Mitsubishi S12A2 - Left Side View - S12 A2-PTK; Right Side View

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1-10

Chapter 1 GENERAL

Left Side View

Right Side View

S12A2-PTK

Note: Configuration may differ depending

on the customization and specifications.

Oil filler

Fuel filter(wire mesh type)

Air cooler

Fuel return port

Starter

Fuel inlet

Fuel injection pump

Water drain cock

Fuel feed pump

Oil level gauge

Stop solenoid

Fuel filter

Engine cooling

water inlet

Engine cooling

water outlet

Turbocharger

Stop lever

Breather

Actuator

Rear

Front

S12A2-PTK

Note: Configuration may differ depending

on the customization and specifications.

Oil filter

Fuel injection pump

Fuel feed pump

Oil cooler

Fuel filter

Water drain cock

Bypass oil filter

Starter

Front

Rear

Air cooler

Main Page

Default Chapter4
- Description Format4
- How to Use this Manual4
- Abbreviations and Standards5
- Terms Used in this Manual5
- Unit of Measurement5
- Fire and Explosion Precautions6
- Safety Cautions6
- Stay Away from Rotating and Moving Parts7
- Be Careful of Exhaust Gas Poisoning8
- Be Careful of Falling8
- Be Careful of Hearing Loss8
- Be Careful of Burns9
- Be Careful When Handling Fuel, Engine Oil or LLC9
- Be Careful with Battery10
- When Abnormality Occurs10
- Other Cautions11
- Cool down the Engine before Stop12
- Do Not Operate the Engine in an Overloaded Condition12
- Use Care to Protect Engine from Water12
- Warm-Up the Engine before Use12
- Be Careful of Engine Room Ventilation13
- Do Not Operate Starter for a Long Time13
- Do Not Touch High Pressure Fuel Jet13
- Do Not Turn off the Battery Switch During Operation13
- Warning Labels14
- Points on Disassembling and Assembling15
- General Contents17
- Table of Contents19
- General Information19
- Engine Front View - S12A2-PTA21
- Engine Rear View - S12A2-PTA21
External View21
- Left Side View - S12A2-PTA22
- Right Side View - S12A2-PTA22
- Engine Front View - S12A2-PTA223
- Engine Rear View - S12A2-PTA223
- Left Side View - S12A2-PTA224
- Right Side View - S12A2-PTA224
- Engine Front View - S12A2-Y1PTA225
- Engine Rear View - S12A2-Y1PTA225
- Left Side View - S12A2-Y1PTA226
- Right Side View - S12A2-Y1PTA226
- Engine Front View - S12A2-PTK27
- Engine Rear View - S12A2-PTK27
- Left Side View - S12A2-PTK28
- Right Side View - S12A2-PTK28
- Engine Front View - S12A2-PTAW29
- Engine Rear View - S12A2-PTAW29
- Left Side View - S12A2-PTAW30
- Right Side View - S12A2-PTAW30
- Engine Front View - S12A2-Y2PTAW31
- Engine Rear View - S12A2-Y2PTAW31
- Left Side View - S12A2-Y2PTAW32
- Right Side View - S12A2-Y2PTAW32
Chapter 1 GENERAL33
- Outline of Fuel System33
- Outline of Lubrication System33
- Outline of Cooling System34
- Outline of Inlet and Exhaust System36
Contents of Plate and Label37
- Name Plate37
- Caution Plate37
- Emissions Certification Label37
Specifications38
- Service Data43
Chapter 2 SERVICE DATA45
- Maintenance Service Data of Engine General45
- Maintenance Service Data of Basic Engine46
- Maintenance Service Data of Fuel System51
- Maintenance Service Data of Lubrication System55
- Maintenance Service Data of Cooling System56
- Maintenance Service Data of Electrical System59
Chapter 5 DISASSEMBLY of BASIC ENGINE83
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect83
- Fuel Pipe - Remove84
- Nozzle Assembly - Remove84
- Valve Clearance - Inspect84
- Fuel Injection Timing - Inspect85
- Rocker Shaft Assembly - Remove85
- Clearance between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect85
- Valve Bridge - Remove86
- Cylinder Head Assembly - Remove86
- Valve Sinkage - Measure86
- Valve and Valve Spring - Remove87
- Nozzle Gland Stud Bolt and Bridge Guide - Remove87
- Fuel Connector - Remove87
Rear Mechanism - Disassemble and Inspect88
- Flywheel Face and Radial Runout - Measure89
