

Check, clean, wash or adjust. Change. S Rely on Cat lift truck dealer if necessary. Notes: 1. 2. 3.

Not required if battery type is full maintenance free. In corrosive or abrasive environments, clean, lubricate, or change more frequently. When fuel with poor quality is used, check, drain, and change more frequently.

2-10