New Holland S4L2 User manual

Part number 84373329
English
August 2010
SERVICE MANUAL
S4L2, S4L
Engine
PrintedinU.S.A.
Copyright © 2010 CNH America LLC. All Rights Reserved. NewHollandisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.

Contents
INTRODUCTION
HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMSA
ELECTRICALPOWERSYSTEM.........................................................A.30.A
ENGINEANDPTOIN....................................................................B
ENGINE...................................................................................B.10.A
FUELANDINJECTIONSYSTEM.........................................................B.20.A
AIRINTAKESYSTEM.....................................................................B.30.A
EXHAUSTSYSTEM.......................................................................B.40.A
ENGINECOOLANTSYSTEM............................................................B.50.A
LUBRICATIONSYSTEM..................................................................B.60.A
STARTINGSYSTEM......................................................................B.80.A
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................4
Specialtools....................................................................................6
Generalspecication...........................................................................8
S4L
Generalspecication...........................................................................9
S4L2
Productidentication..........................................................................10
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INTRODUCTION
Foreword
Thisservicemanualdescribesthespecications,maintenanceandserviceproceduresforMitsubishidieselengines.
Tomaintaintheperformanceoftheengineformanyyearsandtoensuresafeoperation,itisimportanttousetheen-
ginecorrectlyandconductregularinspectionandmaintenance,andalsototakenecessarymeasureswhichinvolves
thedisassembly,inspection,repairandreassemblyoftheengineandengineparts.
Readthismanualcarefullyandunderstandtheworkproceduresfullybeforedisassembling,inspecting,repairingor
reassemblingtheengine.
Thecontentsofthemanualarebasedontheenginemodelsthatarebeingproducedatthetimeofpublication.Due
toimprovementsmadethereafter,theactualenginthatyouworkonmaydifferpartiallyfromtheonedescribedinthis
manual.
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INTRODUCTION
Safetyrules
Standardsafetyprecautions
Beinformedandnotifypersonnelofthelawsinforceregulatingsafety,andprovidedocumentationavailablefor
consultation.
•Keepworkingareasascleanaspossible.
•Ensurethatworkingareasareprovidedwithemergencyboxes.Theymustbeclearlyvisibleandalwayscontain
adequatesanitaryequipment.
•Fireextinguishersmustbeproperlyidentiedandalwaysbeclearofobstructions.Theirefciencymustbechecked
onaregularbasisandpersonnelmustbetrainedonproperinterventionsandpriorities.
•Keepallemergencyexitsfreeofobstructionsandclearlymarked.
•Smokinginworkingareassubjecttoredangermustbestrictlyprohibited.
Preventionofinjury
•Wearsuitableworkattireandsafetyglasseswithnojewelrysuchasringsandchainswhenworkingcloseto
enginesandequipmentinmotion.
•Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
•Toppingofforchanginglubricationoils.
•Usingcompressedairorliquidsatapressuregreaterthan2bar(29psi).
•Wearasafetyhelmetwhenworkingclosetohangingloadsorequipmentworkingatheadlevel.
•Alwayswearsafetyshoesandttingclothes.
•Useprotectioncreamforhands.
•Changewetclothesassoonaspossible.
•Inthepresenceofvoltagesexceeding48-60V,verifytheefciencyofthegroundandmasselectricalconnections.
Ensurethathandsandfeetaredryanduseisolatingfootboards.Workersshouldbeproperlytrainedtoworkwith
electricity.
•Donotsmokeorstartanopenameclosetobatteriesandanyfuelmaterial.
•Placesoiledragswithoil,dieselfuelorsolventsinspeciallyprovidedanti-recontainers.
•Donotuseanytoolorequipmentforanyuseotherthanwhatitwasoriginallyintendedfor.Seriousinjurymay
occur.
•Ifrunninganengineindoors,makesurethereisasufcientexhaustfaninusetoeliminateexhaustfumes.
Duringmaintenance
•Neveropenthellercapofthecoolingsystemwhentheengineishot.Hightemperatureliquidatoperating
pressurecouldresultinseriousdangerandriskofburn.Waituntilthetemperaturedecreasesunder50°C(122
°F).
