Mitsubishi S4S User manual

SERVICE MANUAL
MITSUBISHI
DIESEL ENGINES
S4S
ses
March 2002
J.. !!!!I'D'!S~~!~!.

Foreword
This service manual is written to familiarize you with the maintenance of your S4S and S6S Diesel Engine. If
the engine is carefully maintained it will deliver a long productive life and efficient performance marked by
power and economy.
Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to leam more about
the engine and how to care for it properly. AHdescriptions, illustrations, specifications and serial numbers in
this manual are effective as of the date printing of this manual.
The information contained in this manual applies to the engine model produced at the time of publication.
It should be noted that specifications and design may change due to improvements made thereafter.
For items other than those in this publication, refer to the operation manual for a unit on which the
engine is mounted,
How to UseThis Manual
1. Parts in illustrations are numbered to correspond with references to these numbers in text.
2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembIed views:
IClogged oil hole I
3. Maintenance standards for inspeetion and repair are described in text wherethey are relevant. For a quick
summary of maintenance standards refer to group 2 of this manual.
4. The sequence in which parts are to be reassembled is summarized below eaeh assembIed view.
Sueh as:
@ ..... ~ ..... @ ..... @ ..... CD
5. Tighteningtorque under wet conditions is indieated as "(wet)" in text, drawings, and tables. When so indieated
as (wet), apply engine oil to the threaded portion of the fastener. Unless indieated as such, the tightening
torque is to be assumed in the dry condition.
6. Pay attention to the special notes, cautions and wamings.
Pub. No. 99616-10170

Notes, Cautions, Warnings, Dangers
Notes, cautions, wamings, dangers are used in this manual to emphasize important or critical instructions or
advice.
(&OANGER)
&WARNING
(&CAUTION)
(NOTE)
'Ierms Used in This Manual
Indicates the most serious specific potential hazard
resulting in serious bodily injury or death.
Indicates aspecific potential hazard resulting in
bodily injury.
Indicates operating procedure, practice, etc.,resulting
in personal injury or damage to or destruction of
engine.
An operatingprocedure, condition, etc. that will help
you work more efficiently.
Beforeyou read this manual, note that the following special terms are used in dimensional and other specifications.
Assembly Standard Indicates the dimension of a part, the dimension to be attained at the
time of reassembly or the standard performance. The value is rounded
to the nearest whole number needed for inspeetion and is different from
the design value.
Nominal Value Indicates the standard dimension of a part.
Repair Limit.. A part which has reached this limit must be repaired.
Service Limit A part which has reached this limit must be replaced.
Standard Clearance Indicates the clearance to be obtained between mating parts atreassembly.

Summary of Manual Contents
Group
1. General
2. Maintenance Standards
3. Special Tools
4. Overhaul Instructions
5. Adjustments,
Bench Test,
Performance Tests
6. Engine Auxiliaries Removal
and Installation
7.
Engine Main Parts
8. Inlet
and Exhaust System
9. Lubrication System
lO.Cooling System
11.Fuel System
12.Electrical System
13.Workshop Tips
Contents
External view, engine serial number location, engine model and
application codes, specifications, tips on disassembly and reassembly.
Maintenance standards, tightening torques, sealants and lubricants.
Alist
of special tools required.
Determining when to overhaul the engine, testing compression pressure
Adjustment of valve clearance, fuel system bleeding, fuel injection
timing, no-load
minimum and maximum speed setting, V-belt, bench
testing, performance tests.
Removal and installation of turbocharger, fuel injection pump, alternator,
water
pump, starter, etc.
Disassembly, inspeetion and reassembly of the main parts, to include
cylinderhead and valve mechanism, flywheel, damper, timing gears and
camshaft, pistons, connecting rods, crankshaft, crankcase and tappets.
Disassembly, inspeetion and reassembly of inlet and exhaust system
(exhaust manifold).
Disassembly, inspeetion and reassembly oflubrication system, to inlcude
oil
pump, oil filter, oil cooler, oil pressure relief valve and safety valve.
