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    Grendia S4Q2 Diesel Engine

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    Joaquina_Joaquina
    This document provides an overview and key points about servicing an S4Q2 diesel engine. It includes sections on the external views, main engine parts, cylinder heads and valves, pistons and crankshaft, timing gears and camshaft, fuel system, cooling system, lubrication system, and maintenance schedule. The manual emphasizes reading the full manual for a more in-depth understanding and gaining experience through hands-on work with the equipment.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Grendia S4Q2 Diesel Engine

    Uploaded by

    Joaquina_Joaquina
    429 views64 pages
    This document provides an overview and key points about servicing an S4Q2 diesel engine. It includes sections on the external views, main engine parts, cylinder heads and valves, pistons and crankshaft, timing gears and camshaft, fuel system, cooling system, lubrication system, and maintenance schedule. The manual emphasizes reading the full manual for a more in-depth understanding and gaining experience through hands-on work with the equipment.

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    Grendia S4Q2 Diesel Engine.ppt

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    This document provides an overview and key points about servicing an S4Q2 diesel engine. It includes sections on the external views, main engine parts, cylinder heads and valves, pistons and crankshaft, timing gears and camshaft, fuel system, cooling system, lubrication system, and maintenance schedule. The manual emphasizes reading the full manual for a more in-depth understanding and gaining experience through hands-on work with the equipment.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    429 views64 pages

    Grendia S4Q2 Diesel Engine

    Uploaded by

    Joaquina_Joaquina
    This document provides an overview and key points about servicing an S4Q2 diesel engine. It includes sections on the external views, main engine parts, cylinder heads and valves, pistons and crankshaft, timing gears and camshaft, fuel system, cooling system, lubrication system, and maintenance schedule. The manual emphasizes reading the full manual for a more in-depth understanding and gaining experience through hands-on work with the equipment.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 64
    At a glance
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    The document outlines the main parts and maintenance procedures for a diesel engine.

    The main components include the cylinder heads and valves, pistons, crankshaft, crankcase, timing gears, camshaft, and oil pan.

    To remove the cylinder head, you loosen and remove the rocker shaft assembly and cylinder head bolts, then lift the head off. To install, place the head gasket and tighten the bolts in the specified sequence and torque.

    S4Q2 Diesel Engine

    Service Manual # 99719-77100

    The following modules do not cover all of the material in the manual. We have identified and chosen some of the more important key points. To fully understand the engine in more depth you will need to read the manual. More hands on work with the lift truck, and real life work will improve your overall knowledge of this equipment.

    External View (Left Side)

    External View (Right Side)

    Serial Number Location

    S
    Series code

    Number of cylinders Sagamihara Plant

    Engine Main Parts

    Cylinder Heads & Valve Mechanism


    1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Rocker cover Adjusting screw Bolt (short) Bolt (long) Valve cap Snap ring Rocker arm Rocker shaft bracket Rocker shaft spring Rocket shaft Valve pushrod Cylinder head bolt Cylinder head Valve cotters Upper valve retainer Valve spring Valve (inlet) Valve (exhaust) Valve stern seal Cylinder head gasket

    Cylinder Heads & Valve Mechanism

    Cylinder Head
    Remove the rocker cover Removing rocker shaft assembly. 1. Loosen the adjusting screw one turn. 2. Loosen the bolts, long and short, that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first.Remove the rocket shaft assembly from the cylinder head.

    Cylinder Head
    Remove the cylinder head bolts. Lift the head off the crankcase.

    Cylinder Head
    Tighten the cylinder head bolts to the specific torque in the sequence shown. Tightening torque:118 5N-m (12.00 0.5kgfm) [87 4 lbfft]

    Pistons, Crankshaft & Crankcase


    1. Connecting rod cap 2. Connecting rod bearing (lower half) 3. Main bearing cap 4. Main bearing (lower half) 5. Crankshaft 6. Main bearing (upper half) 7. Connecting rod 8. Connecting rod bearing (upper half) 9. Snap ring 10. Piston pin 11. Piston 12. No.1 ring 13. No. 2 ring 14. Oil ring 15. Tappet 16. Crankcase

    Pistons, Crankshaft & Crankcase

    Piston Head
    Note the shape of the injection swirl chamber on the top of the piston.