•Neveraddcoolanttoanoverheatedengineanduseonlyappropriateliquids.
•Alwaysworkwhentheengineisturnedoff.Certaincircumstancesrequiremaintenanceonarunningengine.Be
awareofalltherisksinvolvedwithsuchanoperation.
•Alwaysuseadequateandsafecontainersforengineuidsandusedoil.
•Keepenginecleanofanyspilleduidssuchasoil,dieselfuel,andorchemicalsolvents.
•Useofsolventsordetergentsduringmaintenancemayemittoxicvapors.Alwayskeepworkingareasaerated.
Wearasafetymaskifnecessary.
•Donotleavesoiledragsthatmaycontainanyammablesubstancesclosetotheengine.
•Alwaysusecautionwhenstartinganengineafteranyworkhasbeenperformed.Bepreparedtocutoffintakeair
incaseofenginerunaway.
•Neverdisconnectthebatterieswhiletheengineisrunning.
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INTRODUCTION
•Disconnectthebatteriespriortoperforminganyworkontheequipment.
•Disconnectthebatteriestoplacealoadonthemwithaloadtester.
•Afteranyworkisperformed,verifythatthebatteryclamppolarityiscorrectandthattheclampsaretightandsafe
fromaccidentalshortcircuitandoxidation.
•Beforedisconnectinganypipelines(pneumatic,hydraulic,fuelpipes,etc.),verifythatallpressurehasbeenre-
leased.T akeallnecessaryprecautionsbleedinganddrainingresidualpressure.Alwayswearthepropersafety
equipment.
•Donotalterthelengthsofanywires.
•DonotconnectanyelectronicservicetooltotheengineelectricalequipmentunlessspecicallyapprovedbyIveco.
•DonotmodifythefuelsystemorhydraulicsystemunlessapprovedbyIveco,Anyunauthorizedmodicationwill
compromisewarrantyassistanceandmayaffectengineoperationandlifespan.
Forengineequippedwithanelectroniccontrolunit
•Donotweldonanypartoftheequipmentwithoutremovingthecontrolunit.
•Removetheincaseofworkrequiringheatingover80°C(176°F).
•Donotpaintthecomponentsandtheelectronicconnections.
•Donotalteranydataledintheelectroniccontrolunitdrivingtheengine.Anymanipulationoralterationofelec-
troniccomponentswillvoidenginewarrantyassistanceandmayaffectthecorrectworkingorderandlifespanof
theengine.
RespectoftheEnvironment
•Respectoftheenvironmentshouldbeofprimaryimportance.Takeallnecessaryprecautionstoensureperson-
nel’ssafetyandhealth.
•Informthepersonnelofthelawsregardingthedispensingofusedengineuids.
•Handlebatterieswithcare,storingtheminawellventilatedenvironmentandwithinanti-acidcontainer.
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INTRODUCTION
Specialtools
31A91-00100
Pistonpinsettingtool
•Forremovalandinstallationofthepistonpin
931011241
ST332340
Camshaftbushinginstaller
•Forpunchingandpress-ttingofthefrontcamshaft
bushing
931011272
ST332270
Compressiongaugeadapter
•Formeasuringcompression
931011263
MD998054
Oilpressureswitchsocketwrench
•Forremovalandinstallationoftheoilpressureswitch
931011294
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INTRODUCTION
31391-12900
Pistonringpliers
•Forremovalandinstallationofthepistonrings
931011235
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INTRODUCTION
Generalspecication
S4L
Refertothefollowingtableforlinkstothespecicationspages.
EngineENGINE-Generalspecication(B.10.A)
LubricationsystemLUBRICATIONSYSTEM-Generalspecication(B.60.A)
FuelandinjectionsystemFUELANDINJECTIONSYSTEM-Generalspecication(B.20.A)
EnginecoolantsystemENGINECOOLANTSYSTEM-Generalspecication(B.50.A)
AirintakesystemAIRINTAKESYSTEM-Generalspecication(B.30.A)
ElectricalpowersystemELECTRICALPOWERSYSTEM-Generalspecication(A.30.A)
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INTRODUCTION
Generalspecication
S4L2
Refertothefollowingtableforlinkstothespecicationspages.
