ENGINE BASE SERVICE MANUAL MITSUBISHI S4S, S6S REFERENCE ONLY - EXCAVATOR(16-18TON, -7SERIES) - FORK LIFT(HDF35-70, -7SERIES)INTRODUCTION This service manual describes the specifications of the Mitsubishi Diesel Engine and the maintenance and adjustment procedures. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before reassembling, inspecting, repairing or reassembling the engine. The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may _IL bJ6 Vebelt . | () Ds D il pan [Right view] Right view of engineGENERAL (©) S4S-DT distributor-type fuel injection pump specification Fan Foelinlet, Fel leak Water pump (coolant inlet), Magnetic valve (top solenoid) Frost Rear Pal ‘ ‘Coolant drain plug Crankshaft pulley i \ Noni Fuel injection pump [Leftview] oj drain plug titer Left view of engine “Turbocharger (exhaust outlet) inlet Oil file. Lad Coolant outlet Hanger | A “Thermostat case Flywheel housing. hj Rear LJ Froat =e] > iterator Ese J U 6 ee (| fl ‘V-belt De Starter Ria view] ‘Oil pan Right view of engineGENERAL (7) 86S distributor-type fuel injection pump specification Fuel filter Fan, ‘ Water pump (Coolant inlet) Front Fuel injection pump’ Oil filler Exhaust outlet Hanger Fuel inlet Flywheel housing, Rear] |= | Starter’ “Magnetic valve Air inlet vise a oe i : oO. | | | a a ‘Oil level gage a — uta ‘Hanger cwimte _ Frm lw, ean U oa ; U = =GENERAL (8) S6S-DT distributortype fuel injection pump specification Fal filter Fuel inet Magnet valve a {top solenoid) \y pape ‘Water pump eo a = = a eee ott ee ‘oil drain plug Left view of engine ‘Turbocharger (exhaust outlet) Aivinlet Hanger Coolant outlet Thermostat case Flywhee! housing, Alternator Rear Front ‘Damper Starter’ ola ‘V-belt [Right view] Right view of engineGENERAL 1.2 Outline of Fuel System (J) S45 in-line fuel injection pump (swirl chamber) specification Fuel filter, Fuel leak-off pipe Fuel injection pump’ Fuel inlet Outline of fuel system @)_S4S-DT in-line fuel injection pump (direct injection) specification Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel injection pump” Fuel Teak "Fuel inlet Outline of fuel system 1-10GENERAL ()_ SAS distributor-type fuel injection pump (swirl chamber) specification ter al Fuel leak-of pi Fuel filter ga pipe te Fuel injestion nozzle Fuel return pipe oct leak Fuel injection pump ‘Outline of fuel system (4) S4S-DT distibutor-type fuel injection pump (direct injection) specification paee. Fuel leakoff pipe Fuel injection nozzle peer Foelretum pipe "Fuel leake Fuel injection pump Outline of fuel systemGENERAL (5) _S6S in-line fuel injection pump (swirl chamber) specification Fuel filter Fuel leak-off pipe Fuel injection nozzle Ory Fuel inlet Outline of fuel system © s6s-DT Fuel filter Fuel leak-off pipe -Fuel injection nozzle Fuel return pipe Fuel injection pump’ "Fuel leak Fuel inlet Cutline of fuel systemGENERAL (1) $68 distibutor-type fue! injection pump (swirl chamber) specification Pal filter Fuel inlet Fuel leake-off pipe Mt Fuel injection nozzle Fuel return pipe ul leak Outline of fuel system (8) $6S-DT distributor-type fuel injection pump (direct