    Installing Piston Assembly


    Make sure the piston ring end gaps are arranged on the piston, as shown in the illustration.

    Timing Gears, Camshaft & Oil Pan


    1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Crankshaft pulley Cover Timing gear case Pump drive gear PTO idler gear Baffle plate Idler gear Oil pan Oil pump Camshaft Front end plate

    Timing Gears, Camshaft & Oil Pan

    Timing Gear Train


    The timing marks of the gears should be aligned as shown when the no. 1 piston is at top dead center on compression stroke.

    Inlet and Exhaust System

    Inlet and Exhaust

    Inlet and Exhaust


    Gasket Exhaust manifold

    Gasket

    Gasket

    Inlet manifold

    Air inlet pipe

    Cooling System

    Coolant Block Diagram

    Water Pump & Fan


    Gasket Cover Water pump Assy Fan Pulley Gasket

    Gasket Spacer

    Fan belt

    Fan Belt Tension

    Unit: mm (in.) Item


    Belt Tension (crankshaft pulley alternator pulley)

    Standard Value
    Approx. 13 (0.5118) (when pressed with force of 98 N (10 kgf) [22 lbf])

    Fuel System
    ZEXEL VE Type Injection Pump

    Fuel System Diagram

    Fuel Injection pump


    1. Distribution VE-type fuel injection pump. 2. Uses a single high pressure pumping plunger to accurately meter and distribute fuel to each of the engine cylinders. 3. Smaller and lighter than its In-line counterpart.

    Comparison of Dimension Size

    Cross-section of VE Pump

    Sectional View of VE Pump

    Fuel Injection Pump

    VE Feed Pump
    1. The rotary-vane type feed pump draws fuel from the fuel tank. 2. Feed pump rotor is driven by the pump drive shaft which is connected to the injection pump gear. 3. As the rotor spins, centrifugal force holds the van against the pressure chamber wall. 4. Due to the off-center, fuel becomes trapped between the vane and is pressurized and force out through the delivery port.

    VE Pressure Regulating Valve


    1. The pressure regulating valve is located in the upper portion of the injection pump housing. 2. Fuel pressure is proportional to pump speed. 3. As fuel pressure increases with pump speed, the piston within the pressure regulator is forced against the tension of the regulator spring. 4. At a predetermined value, the valve will begin to open a port in the regulator to allow excess fuel to bypass back to the intake port.

    Feed Pump Pressure Vs Speed

    Plunger and Camplate

    1. The face cam is driven by drive shaft and its rides on the rollers. 2. The distributor plunger and face cam are held against the roller by the plunger spring. 3. As the face cam & plunger rotate, they reciprocate back and forth, delivers high pressure fuel to each cylinder.

    Plunger Delivery to Each Nozzle

    Intake Stroke
    1. Fuel from feed pump fills the pressure chamber of the head as the plunger moves toward the drive end of the pump and rotates to align the plunger intake port with the fill port in the distributor head.

    Injection Stroke
    2. As the plunger rotates, the intake port is closed and fuel becomes trapped within the pressure chamber. 3. With the continued rotation and now forward motion of the plunger, fuel pressurization and delivery begins. 4. At this point, the outlet port aligns with a distributor passage in the distributor head and injection begins.

    End of Injection
    5. As a point of forward motion, the spill port of the distributor plunger moves out of the spill ring. 6. Pressure is released and injection is stopped.

    Pressure Equalization
    1. An additional 180o degrees of rotation of the distributor plunger aligns the pressure equalization groove with the distributor passage of the head. 2. This allows the pressure in the distributor passage to equalize to that of the pressure in the pump housing. 3. This pressure equalization minimizes fuel delivery spread between cylinders and allows for a smoother running engine.

