Caterpillar S4S Diesel Engine Service Manual 99729-87120

Caterpillar S4S Diesel Engine Service Manual 99729-87120 - Image 2

Caterpillar S4S Diesel Engine Service Manual 99729-87120 - Image 3

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Caterpillar S4S Diesel Engine Service Manual 99729-87120 - Image 5

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Caterpillar S4S Diesel Engine Service Manual 99729-87120

$50.00

Type Of Manual: Service Manual
Manual ID: 99729-87120
Number of Pages: 188
Size: 14.5MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- S4S Diesel Engine

1. INTRODUCTION
1.1. How to use this manual
1.1.1. Methods of presentation
1.1.2. Terms used in this manual
1.1.3. Abbreviations
1.1.4. Units of measurement
1.2. Safety Cautions
1.2.1. Fire and explosion
1.2.2. Stay clear of all rotating and moving parts
1.2.3. Be careful of burns
1.2.4. Be careful of exhaust fume poisoning
1.2.5. Protect ears from noises
1.2.6. Be careful of falling down
1.2.7. Be careful of handling fuel, engine oil and LLC
1.2.8. Service battery
1.2.9. When abnormality occurs
1.2.10. Other cautions
2. GENERAL CONTENTS
3. GENERAL
3.1. External view
3.2. System flow diagrams
3.2.1. Fuel system – flow diagram
3.2.2. Lubrication system – flow diagram
3.2.3. Cooling system – flow diagram
3.2.4. Inlet and exhaust system – flow diagram
3.3. Engine serial number location
3.4. Main specifications
3.5. Tips on disassembling and reassembling
3.5.1. Disassembling
3.5.2. Reassembling
4. SERVICE DATA
4.1. Maintenance service data
4.1.1. General
4.1.2. Basic engine
4.1.3. Fuel system
4.1.4. Lubrication system
4.1.5. Cooling system
4.1.6. Inlet and exhaust system
4.1.7. Electrical system
4.2. Tightening torque table
4.2.1. Major bolt tightening torque
4.2.2. Standard bolt and nut tightening torque
4.2.3. Standard eyebolt tightening torque
4.2.4. Standard union nut tightening torque
4.2.5. High-pressure fuel injection pipe tightening torque
5. SERVICE TOOLS
5.1. Special tool
6. DETERMINATION OF OVERHAUL
6.1. Determining overhaul timing
6.2. Testing compression pressure
7. DISASSEMBLY OF BASIC ENGINE
7.1. Disassembling and inspecting cylinder head and valve mechanism
7.1.1. Removing rocker shaft assembly
7.1.2. Disassembling rocker shaft assembly
7.1.3. Removing cylinder head bolt
7.1.4. Removing cylinder head assembly
7.1.5. Removing valve and valve spring
7.1.6. Removing valve stem seal
7.2. Disassembling and inspecting flywheel
7.2.1. Removing flywheel
7.2.2. Removing oil seal case
7.2.3. Removing rear plate
7.3. Disassembling and inspecting damper, gear case, timing gear and camshaft
7.3.1. Removing crankshaft pulley and damper
7.3.2. Removing cover
7.3.3. Removing timing gear case
7.3.4. Measuring timing gear backlash
7.3.5. Measuring idler gear and camshaft gear end play
7.3.6. Removing fuel injection pump
7.3.7. Removing oil pan
7.3.8. Removing oil strainer
7.3.9. Removing oil pump gear
7.3.10. Removing idler gear
7.3.11. Removing PTO drive gear
7.3.12. Removing camshaft
7.3.13. Separating camshaft gear
7.3.14. Installing camshaft gear and thrust plate
7.3.15. Removing front plate
7.3.16. Removing oil pump
7.4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
7.4.1. Removing connecting rod cap
7.4.2. Removing carbon deposits from the upper part of cylinder liner
7.4.3. Pulling out piston
7.4.4. Removing piston ring
7.4.5. Removing piston pin and piston
7.4.6. Removing main bearing cap
7.4.7. Removing crankshaft
7.4.8. Removing tappet
8. INSPECTION AND REPAIR OF BASIC ENGINE
8.1. Inspecting and repairing cylinder head and valve mechanism
8.1.1. Measuring clearance between rocker bushing and rocker shaft
8.1.2. Measuring valve stem outside diameter and valve guide inside diameter
8.1.3. Replacing valve guide
8.1.4. Inspecting valve face
8.1.5. Refacing valve face
8.1.6. Refacing valve seat