EngineENGINE-Generalspecication(B.10.A)
LubricationsystemLUBRICATIONSYSTEM-Generalspecication(B.60.A)
FuelandinjectionsystemFUELANDINJECTIONSYSTEM-Generalspecication(B.20.A)
EnginecoolantsystemENGINECOOLANTSYSTEM-Generalspecication(B.50.A)
AirintakesystemAIRINTAKESYSTEM-Generalspecication(B.30.A)
ElectricalpowersystemELECTRICALPOWERSYSTEM-Generalspecication(A.30.A)
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INTRODUCTION
Productidentication
Engineserialnumberlocation
Theengineserialnumber(1)isstampedonthelabelof
theuppersideoftherockercover.
931015551
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SERVICEMANUAL
HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMS
SLSeries
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A

Contents
HYDRAULIC-PNEUMATIC-ELECTRICAL-
ELECTRONICSYSTEMS-A
ELECTRICALPOWERSYSTEM...........................................................A.30.A
SLSeries
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HYDRAULIC-PNEUMATIC-ELECTRICAL-
ELECTRONICSYSTEMS-A
ELECTRICALPOWERSYSTEM-30.A
SLSeries
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Contents
HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONIC
SYSTEMS-A
ELECTRICALPOWERSYSTEM-30.A
TECHNICALDATA
ELECTRICALPOWERSYSTEM
Generalspecication.......................................................................3
S4L,S4L2
Torque....................................................................................3
SERVICE
ELECTRICALPOWERSYSTEM
Remove-Stopsolenoid.....................................................................4
Remove-Glowplugs.......................................................................6
Inspect-Glowplugs........................................................................7
Install-Glowplugs.........................................................................8
Alternator
Inspect..................................................................................11
Remove.................................................................................14
Disassemble.............................................................................16
Assemble................................................................................21
Install....................................................................................22
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HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMS-ELECTRICALPOWERSYSTEM
ELECTRICALPOWERSYSTEM-Generalspecication
S4L,S4L2
EnginemodelS4L,S4L2
Voltage-polarity12V-negative(-)ground
Starter
-TypeM008T70471A
-ManufacturerMitsubishiElectricCorporation
-PinionengagementtypePinionshift(reductiontype)
-Output12V-2.0kW
-Numberofunits1
-Pinion/ringgearratio13/120
Alternator
-TypeThree-phasealternatinggenerator,internalICregulator
-ManufacturerMitsubishiElectricCorporation
-Output12V-50A
-Ratedvoltagegeneratingspeed13.5V-47A@5000RPM
-Regulatoradjustingvoltage14.4-15V
Glowplug
-TypeSheathed
-Ratedvoltage-armaturecurrent10.5V-9.7A@30secondduration
Stopsolenoid
-TypeRunontype
-Workingvoltage12V
-Insulatingresistance100MΩormore@500VDC
-Stroke13-14mm(0.512-0.551in)
ELECTRICALPOWERSYSTEM-Torque
DescriptionThreads
Diameterxpitch
TorqueRemark
StarterterminalBM8x1.2510-12N·m(7-9lbft)
StopsolenoidxingnutM30x1.539-49N·m(29-36lbft)
StopsolenoidblindplugM30x1.539-49N·m(29-36lbft)
GlowplugM10x1.2515-20N·m(11-15lbft)
GlowplugconnectionplatexingnutM4x0.71-1.5N·m(9-13lbin)
AlternatorterminalBM5x0.83-5N·m(27-44lbin)
M6x1.04-6N·m(35-53lbin)
M8x1.257-13N·m(62-115lbin)
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HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMS-ELECTRICALPOWERSYSTEM
ELECTRICALPOWERSYSTEM-Remove-Stopsolenoid
931013241
Removingsequence
1.Nut
2.Stopsolenoid
3.Rubbercap
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HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMS-ELECTRICALPOWERSYSTEM
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HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMS-ELECTRICALPOWERSYSTEM
ELECTRICALPOWERSYSTEM-Remove-Glowplugs
931013201
1.Glowplug
2.Glowplugplate
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