Disassembly, inspeetion and reassembly of cooling system, to include
water
pump and thermostat.
Disassembly, inspeetion and reassembly
offuel systern, to include fuel
filter
and injection nozzles.
Disassembly, inspeetion and reassembly of electrical system, to include
starter, alternator, glow plugs and stop solenoid (option).
Basic
recommended assembly procedures: oil seals, O-rings, bearings,
split pins and spring pins.

GENERAL
1. Outline 1- 2
1.1 External View 1- 2
1.2 Engine Serial Number Location 1- 6
1.3 Engine Model and Application Codes 1- 6
2. Specifications 1- 7
3. Tips on Disassembly and Reassemb1y 1-13
3.1 Disassembly 1-13
3.2 Reassembly 1-13
Di

GENERAL
1. Outline
1.1 External View
[848 - Standard]
Fuel filter Fuel injection pump
Fan
IFront I
Fuel feed pump
C'-I)
n
Inlet manifold Fuel injection nozzle
ETR stop solenoid
Governor
Coolant drain plug
Dipstick IRear I
<>-tt-++--Flywheel
Oil drain plug
ILeft view
Oil filler
onfilter
Exhaust manifold
IRear I
Starter n
I-I:)
Thermostat
Alternator
IFront I
V-belt
üil pan
I Right viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-2

GENERAL
[S4S-DT - Standard]
IRear I
::n
"
.'
(I~I\
Fuel injection pumpn
Fuel filter \ <, I/In, let manifold
h--.rT,----1JI Fuel injection nozzle
Fan
~ rr-. ~ tJUI fT"i"T"i:
~ r~~ ~?n'\~ I
hl
vETRstopsolenoid
Water pump~ F-\.lIJ 11 (( --r
~Governor
I ~ ;:, Ip,~ -~ ! :;:: p "/ /Coolant drain plug
): [l.l.AF::J"1"- ~ ~
:::" f'\f r~ 'Q , ~ _
~!::L- ~.\ K" Q.r- ~
~ I ",- '" Tb. y ~ VDipstick
13 --1. ~ ~ ___
0:/ ra 11 : ~ "\
V ~ (0 ,0
/1, 0 ol-- ~ 0 ,,~ ,-'-
h>' •F ;:; : I1 \ '--'-ol
Fuel feed pump -: rUi;!=~~o?J;»-~~'-.-i~0Ë=Q:~~: jl~~, \~~r-~-dn
1111 ~f--Ij'---H--FI ywheel
IFront I
ondrain PIL
I Left view I
on filter
IFront I
Altemator
Thermostat
V-belt
Oil pan
Turbocharger
(1-1\
n
onfiller
Starter
Exhaust manifold
------.11ll-
~~~~~~
I Rear I
IRignt viewl
Remark: Direction of rotation
of this engine is counterclockwise as seen from flywheel side.
1-3

GENERAL
[868 -Standard]
uel filter Fuel injection pump lnlet manifold
I Rear I
Flywheel
Oil filter
Dipstick
Governor
t:~~~ah~~::~~r Coolant drain plug
Oil drain plug
%~-1----le:::::~I-~e:::::~~--:v: Fuel injection nozzle
1NI"bb!l;a ETR stop solenoid
Fan
Water pump
I Front I
I Left view
Oil filler
Exhaust manifold
IRear I
Starter
Oilpan
Thermostat
Alternator
I Front I
V-belt
I Right viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-4

GENERAL
[S6S-DT- Standard]
Fan
Water pump
IFront I
Gil filler
Exhaust manifold
IRea.. I
Starter
Fuel injection nozzle
ETR stop solenoid
).F~~~~~~ Governor
IRear I
Flywheel
Gil drainplug Dipstick
ILef! view I
Turbocharger
Thermostat
Alternator
IFront I
V-belt
Gil pan
IRight viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-5

GENERAL
1.2 Engine Serlal Number Location
The engine serial number is located on the side of
the crankcase.
