Mitsubishi S4Q2 User manual

Service Manual
99719-77100
For use with FD10N, FD15N, FD18N, FD20CN
Chassis Service Manual.
S4Q2 Diesel Engine
24467-up
FD10N F16D-00011-up, F16D-10001-up
FD15N F16D-50001-up, F16D-60001-up
FD18N F16D-70001-up, F16D-80001-up
FD20CN F16D-85001-up, F16D-87001-up

FOREWORD
This service manual covers S4Q2 Diesel Engine of Mitsubishi Forklift Trucks and gives
detailed maintenance and repair information. The instructions are grouped by systems to serve
the convenience of your ready reference.
Long productive life of your forklift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on
before attempting any work.
All descriptions, illustration, specifications, and serial numbers in this manual are effective as
of the date printing of this manual. Mitsubishi reserves the right to change specifications or
design without notice and without incurring obligation.
Pub. No. 99719-77100

Hou to Use This Manual
In this service manual, the Mitsubishi Diesel Engine (standard model for land use) specifications, maintenance
standards and adjustment procedure as well as service procedures such as disassembly, inspection, repair and
reassembly are arranged in groups for quick reference.
There are separate manuals for the fuel injection pump, governor and turbocharger.
Ashort summary of each Group is given in the General Contents, and there is also a table of contents at the
beginning of each Group.
Regarding engine operation and periodical maintenance, refer to the Operation & Maintenance Manual. For
component parts and ordering of servie parts, refer to the Parts Catalogue. Structure and function of the engine are
described in various training manuals.
1. Methods of Indication
(1) Parts shown in illustrations and described in text are numbered to correspond with the sequence of disassembly.
(2) Inspections to be conducted during disassembly are indicated in a box in disassembled views.
(3) Maintenance standards for inspection and repair are described in text where they are relevant, are also listed in
Group 1 in the General Contents.
(4) The sequence in which parts are to be assembled is summarized below each assembled view.
Such as: trewq.
(5) The following marks are used in this manual to emphasize important safety cautions.
…Indicates a potentially hazardous situation which, if not avoided, can result in death or serious
injury.
…Indicates a potentially hazardous situation which, if not aboided, can result in minor or
moderate injury.
…Indicates important information or information which is useful for engine operation or
maintenance.
(6)Tightening torque under wet conditions is indicated as “[Wet]”. When so indicated, apply engine oil to the
threaded portion of the fastener. Unless indicated as such, the tightening torque is to be assumed in the dry
condition.
←←←←
WARNING
CAUTION
NOTE

2. Terms Used in This Manual
Nominal value: Indicates the standard dimension of a part to be measured.
Standard: Indicates the dimension of a part, the clearance between parts, or the standard performance. Since the
value is indicated in a range needed for inspection, it is different from the design value.
Limit: A part must be repaired or replaced with a new part when it reaches the limit value.
3. Abbreviations, Standards, Etc.
•BTDC = Before Top Dead Center
•ATDC = After Top Dead Center
•BBDC = Before Bottom Dead Center
•ABDC = After Bottom Dead Center
•TIR = Total Indicated Reading
•API = American Petroleum Institute
•ASTM = American Society for Testing and Materials
•JIS = Japanese Industrial Standards
•LLC = Long Life Coolant
•MIL = Military Specifications and Standards (U.S.)
•MSDS = Material Safety Data Sheet
•SAE = Society of Automotive Engineers (U.S.)
4. Units of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in
parentheses ( ). For metric conversion, the following rates are used.
•Pressure: 1 MPa = 10.197 kgf/cm2
•Torque: 1 N·m = 0.10197 kgf·m
•Force: 1 N = 0.10197 kgf
•Horsepower: 1 kW = 1.341 HP = 1.3596 PS
•Meter of mercury: 1 kPa = 0.7 cmHg
•Meter of water: 1 kPa = 10.197 cmH2O (cmAq)
•Rotational speed: 1 min−1= 1 rpm

GROUP INDEX Items
1
2
3
4
5
6
7
8
9
10
11
12
GROUP INDEX
GENERAL
GENERAL INSTRUCTIONS
ENGINE MAIN PARTS
INLET AND EXHAUST
SYSTEM
COOLING SYSTEM
FUEL SYSTEM
OIL SYSTEM
ELECTRICAL SYSTEM
TESTING AND ADJUSTING
TROUBLESHOOTING
MAINTENANCE STANDARD
SPECIAL TOOL
Determination of Engine Overhaul Timing, Testing Compression Pressure, Tips
on Disassembly and Reassembly, Precautions for Disassembly and Reassembly
Cylinder Heads and Valve Mechanism, Flywheel, Timing Gears, Camshaft and
Oil Pan, Pistons, Connecting Rods, Crankshaft and Crankcase
Description, Disassembly, Inspection and Reassembly
Description, Water Pump, Fan, Thermostat
Description, Fuel System Bleeding, Disassembly, Fuel Filter (Paper-Element
Cartridge Type), Fuel Injection Nozzles
Description, Oil Pump, Oil Filter, Pressure Relief Valve
Starter, Alternator, Glow Plugs
Bench Test, Idling Speed and Maximum Speed Seting Inspection and
Adjustment, Performance Test
Outline, Spcifications
Causes of Engine Problems and Remedies
Maintenance Standards Table, Tightening Torques, Thread Sealants,
Maintenance Schedule
Special Tool List