    Non-Reversing
    1. As illustrated in the figure, if the pump is rotated in the wrong direction, fuel pressurization cannot take place because the fuel intake port is open during cam lift. 2. This non-reversing feature in the pump prevents the engine from running backwards.

    Fuel Shut-Off Solenoid

    1. Turning the ignition switch to OFF position shuts off the current to the solenoid. 2. With no current to hold the valve, the spring forces the valve to close the fill port. 3. This shut off the fuel supply and the engine stop.

    Fuel Filter
    Priming pump

    Bracket

    Element assembly

    Level sensor assembly

    Drain plug

    Draining Water and Sediment


    Loosen the drain plug at the bottom of the fuel filter. Operate (push down on) the priming pump of the filter seven times to facilitate draining. After draining, tighten the drain plug. After draining, prime the fuel system.

    Priming Filter Side

    Pump the priming button on the fuel feed pump.

    Bleeding Air from Fuel Filter

    Loosen the air vent plug of the fuel filter (by turning it 1.5 turns)

    Remove Injection Pump


    Remove the pipe clamps from the injection pipe. Disconnect the injection pipes at the injection pump and at the injection nozzles. Disconnect the leak-off pipes from the nozzles by loosening the lock nuts.

    Remove Injection Pump


    Using a box wrench, remove the fuel injection nozzles with gaskets from the engine. Note: remove the nozzle gaskets from the cylinder head, if any, with a wire or a screwdriver and discard them.

    Remove Injection Pump


    Check the alignment of the mark on the fuel injection pump with mark on the flange plate

    Remove Injection Pump


    Remove the front end cover from the engine. Put marks on the fuel injection pump drive gear and idler. Unscrew the bolts that hold the fuel injection pump flange to the front end plate and remove the pump and flange from the end plate..
    Note: (1)Do not attemp to run engine after removing the injection pump from the engine. (2)To remove the fuel injection pump drive gear, loosen its nut with the pump on the engine

    Lubrication System

    Engine oil Lubricating system

    Oil Filter

    Oil filter

    500

    Pressure Relief Valve


    Unit: MPa (kgf/cm2) [psi] Item Valve opening pressure Assembly Standard 0.29 to 0.39 (3.0 to 4.0) [43 to 57]

    Check the valve opening pressure (the oil pressure when engine is running at the rated rpm). If the pressure is not correct, remove the cap bolt and make adjustment by adding or removing shims. The pressure tap (RP 1/8 thread [PS 1/8]) is located near the oil filter.

    Adjusting Ignition Timing

    WARNING
    Always adjust valves with engine stopped to avoid personal injury. Turn the engine by hand and not by use of the starter. Disconnect the battery.

    Adjusting Ignition Timing


    Bring no. 1 cylinder piston to top dead center on compression stroke

    Adjusting Ignition Timing


    Confirm TDC1 by attempting to move the inlet and exhaust rocker arms for no. 1 cylinder

    Adjusting Ignition Timing


    Set the timing to 6 before top dead center

    Adjusting Ignition Timing

    If the injection timing is retarded, move the injection pump toward the crankcase. If the timing is advanced, move the pump away from the crankcase.

    Adjusting Valve Clearance

    Governor Adjustment
    Warm up engine until coolant and oil temperature rise to 70 oC (158oF) or higher. Low idling setting (no-load minimum rotation speed setting). 700 rpm. Adjust by idling adjust screw. Governor setting (maximum rotation speed setting) 2700 rpm. Adjust by maximum speed adjusting screw.

    Caution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.

    Testing Compression Pressure


    Measure the compression pressure on all cylinders Measure the compression pressure with the engine running at 150 to 200 rpm.

    Unit: MPa (kgf/cm2) [psi] Item Compressure pressure Assembly Standard 2.94 (30) [427] Repair Limit 2.55 (26) [370]

    Maintenance Schedule

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