injection) specification Foe! filter, uel retum pipe "Fuel leak: Fuel injection pump’ Outline of fuel system 1-13GENERAL 1.3 Outline of Lubrication System (Q)_ S43 in-line fuel injection pump specification Pushrod Piston Valve mechanism (Crankshatt ‘Tappet__| caiman Relief valve Oil main gallery: il filter Teter gear ——t6 Fuel injection pump ill pump’ Ol strainer ‘Oil pan Outline of lubrication system (2) S4S-DT in-line fuel injection pump specification Idler gear Fuel injection pump: ‘Relief valve il pump’ Oil strainer Safery valve are Outline of lubrication system 1-14GENERAL a EEEEEENEEEEma () $48 distributor-type fuel injection pump specification Pison —_Yalve mechanism Pashrod Crankshaft fi Tappet Gusar Relief valve 7 =a Oil main gallery- By Idler gear” >) : Oil pump” ‘Oil filter, Ot ssiner ‘oi pan Outline of lubrication system (4) S4S-DT distributor-type fuel injection pump specification il main gallery. Idler gear: | Retiot valve Crankahat Oil pump’ Pon ater Oi sine’ \afey valve” Oil pan Outline of lubrication systemGENERAL (S) $68 in-line fuel injection pump specification Pushroy “Tappet. Camshaft —} i main gallery —| ‘oil strainer bil pan (Outline of lubrication system (©) S6S-DT in-line fuel injection pump specification Oil strainer ‘Safety valve ‘Oil pan ‘Outline of lubrication system 1-16GENERAL (7) $68 distributor-type fuel injection pump specification Piston Crankshaft Relief valve Oil filter Oil strainer ‘oil pan Outline of lubrication system (8) S6S-DT distributor-type fuel injection pump specification Safety Oil strainer Outline of lubrication system 1-17GENERAL 1.4 Outline of Cooling System a) s4s Coolant outlet, Cylinder head ‘Thermostat Bypass pipe Winer jacket Water pump, Coolant inlet Outline of cooling system @) s4s-vT Coolant outlet, ‘Thermostat Bypass pipe. Water jcc ‘Water pump- Coolant inlet Oil cooler’ Outline of cooling systemGENERAL @) s6s Cylinder head Coolant outlet ‘Thermostat, Bypass pipe. Water jacket Water pump. Coolant infet Outline of cooling system (@) s6s-DT ‘Coolant outlet, (Cylinder head Water jacket Coolant inlet Oil cooler Outline of cooling systemGENERAL 1.5 Outline of inlet and Exhaust Systems (Q)_ Non-turbocharged engine ‘Air breather hose oe mmc P UP lita air Banaust ges PL] « [ = — O Outline of inlet and exhaust systems oo Prt Exhaust gas Sint sir WS Blow-by gas t Air breather hose & (Open {9 atmosphere Exhaust manifold ° inlet manifold Cutline of inlet and exhaust systemsGENERAL —————— 1.6 Engine Serial Number ‘The engine serial number is stamped on the side of the crankcase. Engine serial number HT lol tJ lol A 'S4S engine serial number location te EDs av fl LCL 6 ‘86S engine serial number location 1.7 Engine Model and Application Code ‘Non-turbocharged engine ‘Turbocharged engine {a Swirl chamber Combustion retot { Baas vweweses Direct injection Series code ‘Number of cylinders General Machinery & Special Vehicle Headquarters(Sagamihara)GENERAL 2. Specifications 2.4_S4S indine fuel injection pump specification (may differ in detail) Engine type sS SDT Type Titsubihi diel engine [Cooling method ‘Watercooling No. of strokes -estroke cycle No. of cylinders eylinder arrangement 4 in-line [Combustion method Suir chamber [Dive ingestion Valve mechanism ‘Overhead # [Cylinder bore x stroke ‘aim ia] 3452120 3.701 47H] © [Total displacement 4 {cu in] 3.331 (203) & [Compression ratio Bz 1 7 @ [Fuel ‘Diesel fuel GIS No, D equivalent) & [Firing order 1342 & | Rotational direction “Counterclockwise as viewed from flywheel side f reel aaa 781 (30.7) ‘mm {in] Dimension (Overall width ein oo. $67 22.3} eee 717 (282) 815 (32.11 Dry weight kg fb.) 245 [540] 250 (551) {Cylinder sieeve pe Dry Gatepral with eylinder Block) A ‘Compression ring: 2 § [Piston ring No of ings Oi rig (with expander T = (Open BIDCIO" BIDCIE Blues Inletvalv® [Close ‘ABDC 50° ‘ABDC 54" ane Exhaust — [Open BBDC 74° BBDC 66" 2 vale [Close ‘ATDC30° ‘AIDC 22" 4 | Sartng system lest saver Stating aid Glow plug Type. In-line (Bosch Type A) fen eee Peneetemt 6710.28) 69035] Feed pump ips Piston pump (Boseh) Speed control |Governor stem Contig £ Type. Bosch Type RSV. & [ype Tirole nozzle (Bosch) Hole nozzle (Bosch) i [No. of spray holes. 1 4 aE a ee $1.0 [0.039] 60.28 [0.011] Injection nozle mm fin] Sevan = 155° Valve opening sue 11.77 (120) (1707) 1765 (180) 2561] Pa (kaffem psi] Fue filter Type Paper-clement caridgeGENERAL, Engine pe SS SSDE Tbricating method Forced circulation oil pump pressure feed) (Grade (API service mi ae Seca (Class CF (SAF30 equivalent) gine ol Capacity Entire engine: 10 [2.64], £{US.gal] il pan: Maximum of 9 (2.38, oil filter: 1 [0.26] Tipe ‘Trochoid g Speed ratio to i 2 |oil pump crankshaft a 2 Discharge capacity | 286 7.6] at O3MPa G keen) (43 psi] discharge pressure of & ¢{USgal]/ min ppamp running at 2230min" 3 Type Piston valve 5 | peti Valve opening Bi | Relief valve pressure 0.3820.05 (3.620.5) [5147] ‘MPa (kgficm") [psi] ‘Valve opening Safety valve pressure - 1.10 156} ‘MPa (kgf/cm [psi] [Oil cooler Type = ‘Waier-cooled, multi-plate (Oil filter Type ‘Paper-clement cartridge Cooling method ‘Water-cooled, forced circulation (Coolant capacity (engine water jacket) aa races 55 [145] 1132] Type ‘Ceniifugal volute pamp Speedratio to i Water pump crankshaft 4 Decaecapacly | 160 G3] a 075 Mia C73 eae) [107 pal dicharge 3 £{U.S.gal] / min| ‘pressure of pump running at 3600min"* 2 Type Pusher (PP fan) 5 | cool No. of blades 6 Cooling fan of a & out meer $440 1173) Vibe Type Raw-edge cog V-belt Type B* 1 [ype ‘Wax Thermostat Waive opening 76.5215 [169.722.7] E ‘Approx.90 [194] when fully opened) CLF] i Air cleaner Type Paper element | Turbocharger type - ‘Dom iGENERAL ngine type SS SDT [Voltage ~ polarity TEV =negative ©) ground | 24 V negative C) ground Fiype MBTISITL M2TSSO71 Pinion mesh type Pinion shit Starter [Output V-W. 1222 I 2432 PinionFing gear as 122 Type Sophase alternating: current generator, builtin reciier Output ____V-A BE 24-25 eerie 1000 to 18000 Rated output ahectate generating speed 3000 Maximum permissible speed 22000 min Speed ratio i crankshaft : [Type Sheathed { loons aaa ae a) & s y-a{ _@0-second application) (G0-second application) i Operating 3 