Caterpillar S4S-E35AFL(F) Diesel Engine Service Manual SCEEG-CT14J-230

Caterpillar S4S-E35AFL(F) Diesel Engine Service Manual SCEEG-CT14J-230 - Image 2

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caterpillar s4s e35aflf diesel engine service manual sceeg ct14j 230 2

caterpillar s4s e35aflf diesel engine service manual sceeg ct14j 230 3

Caterpillar S4S-E35AFL(F) Diesel Engine Service Manual SCEEG-CT14J-230

$50.00

Type Of Manual: Service Manual
Manual ID: SCEEG-CT14J-230
Number of Pages: 222
Size: 9.3MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- S4S-E35AFL(F) Diesel Engine

1. BINDING
2. INTRODUCTION
2.1. How to use this manual
2.1.1. Methods of presentation
2.1.2. Terms used in this manual
2.1.3. Abbreviations
2.1.4. Units of measurement
2.2. Safety Cautions
2.2.1. Fire and explosion
2.2.2. Stay clear of all rotating and moving parts
2.2.3. Be careful of burns
2.2.4. Be careful of exhaust fume poisoning
2.2.5. Protect ears from noises
2.2.6. Be careful of falling down
2.2.7. Be careful of handling fuel, engine oil and LLC
2.2.8. Service battery
2.2.9. When abnormality occurs
2.2.10. Other cautions
2.2.11. About warning labels
3. GENERAL CONTENTS
4. GENERAL
4.1. External view (in-line fuel injection pump and distributor-type fuel injection pump)
4.1.1. S4S in-line fuel injection pump specification
4.1.2. S4S-DT in-line fuel injection pump specification
4.1.3. S4S distributor-type fuel injection pump specification
4.1.4. S4S-DT distributor-type fuel injection pump specification
4.2. System flow diagrams
4.2.1. Fuel system – flow diagram
4.2.2. Lubrication system – flow diagram
4.2.3. Cooling system – flow diagram
4.2.4. Inlet and exhaust system – flow diagram
4.3. Engine serial number location
4.4. Main specifications
4.4.1. S4S in-line fuel injection pump specification (varies depending on the specification)
4.4.2. S4S distributor-type fuel injection pump specification (varies depending on the specification)
4.5. Tips on disassembling and reassembling
4.5.1. Disassembling
4.5.2. Reassembling
5. SERVICE DATA
5.1. Maintenance service data
5.1.1. General
5.1.2. Basic engine
5.1.3. Fuel system
5.1.4. Lubrication system
5.1.5. Cooling system
5.1.6. Inlet and exhaust system
5.1.7. Electrical system
5.2. Tightening torque table
5.2.1. Major bolt tightening torque
5.2.2. Standard bolt and nut tightening torque
5.2.3. Standard stud tightening torque
6. SERVICE TOOLS
6.1. Special tool
7. DETERMINATION OF OVERHAUL
7.1. Determining overhaul timing
7.2. Testing compression pressure
8. DISASSEMBLY OF BASIC ENGINE
8.1. Disassembling and inspecting cylinder head and valve mechanism
8.1.1. Removing rocker shaft assembly
8.1.2. Disassembling rocker shaft assembly
8.1.3. Removing cylinder head bolt
8.1.4. Removing cylinder head assembly
8.1.5. Removing valve and valve spring
8.1.6. Removing valve stem seal
8.2. Disassembling and inspecting flywheel
8.2.1. Removing flywheel
8.2.2. Removing flywheel housing
8.3. Disassembling and inspecting gear case, timing gear and camshaft
8.3.1. Removing crankshaft pulley
8.3.2. Removing cover
8.3.3. Removing timing gear case
8.3.4. Measuring timing gear backlash
8.3.5. Measuring idler gear and camshaft gear end play
8.3.6. Removing fuel injection pump
8.3.7. Removing oil pan
8.3.8. Removing oil strainer
8.3.9. Removing oil pump gear
8.3.10. Removing idler gear
8.3.11. Removing camshaft
8.3.12. Separating camshaft gear
8.3.13. Installing camshaft gear and thrust plate
8.3.14. Removing front plate
8.3.15. Removing oil pump
8.4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
8.4.1. Removing connecting rod cap
8.4.2. Removing carbon deposits from the upper part of cylinder
8.4.3. Pulling out piston
8.4.4. Removing piston ring
8.4.5. Removing piston pin and piston
8.4.6. Removing main bearing cap
8.4.7. Removing crankshaft
8.4.8. Removing tappet
9. INSPECTION AND REPAIR OF BASIC ENGINE
9.1. Inspecting and repairing cylinder head and valve mechanism
9.1.1. Measuring clearance between rocker bushing and rocker shaft
9.1.2. Measuring valve stem outside diameter and valve guide inside diameter
9.1.3. Replacing valve guide
9.1.4. Inspecting valve face
9.1.5. Refacing valve face
9.1.6. Refacing valve seat
9.1.7. Replacing valve seat
9.1.8. Lapping valve and valve seat