8.1.7. Replacing valve seat
8.1.8. Lapping valve and valve seat
8.1.9. Measuring perpendicularity and free length of valve spring
8.1.10. Measuring distortion of the bottom surface of the cylinder head
8.1.11. Measuring push rod runout
8.1.12. Removing combustion jet
8.2. Inspecting and repairing flywheel
8.2.1. Measuring flatness of flywheel
8.2.2. Measuring flywheel face and radial runouts
8.2.3. Inspecting ring gear
8.2.4. Replacing ring gear
8.3. Inspecting and repairing timing gear and camshaft
8.3.1. Measuring timing gear backlash
8.3.2. Measuring idler gear and camshaft gear end play
8.3.3. Measuring cam lift
8.3.4. Measuring camshaft runout
8.3.5. Measuring camshaft journal outside diameter
8.3.6. Measuring idler bushing inside diameter and idler shaft outside diameter
8.3.7. Replacing idler shaft
8.3.8. Measuring clearance between tappet and tappet guide hole
8.3.9. Inspecting tappet
8.3.10. Inspecting V-belt groove wear
8.4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase
8.4.1. Measuring crankcase top surface distortion
8.4.2. Measuring cylinder inside diameter
8.4.3. Measuring piston outside diameter
8.4.4. Measuring piston ring end gap
8.4.5. Measuring clearance between piston ring groove and piston ring
8.4.6. Measuring piston pin bore diameter and piston pin outside diameter
8.4.7. Measuring piston protrusion
8.4.8. Measuring clearance between connecting rod bearing and crankpin
8.4.9. Measuring clearance between connecting rod bushing and piston pin
8.4.10. Replacing connecting rod bushing
8.4.11. Inspecting connecting rod bend and twist
8.4.12. Inspecting connecting rod bearing
8.4.13. Measuring connecting rod end play
8.4.14. Weight difference of connecting rod assembly in one engine
8.4.15. Measuring crankshaft journal outside diameter
8.4.16. Measuring crankshaft crankpin outside diameter
8.4.17. Grinding crankshaft
8.4.18. Measuring crankshaft end play
8.4.19. Measuring crankshaft runout
8.4.20. Replacing crankshaft gear
8.4.21. Inspecting oil seal contact surface
8.4.22. Installing oil seal sleeve
8.4.23. Removing oil seal sleeve
8.4.24. Inspecting main bearing surface
8.4.25. Measuring clearance between main bearing and crankshaft journal
9. REASSEMBLY OF BASIC ENGINE
9.1. Reassembling piston, connecting rod, crankshaft and crankcase
9.1.1. Installing main bearing
9.1.2. Installing thrust plate
9.1.3. Installing tappet
9.1.4. Installing crankshaft
9.1.5. Installing main bearing caps
9.1.6. Inserting side seal
9.1.7. Installing main bearing cap bolt
9.1.8. Measuring crankshaft end play
9.1.9. Reassembling piston and connecting rod
9.1.10. Installing piston ring
9.1.11. Preparation for installing pistons
9.1.12. Installing connecting rod bolt and connecting rod bearing
9.1.13. Installing pistons
9.1.14. Installing connecting rod cap
9.2. Reassembling timing gear and camshaft
9.2.1. Installing oil pump
9.2.2. Installing front plate
9.2.3. Installing camshaft gear and thrust plate
9.2.4. Installing camshaft
9.2.5. Installing PTO drive gear
9.2.6. Installing idler gear
9.2.7. Installing oil pump gear
9.2.8. Installing fuel injection pump
9.2.9. Inspecting and adjusting timing gear after installation
9.2.10. Installing front oil seal
9.2.11. Installing timing gear case
9.2.12. Installing oil strainer
9.2.13. Installing oil pan
9.2.14. Installing cover
9.2.15. Installing crankshaft pulley
9.3. Reassembling flywheel
9.3.1. Installing rear plate
9.3.2. Installing oil seal
9.3.3. Installing flywheel
9.4. Reassembling cylinder head and valve mechanism
9.4.1. Cleaning cylinder head bottom surface
9.4.2. Installing valve stem seal
9.4.3. Installing valve and valve spring
9.4.4. Installing cylinder head assembly
9.4.5. Tightening cylinder head bolts
9.4.6. Inserting push rod
9.4.7. Reassembling rocker shaft assembly
9.4.8. Installing rocker shaft assembly