1.3 Engine Model and Application Codes
sDs - [Q][ïJ
~
1-6
T : Equipped with turbocharger
D : Direct injection type
Series code
Number of cylinders
Manufactured by Sagamihara machinery works

2. Specifieations
GENERAL
Model designation S4S S4S-DT
Type Water-cooled, 4-stroke cycle
No. of cylinders - arrangement
4- in line
Combustion chamber type Swirl chamber Direct injection
Valve mechanism Overhead
Cylinder bore xstroke mm[in.] 94 x120 [3.70 x4.72]
Piston displacement liter [cu in.] 3.331 [203]
";J Compression ratio
22: 1
17: 1
...
<Ll
I:
Firing order
1-3-4-2
<Ll
0Direction of rotation Counterclockwise as viewed from flywheel side
Overall1ength 781 [30.7]
mm[in.]
Dimension Overall width 593 [23.3]
mm[in.]
Overall height 710 [28.0] 821 [32.3]
mm[in.]
Weight (dry) kg [Ib] 245 [540] 250[551]
Type of cylinder sleeve Integral with cylinder block
Ol:>
No. of piston ring Compression ring 2
~
0.. Oilring 1 (w/spring expander)
I:
Open BTDC 30° BTDC 18°
.e; InIet valve
a
<Ll
Valve timing Close ABDC 50° ABDC 54°
I:
·So
Open BBDC 74° BBDC 66°
I:
Exhaust valve
p:l Close ATDC 30° ATDC 22°
Starting system Electric-starter
Starting aid G10wplugs
"0_",
Air cleaner Type Paper-element
§~e
"t).2 *Turbocharger Model TD04HL
-><>-.
-
~lUtI'.:l
Type Force feed by oil pump
Specification Class CD oil (API Service Classification)
Engine oil Capacity (engine) Approx. 10 [2.6]
liter [U.S. gal] (Oil pan: 9 [2.4], Filter: 1 [0.3])
Type Trochoid
aSpeedratioto
crankshaft
0.74
~
Oil pump
Ol:>
Capacity 28.6 [7.6] at 0.3MPa (3 kgf/cm") discharge pressure
;>,
Ol:>
I:
liter [U.S gal] of pump running at 2 230 min:'
0
.~
Type Piston valve
u
·C Re1iefva1ve Opening pressure
..0
::l 0.35 ± 0.05 (3.5±0.5) [50±7]
....:l
MPa (kgf/cm") [psi]
Oil Cooler IWater-cooled
Type -multi-plate
Oil filter Type Cartridge of paper element
Safety valve Opening pressure -I1.1
(11) [156]
MPa (kgf/cm") [psi]
1-7

GENERAL
Model designation S4S S4S-DT
Refill capacity (engine water jacket) 5.5 [1.5] 5 [1.3]
liter [U.S. gal.]
Type Centrifugal
Water
pump
Speedrationto crankshaft
1.3
Ei
Capacity 160 [42.3] at 0.075 MPa [0.75 kgf/cm'] discharge pressure
2liter [U.Sgalj/min/mirr'
of pump running at 3600 min'
'Jl
;>,
'Jl Fan belt Type Low-edge B type V-belt x 1
eo
.S Type Wax pellet
0
0Thermostat
U
Valve opening temperature
°C [OF]
76.5±1.5 [170±2.7]
Type Pusher (PP)
Fan
No.ofblade
6
Diameter mm [in.] 440 [17.3]
Type Bosch A
Injection
pump
Diameter of plunger 7 [0.276] 9 [0.354]
mm [in.]
Type Bosch, piston
Feedpump
Cam lobe lift 8 [0.315] 9 [0.354]
mm [in.]