9.1.9. Measuring perpendicularity and free length of valve spring
9.1.10. Measuring distortion of the bottom surface of the cylinder head
9.1.11. Measuring pushrod runout
9.1.12. Removing combustion jet
9.2. Inspecting and repairing flywheel
9.2.1. Measuring flatness of flywheel
9.2.2. Measuring flywheel face and radial runouts
9.2.3. Inspecting ring gear
9.2.4. Replacing ring gear
9.3. Inspecting and repairing timing gear and camshaft
9.3.1. Measuring timing gear backlash
9.3.2. Measuring idler gear and camshaft gear end play
9.3.3. Measuring cam lift
9.3.4. Measuring camshaft runout
9.3.5. Measuring camshaft journal outside diameter
9.3.6. Measuring camshaft hole (bushing) inside diameter
9.3.7. Replacing camshaft bushing
9.3.8. Measuring idler bushing inside diameter and idler shaft outside diameter
9.3.9. Replacing idler shaft
9.3.10. Measuring clearance between tappet and tappet guide hole
9.3.11. Inspecting tappet
9.3.12. Inspecting V-belt groove wear
9.4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase
9.4.1. Measuring crankcase top surface distortion
9.4.2. Measuring cylinder inside diameter
9.4.3. Measuring piston outside diameter
9.4.4. Measuring piston ring end gap
9.4.5. Measuring clearance between piston ring groove and piston ring
9.4.6. Measuring piston pin bore diameter and piston pin outside diameter
9.4.7. Measuring piston protrusion
9.4.8. Measuring clearance between connecting rod bearing and crankpin
9.4.9. Measuring clearance between connecting rod bushing and piston pin
9.4.10. Replacing connecting rod bushing
9.4.11. Inspecting connecting rod bend and twist
9.4.12. Inspecting connecting rod bearing
9.4.13. Measuring connecting rod end play
9.4.14. Weight difference of connecting rod assembly in one engine
9.4.15. Measuring crankshaft journal outside diameter
9.4.16. Measuring crankshaft crankpin outside diameter
9.4.17. Grinding crankshaft
9.4.18. Measuring crankshaft end play
9.4.19. Measuring crankshaft runout
9.4.20. Replacing crankshaft gear
9.4.21. Inspecting oil seal contact surface
9.4.22. Installing oil seal sleeve
9.4.23. Removing oil seal sleeve
9.4.24. Inspecting main bearing surface
9.4.25. Measuring clearance between main bearing and crankshaft journal
10. REASSEMBLY OF BASIC ENGINE
10.1. Reassembling piston, connecting rod, crankshaft and crankcase
10.1.1. Installing main bearing
10.1.2. Installing thrust plate
10.1.3. Installing tappet
10.1.4. Installing crankshaft
10.1.5. Installing main bearing caps
10.1.6. Inserting side seal
10.1.7. Installing main bearing cap bolt
10.1.8. Measuring crankshaft end play
10.1.9. Reassembling piston and connecting rod
10.1.10. Installing piston ring
10.1.11. Preparation for installing pistons
10.1.12. Installing connecting rod bolt and connecting rod bearing
10.1.13. Installing pistons
10.1.14. Installing connecting rod cap
10.2. Reassembling timing gear and camshaft
10.2.1. Installing oil pump
10.2.2. Installing front plate
10.2.3. Installing camshaft gear and thrust plate
10.2.4. Installing camshaft
10.2.5. Installing idler gear
10.2.6. Installing oil pump gear
10.2.7. Installing fuel injection pump
10.2.8. Inspecting and adjusting timing gear after installation
10.2.9. Installing front oil seal
10.2.10. Installing timing gear case
10.2.11. Installing oil strainer
10.2.12. Installing oil pan
10.2.13. Installing cover
10.2.14. Installing crankshaft pulley
10.3. Reassembling flywheel
10.3.1. Installing oil seal
10.3.2. Installing flywheel housing
10.3.3. Installing flywheel
10.4. Reassembling cylinder head and valve mechanism
10.4.1. Cleaning cylinder head bottom surface
10.4.2. Installing valve stem seal
10.4.3. Installing valve and valve spring
10.4.4. Installing cylinder head gasket
10.4.5. Installing cylinder head assembly
10.4.6. Tightening cylinder head bolts
10.4.7. Inserting pushrod
10.4.8. Reassembling rocker shaft assembly
10.4.9. Installing rocker shaft assembly
10.4.10. Determining top dead center of No.1 cylinder compression stroke
10.4.11. Adjusting valve clearance
10.4.12. Installing rocker cover
11. FUEL SYSTEM
11.1. Removing fuel system
11.1.1. Removing fuel filter and fuel pipe
11.1.2. Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle
11.1.3. Removing fuel injection pump
11.2. Disassembling, inspecting and reassembling fuel system