- Flywheel - Remove89
- Timing Gear Case - Remove89
- Timing Gear Backlash - Measure90
- Idler Gear End Play - Measure90
- Camshaft End Play - Measure90
- Idler Gear - Remove91
- Fuel Injection Pump Gear - Remove91
- Governor Drive and Fuel Injection Pump Accessory Drive - Remove91
- Camshaft Gear - Remove92
- Idler Shaft - Remove92
- Rear Plate - Remove93
Front Mechanism - Disassemble and Inspect94
- Fan, Fan Bracket Assembly and Belt - Remove95
- Damper Face and Radial Runout - Measure95
- Front Pulley, Damper and Crankshaft Pulley - Remove95
- Front Cover - Remove96
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect97
- Piston Protrusion - Measure98
- Connecting Rod End Play - Measure98
- Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove98
- Connecting Rod Cap - Remove98
- Piston - Remove99
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect102
- Crankcase - Turn over (Upend)103
- Crankshaft End Play - Measure103
- Main Bearing Cap - Remove103
- Piston Cooling Nozzle - Remove103
- Crankshaft - Remove104
- Inspection and Repair of Basic Engine105
Chapter 6 INSPECTION and REPAIR of BASIC ENGINE107
Cylinder Head and Valve Mechanism - Inspect and Repair107
- Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure107
- Rocker Bushing - Replace107
- Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure108
- Valve Guide - Replace108
- Valve Face - Inspect109
Rear Mechanism - Inspect and Repair115
- Cam Lift of Cam Shaft Lobe - Measure115
- Idler Bushing - Replace115
- Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure115
- Camshaft Bushing - Inspect116
- Camshaft Journal Outside Diameter - Measure116
- Camshaft Runout - Measure116
- Camshaft Bushing - Replace117
- Damper - Inspect Visually118
Front Mechanism - Inspect and Repair118
- Pulley - Inspect118
- Piston - Inspect Visually119
Piston and Connecting Rod - Inspect and Repair119
- Piston Outside Diameter - Measure119
- Piston Ring Groove - Inspect119
- Piston Weight119
- Piston Pin Bore Inside Diameter - Measure120
- Piston Ring - Inspect Visually120
- Piston Ring End Gap - Measure120
- Connecting Rod Bushing Inside Diameter - Measure121
- Deflection of Connecting Rod - Measure126
Crankcase and Crankshaft - Inspect and Repair127
- Crankcase Top Surface Distortion - Measure127
- Inside Diameter of Main Bearing Housing Bore - Measure127
- Counterbore in Crankcase - Repair128
- Crankpin and Journal Outside Diameters - Measure128
- Cylinder Liner Fitting Bore in Crankcase - Inspect128
Chapter 7 ASSEMBLY of BASIC ENGINE139
- Crankcase - Turn over (Upend)139
- Upper Main Bearing - Install140
- Crankshaft - Install141
- Upper Thrust Plates - Install141
- Lower Main Bearing Shell and Lower Thrust Plate - Install141
- Main Bearing Cap - Install142
- Crankshaft End Play - Measure143
- Crankcase - Turn over143
Crankshaft and Main Bearing - Install139
- Piston Cooling Nozzle - Install139
Cylinder Liner, Piston and Connecting Rod - Assemble144
- Cylinder Liner Protrusion - Measure144
- Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed)144
- Cylinder Liner - Install146
- Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)146
- Piston and Connecting Rod - Assemble147
- Cylinder Liner Inside Diameter - Measure147
- Piston Ring - Install148
- Crankshaft - Turn148
- Piston Installation - Prepare149
- Upper Connecting Rod Bearing - Install149
- Piston - Install150
- Connecting Rod Cap - Install152
  - Connecting Rod End Play - Measure153
  - Piston Protrusion - Measuring153
Front Mechanism - Assemble154
- Front Oil Seal - Install154
- Crankshaft Pulley, Damper and Front Pulley - Install155
  - Damper Face and Radial Runout - Measuring155
  - Pointer - Install and Adjust155
Rear Mechanism - Assemble156
- Idler Shaft - Install156
- Rear Plate - Install156
- Camshaft Gear - Install157