Ei
Governor Type Bosch RSV, centrifugal
2
co
;>, Type
of nozz1e Bosch throttle Bosch hole
'Jl
Q) No.
of spray orifice 1 4
::l
~
Diameterof sprayorifice 1.0 [0.039] 0.28 [0.011] (for D/G)
Injection nozz1e mm [in.] 0.24 [0.009] (for Power Unit)
Sprayangle 0° 155°
Valve opening pressure 11.77
(I20) [1707] \7.65 (I 80) [2561]
MPa (kgf/cm") [psi]
Fuel filter Type Cartridge of paper element
Ei
Voltage - polarity 12V - eground
2Model M008T75171
'Jl
;>,
'Jl Type Pinion shift
ë<i
Cl Starter Output
V-kW
12 - 2.2
'5
Cl
Cl) No.
of pinion teeth/
ü3
flywheel ring gear teeth lO/l22
1-8

GENERAL
Model designation S4S IS4S-DT
Type 3-phase, with rectifier
Output
V-A 12-50
Working speed
min:' 1000 to 18000
Altemator
Rated output generating 5000
Ei
speed min:'
s
<IJ
Maximum perrnissib1e>-. 22000
co
C;; speed min:'
o
oE
Speed ratio to crankshaft 2.0
o
Il.l
iii Type Sheathed
G10w plug Rated voltage -current Direct injection: 11- 5.5 (30 sec. rating)
V-A
Swir1 chamber: 10.5 - 9.7 (30 sec. rating)
Stop solenoid Rated voltage V 12
(option) Rated temp.
oe [OP]
20 [68]
1-9

GENERAL
Model designation S6S S6S-DT
Type Water-cooled, 4-stroke cycle
No. of cylinders -arrangement
6-in line
Combustion chamber type Swirl chamber Direct injection
Valve mechanism Overhead
Cylinder bore x stroke mm [in.] 94 x 120 [3.70 x 4.72]
Piston displacement liter [cu in.] 4.996 [305]
~
Compression ratio
22: 1 17: 1
...
Q)
::: Firing order I - 5 - 3 - 6 -
2- 4
Q)
Cl Direction of rotation Counterclockwise as viewed from flywheel side
Overall length 1033 [40.7] SG type, 1029 [40.5] SP type
mm[in.]
Dimension Overall width 593 [23.3] 626 [24.6]
rum [in.]
Overall height 748 [29.4] 896 [35.3]
mm[in.]
Weight (dry) kg [Ib] 340 [750] 350 [772]
Type of cylinder sleeve Integral with cylinder block
I!J No. of piston ring Compression ring 2
...
0::1
Oil ring I (w/spring expander)
0..
::: Open BTDC 30° BTDC 18°
.;:;
Inlet valve
8
Q) Valve timing Close ABDC 50° ABDC 54°
:::
·öo
Open BBDC 74° BBDC 66°
:::
Exhaust valve
"'-l Close ATDC 30° ATDC 22°
Starting system Electric-starter
Starting aid Glow plugs
"0_",
Air cleaner Type Paper-element
a~E
~~*
Turbocharger Model TE06H
-><>,
- ,.5CUoZl
Type Force feed by oil pump
API Service Classification
CD
Engine oil Refill capacity Whole system: Approx. 12 liters [3.2 U.S. gal];
liter [U.S. gal.] Oil pan:II liters [2.9 U.S. gal]; Filter: I liters [0.3 U.S. gal]
Type Trochoid
8Speedratioto crankshaft 0.74
2Oil pump
<J) Capacity 38.7 [10.2] at 0.3 MPa (3 kgf/cm') discharge pressure
>.
<J)
eliter [U.S gal]/min of pump running at 2230
min'
0
.~
Type Piston valve
oOil pressure
.e:
Opening pressure
.D relief valve
::l 0.35±0.05 (3.5±0.5) [50±7]
....:l
MPa (kgf/cm") [psi]
Oil Cooler Type Water-cooled
-multi-plate
Oil filter Type Cartridge of paper element
Safety valve Opening pressure -
1.1(11)[156]
MPa (kgf/cm') [psi]
1-10

GENERAL
Model designation S6S S6S-DT
Refill capacity (engine water jacket) 9 [2.4] 8 [2.1]
liter [U.S. gal.]
Type Centrifugal
Water
pump
Speedrationto crankshaft
1.3
Ei
Capacity 160 [42.3] at 0.075 MPa [0.75 kgf/cm"] discharge pressure
Bliter [U.S
gall/rnin/mirr' of pump running at 3600 min'!