11.2.1. Disassembling and inspecting fuel filter (in-line type fuel injection pump)
11.2.2. Disassembling and inspecting fuel filter
11.2.3. Changing fuel filter
11.2.4. Disassembling and inspecting fuel injection nozzle (swirl chamber type)
11.2.5. Disassembling and inspecting fuel injection nozzle (direct injection type)
11.2.6. Inspecting and adjusting fuel injection valve opening pressure
11.2.7. Inspecting fuel spray pattern of fuel injection nozzle
11.2.8. Cleaning and inspecting nozzle tip
11.2.9. Reassembling fuel injection nozzle (swirl chamber type)
11.2.10. Reassembling fuel injection nozzle (direct injection type)
11.2.11. Inspecting and cleaning gauze filter of distribute type fuel injection pump (Bosch)
11.3. Installing fuel system
11.3.1. Installing fuel injection pump
11.3.2. Checking fuel injection timing (in-line fuel injection pump type)
11.3.3. Inspecting fuel injection timing (distributor-type fuel injection pump)
11.3.4. Installing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle
11.3.5. Installing fuel filter and fuel pipe
12. LUBRICATION SYSTEM
12.1. Removing lubrication system
12.1.1. Removing oil filter and relief valve
12.1.2. Removing oil cooler
12.1.3. Removing oil pump, oil pan and oil strainer
12.2. Disassembling, inspecting and reassembling lubrication system
12.2.1. Disassembling and inspecting oil pump
12.2.2. Inspecting oil pump
12.2.3. Reassembling oil pump
12.2.4. Disassembling and inspecting oil cooler
12.2.5. Inspecting oil filter
12.2.6. Inspecting relief valve
12.2.7. Inspecting safety valve (for the engine with oil cooler)
12.3. Installing lubrication system
12.3.1. Installing oil pump, oil pan and oil strainer
12.3.2. Installing oil cooler
12.3.3. Installing oil filter and relief valve
13. COOLING SYSTEM
13.1. Removing cooling system
13.1.1. Removing cooling fan, fan pulley and V-belt
13.1.2. Removing thermostat
13.1.3. Removing water pump
13.2. Disassembling, inspecting and reassembling cooling system
13.2.1. Disassembling and inspecting thermostat
13.2.2. Inspecting thermostat
13.2.3. Disassembling water pump
13.2.4. Inspecting water pump
13.3. Installing cooling system
13.3.1. Installing water pump
13.3.2. Installing thermostat
13.3.3. Installing cooling fan, fan pulley and V-belt
14. INLET AND EXHAUST SYSTEMS
14.1. Removing turbocharger, inlet and exhaust systems
14.1.1. Removing turbocharger
14.1.2. Removing inlet manifold
14.1.3. Removing exhaust manifold
14.2. Disassembling, inspecting and reassembling inlet and exhaust systems
14.2.1. Measuring exhaust manifold distortion
14.3. Installing turbocharger, inlet and exhaust systems
14.3.1. Installing exhaust manifold
14.3.2. Installing inlet manifold
14.3.3. Installing turbocharger
15. ELECTRICAL SYSTEM
15.1. Removing electrical system
15.1.1. Removing starter
15.1.2. Inspection before removing alternator
15.1.3. Removing alternator (12V-50A)
15.1.4. Removing alternator (12V-75A, option)
15.1.5. Removing glow plug
15.2. Disassembling, inspecting and reassembling electrical system
15.2.1. Inspection before disassembling starter
15.2.2. Disassembling and inspecting starter
15.2.3. Inspecting and repairing starter
15.2.4. Reassembling starter
15.2.5. Disassembling and inspecting alternator
15.2.6. Inspecting and repairing alternator
15.2.7. Reassembling alternator
15.2.8. Heating test of glow plug
15.2.9. Inspecting air heater
15.2.10. Inspecting magnetic valve (stop solenoid, distributor-type)
15.2.11. Installing magnetic valve (stop solenoid)
15.2.12. Installing stop solenoid (RUN-ON type, for in-line pump type)
15.3. Installing electrical system
15.3.1. Installing glow plug
15.3.2. Installing alternator (12V-50A)
15.3.3. Installing alternator (12V-75A, option)
15.3.4. Installing starter
16. ADJUSTMENT AND OPERATION
16.1. Adjusting engine
16.1.1. Inspecting and adjusting valve clearance
16.1.2. Draining fuel system
16.1.3. Bleeding fuel system
16.1.4. Inspecting V-belt and adjusting V-belt tension
16.1.5. Inspecting V-belt
16.1.6. Adjusting V-belt tension
16.2. Break-in operation
16.2.1. Starting up
16.2.2. Inspecting engine condition after starting up
16.2.3. Break-in operation time
16.2.4. Inspection and adjustment after break-in operation
16.3. Performance test (JIS standard)

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