Cylinder Head and Valve Mechanism - Assemble163
- Cylinder Head - Assemble163
- Fuel System173
Chapter 8 FUEL SYSTEM175
- Fuel Injection Pipe - Remove and Inspect175
- Fuel Leak-Off Pipe and Fuel Pipe - Remove and Inspect176
- Tamper Proof Attachment Spec185
Fuel System - Remove and Inspect175
Fuel System - Disassemble, Inspect and Assemble186
- Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble186
- Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble187
Fuel System - Install205
- Rubber - Install204
- Fuel Injection Pump - Install205
Chapter 9 LUBRICATION SYSTEM221
- Oil Pipe - Remove221
- Oil Pipe for Fan Drive - Remove222
- Oil Cooler and Oil Filter - Remove and Inspect223
- Breather - Remove and Inspect226
- Oil Level Gauge and Oil Filler - Remove and Inspect227
- Oil Filter for Governor - Remove and Inspect228
- Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect229
Lubrication System - Remove and Inspect221
Lubrication System - Disassemble, Inspect and Assemble231
- Oil Strainer - Disassemble and Inspect231
- Oil Pump and Safety Valve - Disassemble and Inspect232
- Oil Pump and Safety Valve - Inspect233
Lubrication System - Install241
- Backlash When Installing Oil Pump - Adjust241
- Oil Pan - Install241
- Oil Pump, Oil Strainer and Oil Pan - Install241
- Cooling System243
Chapter 10 COOLING SYSTEM245
- Tension Pulley - Remove and Inspect (Water Pump Side)245
- Tension Pulley - Remove and Inspect (Fan Side)246
- Thermostat Case and Water Pipe - Remove and Inspect247
Cooling System - Remove and Inspect245
Cooling System - Disassemble, Inspect and Assemble257
- Tension Pulley - Disassemble and Inspect (Water Pump Side)257
Cooling System - Install292
- Fan Pulley - Lock291
- Tension Pulley - Install292
- Water Outlet Pipe - Install292
- Water Pipe (Air Cooler) - Install292
- Inlet and Exhaust Systems293
Chapter 11 INLET and EXHAUST SYSTEMS295
Inlet and Exhaust Systems - Remove and Inspect295
- Air Duct and Air Cooler - Remove and Inspect (PTA,PTK,MPTA Spec)295
- Air Duct and Air Cooler - Remove and Inspect (PTA2 Spec)296
- Air Duct and Air Cooler - Remove and Inspect (MTK,MPTK Spec)297
- Pre-Cleaner and Paper Type Air Cleaner - Remove and Inspect298
Inlet and Exhaust Systems - Disassemble, Inspect and Assemble303
- Air Cooler - Disassemble, Inspect and Assemble (PTA,PTK,PTAW,MPTA Spec)303
- Air Cooler - Disassemble, Inspect and Assemble (PTA2 Spec)304
- Air Cooler - Disassemble, Inspect and Assemble (MTK,MPTK Spec)305
- Air Cooler - Clean306
- Air Cooler - Inspect306
- Air Cooler - Assemble307
- Pre-Cleaner - Clean307
Inlet and Exhaust Systems - Install308
- Air Cooler - Inspect for Leakage307
- Exhaust Manifold - Install308
  - Exhaust Manifold Coupling - Tighten308
  - Air Start System309
Air Start System - Remove and Inspect311
Chapter 12 AIR START SYSTEM311
- Magnetic Valve - Remove and Inspect311
- Air Pipe, Starter Valve and Distributor Valve - Inspect312
- Air Starter - Remove and Inspect313
Air Start System - Disassemble, Inspect and Assemble314
- Starter Valve - Disassemble and Inspect314
- Starter Valve - Inspect315
Air Start System - Install319
- Adjustment and Operation321
Chapter 13 ADJUSTMENT and OPERATION323
Engine - Adjust323
- Valve Bridge and Adjusting Screw - Check323
- Fuel System - Bleed Air323
Break-In Operation330
- Break-In Operation Load and Time330
- Engine Start-Up330
- Preparation before Engine Starting330
- Inspection and Adjustment after Break-In Operation331
Engine-Test and Adjustment332
- Inspection While the Engine Is Running331
- Alarm Action and Emergency Stop Tests332
- Emission Gas Test332
- Engine Performance Test332
- Maximum Fuel Injection Volume - Set332

Mitsubishi S12A2 - Left Side View - S12 A2-PTK; Right Side View - S12 A2-PTK

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