CI:l
;>,
CI:l Fan belt Type Low-edge Btype V-belt x I
en
.5 Type Wax pellet
Ö
0
Thermostat
U
Valve opening temperature
°C [OF]
76.5±1.5 [170±2.7]
Type Pusher (PP)
Fan No.
of blades 7
Diameter mm [in.]
500 [19.7]
Type Bosch A
Injection
pump
Diameter of plunger 7[0.276] 9[0.354]
mm[in.]
Type Bosch, piston
Feed
pump
Cam lobe lift 8[0.315] 9[0.354]
mm [in.]
Ei
Governor
Type Bosch RSV, centrifugal
B
CI:l
;>, Type
of nozzle Bosch throttle Bosch hole
CI:l
03 No. of dischargeorifice I4
;:l
"'"
Diameter of discharge 1.0 [0.039] 0.28 [0.011] (for D/G)
Injection nozzle
orifice mm [in.]
0.24 [0.09] (for Power Unit)
Discharge angle 0° 155°
Valve opening pressure 11.77 17.65 (180) [2561]
MPa (kgf/cm') [psi] (120) [1707]
Fuel filter Type Cartridge
of paper element
Ei
Voltage - polarity
12V - 8ground
BModel
M008T5027I
CI:l
;>,
CI:l Type Pinion shift
ca
oStarter Output
V-kW
12 - 3
"5
o
<I) No.
of pinion teeth/
Wflywheel ring gear teeth 10/122
1-11

GENERAL
Model designation S6S IS6S-DT
Type 3-phase, with rectifier
Output
V-A
12 -50
Working speed min-I 1000 to 18000
aAltemator Rated output generating 5000
Bspeed min-I
'"
>. Maximum permissible
'" 22000
'<'J
speed min-I
.~
:: Speedratioto crankshaft 2.0
o
<l.l
mType Sheathed
Glow plugs Rated voltage- current Direct injection: 11-5.5 (30 sec. rating)
V-A
Swirl chamber: 10.5 -9.7 (30 sec. rating)
Stop solenoid Rated voltage V 12
(option) Rated temp. °C
[OF]
20 [68]
1-12

3. Tips on Disassembly and Reassembly
This service manual covers recommended
procedures to be followed when servicing diesel
engines. It also contains information on special
tools required and basic safety precautions.
It is the responsibility
of service personnel to be
familiar withthese requirements, precautions and
potential hazards and to discuss these points with
their foreman or supervisor.
Study this manual carefully and observe the
following general precautions to prevent serious
personal injury and to avoid
damage to the
engine, equipment and parts.
3.1 Disassembly
(1) Use the correct tools and instruments. Serious
injury or damage to the engine can result from
using the wrong tools and instruments.
(2) Use an
overhaul stand or work bench if
necessary. Also, use assembly bins to keep the
engine parts in order of removal.
(3) Lay down disassembied or c1eanedparts in the
order in which they were removed. This will
save you time at reassembly.
(4) Pay attention to the marks on
assemblies,
components and parts for positions or directions.
Put on your own marks, if necessary, to aid
reassembly.
(5) Carefully
check each part for faults during
removal or cleaning. Signs of abnormal wear
will tell if parts or assemblies are functioning
improperly.
(6) When
lifting or carrying heavy parts, get
someone to help you if the part is too awkward
for one person to handle. Use jacks and chain
blocks when necessary.
GENERAL
3.2 Reassembly
(1) Wash all engine parts, exceptoil seals, O-rings,
rubber seals, etc. in c1eaning solvent and dry
them with compressed air.
(2) Use only the correct tools and instruments.
(3) Use only
good quality lubricating oils and
greases. Be sure to apply a coat of oil, grease,
or sealantto parts as specified. (Referto section
3, of Group 2, "Maintenance Standards".)
(4) Use a torque wrench to tighten parts when
specified tightening torques arerequired.(Refer
to
section 2, of Group 2, "Maintenance
Standards".)
(5)
Replace all gaskets and packing. Apply
appropriate amountof adhesiveor liquidgasket
when required.
1-13