9.4.9. Determining top dead center of No.1 cylinder compression stroke
9.4.10. Adjusting valve clearance
9.4.11. Installing rocker cover
10. FUEL SYSTEM
10.1. Removing fuel system
10.1.1. Removing fuel filter
10.1.2. Removing fuel injection pipe
10.1.3. Removing fuel injection pump
10.2. Disassembling, inspecting and reassembling fuel system
10.2.1. Disassembling and inspecting fuel filter
10.2.2. Changing fuel filter
10.2.3. Disassembling and inspecting fuel injection nozzle
10.2.4. Inspecting and adjusting fuel injection valve opening pressure
10.2.5. Inspecting fuel spray pattern of fuel injection nozzle
10.2.6. Cleaning and inspecting nozzle tip
10.2.7. Reassembling fuel injection nozzle
10.2.8. Inspecting and cleaning gauze filter of distribute type fuel injection pump
10.3. Installing fuel system
10.3.1. Installing fuel injection pump
10.3.2. Installing fuel injection pipe
10.3.3. Installing fuel filter
11. LUBRICATION SYSTEM
11.1. Removing lubrication system
11.1.1. Removing oil filter and relief valve
11.1.2. Removing oil pump, oil pan and oil strainer
11.2. Disassembling, inspecting and reassembling lubrication system
11.2.1. Disassembling and inspecting oil pump
11.2.2. Inspecting oil pump
11.2.3. Reassembling oil pump
11.2.4. Inspecting oil filter
11.2.5. Inspecting relief valve
11.3. Installing lubrication system
11.3.1. Installing oil pump, oil pan and oil strainer
11.3.2. Installing oil filter and relief valve
12. COOLING SYSTEM
12.1. Removing cooling system
12.1.1. Removing cooling fan, fan pulley and V-belt
12.1.2. Removing thermostat
12.1.3. Removing water pump
12.2. Disassembling, inspecting and reassembling cooling system
12.2.1. Disassembling and inspecting thermostat
12.2.2. Inspecting thermostat
12.2.3. Disassembling water pump
12.2.4. Inspecting water pump
12.3. Installing cooling system
12.3.1. Installing water pump
12.3.2. Installing thermostat
12.3.3. Installing cooling fan, fan pulley and V-belt
13. INLET AND EXHAUST SYSTEMS
13.1. Removing turbocharger, inlet and exhaust system
13.1.1. Removing inlet manifold
13.1.2. Removing exhaust manifold
13.2. Disassembling, inspecting and reassembling inlet and exhaust systems
13.2.1. Measuring exhaust manifold distortion
13.3. Installing inlet and exhaust systems
13.3.1. Installing exhaust manifold
13.3.2. Installing inlet manifold
14. ELECTRICAL SYSTEM
14.1. Removing electrical system
14.1.1. Removing starter
14.1.2. Inspection before removing alternator
14.1.3. Removing alternator
14.1.4. Removing glow plug
14.2. Disassembling, inspecting and reassembling electrical system
14.2.1. Inspection before disassembling starter
14.2.2. Disassembling and inspecting starter
14.2.3. Inspecting and repairing starter
14.2.4. Installing starter
14.2.5. Disassembling and inspecting alternator
14.2.6. Inspecting and repairing alternator
14.2.7. Reassembling alternator
14.2.8. Inspecting glow plug
14.2.9. Inspecting magnet valve (stop solenoid)
14.2.10. Installing magnet valve (stop solenoid)
14.3. Installing electrical system
14.3.1. Installing glow plug
14.3.2. Installing alternator
14.3.3. Installing starter
15. ADJUSTMENT AND OPERATION
15.1. Adjusting engine
15.1.1. Inspecting and adjusting valve clearance
15.1.2. Draining fuel system
15.1.3. Bleeding fuel system
15.1.4. Inspecting and adjusting fuel injection timing
15.1.5. Inspecting V-belt and adjusting V-belt tension
15.1.6. Inspecting V-belt
15.1.7. Adjusting V-belt tension
15.2. Break-in operation
15.2.1. Starting up
15.2.2. Inspecting engine condition after starting up
15.2.3. Break-in operation time
15.2.4. Inspection and adjustment after break-in operation
15.3. Performance test (JIS standard)
15.3.1. Engine equipment condition
15.3.2. Test items and purposes
15.3.3. Other inspections
15.3.4. Engine output adjustment

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