voltage 810 14 (for 12.V) 16 t027 (for 24 V) a v ie &]Openting 3 S| temperature 30 t0 90 [-22 to 194] Eater Rated time 10 or less see liana Dar les 17 ores Stop solenoid Rated voltage (option) Vv Ee a Rated 20 [68] ee °C iy Shama i Be absorbing. ss Py A Rated hold current 1 06 AGENERAL 2.2.68 in-ine fuel injection pump specification (may differ in detail) Tngine (ype 3 SDT ie TMiisab ih diesel engine (Cooling method ‘Water coo [No.of strokes “stroke cycle No. of cylinders ~eylinder arrangement in-line [Combustion method Swidchamber——_|___Direet injection Valve mechanism Overhead 4 [Colinder bore x stoke ‘mmfin] 34120 [3.701 AT] [Total displacement ‘fein 4.996 [303] & [Compression ratio. Bl 1 TH ‘G [Fuel Diesel fuel GIS No. 2 equivalent) & [Firing order 15-56-24 & [Rotational direction CountecTockowise as viewed fom Ajwheel side = (Overall engih ae ‘om fin] Dimension Senet] 579 [22.8] ee, 748 [29.4] 839 (33.0) Dryweight ig [ib 335 (7611 335 TH [Cylinder slave riype ‘Diy (integral with cylinder Block) , 5 ‘Compression ring: 2 § [Psonsing Nocorigs ‘Giring (with expander)T £ Tet vane FOREE BIDC0" BIDCIE Bae Ne TClose ‘ABDC 50° “ABDC 54° 2 ing Exhaust [Open BBDC 74° BRDC 66" 2 vatve [Close TATDC 30" ‘ATDC22° © [Saning atom Blecirc sarier Starting aid Glow plug [iipe Treline Bosch Type AD fee eee eet 6710.28) 6910.38) Feed pump Fiype Piston pump (Bosch) Speed contol aan Governor |system al i Type Bosch Type RSV. g [ype “Tiros nozzle (Bosch) Hole nozzle Gosch) q No. of spray holes 1 4 £ Spray hole diameter ; 1.0 [0.039 0.28 0.011 Injection nozzle mm fin) oe Loess) Sprayangle F 15 Valve opening presse 11.77 420) (1707) 17465 (180) (2561) MPa (kgf/cm?) psi} uel Aker Type Paper-lementcarridge 1-25GENERAL Engine pe 36S SET Eubricating method Forced circulation (oil pump pressure feed) Gea GPT seve Class CF (SAESO equivalent Engine oi! Capacity Enlre engine: 12.5 (5.30), £fUS.gal)| __Oil pan: Maximum of 11.5 [3.04], ol filter: 1 [0.26] Tipe Trochoid i ‘Speed ratio to aaa 2 Joi pump crankshaft s Discharge capactiy | 38.7 {10.2} at 03M¢Pa G kaon) [43 pl] discharge pressure of § ¢{US.gal] / min ‘pump running at 2230min 3 ype Piston valve | ketlet vabe Valve opening 3 | Patiet vat pressure 03540.085 (.620.5) [S127] MPa (kgt/em’ [psi Valve opening Safety valve pressure i 1.1 156) MPa (kgflem?) [ps] [Oil cooler Type = ‘Water cooled, muli-plaie [Oil fier Fiype Paper-element cartridge [Cooling method ‘Water-cooled, forced circulation Coolant capacity (engine wate jacket) ahaa opal 8p] ype Centrifugal volute pump ‘Speed ratio to i | Water pump crankshaft a Discharge capacity | 160 [42.3] a 0.75 MPa (7.5 katfem’) (107 psi] discharge B 4£{U.S.gal} / min’ pressure of pump running at 3600min'* # Type Pusher (PP fan) 5 | cool No. oF blades 7 iB eae [Outside diameter $500 [1927 ‘mm fin} Ce VobelE ype ‘Raveedge cog V-belt Type B = 1 [ype Wax Valve opening Thermostat, 76.521.5 (169.722.7] eee (Approx.90 [194] when fully opened) LF Lecce fae Peper nen | Trbocharger Type 7 ‘TEO6H 1-26GENERAL Engine pe 3 SDT [Voltage - polarity ‘12 V- negative (-) ground ‘24 V - negative (-) ground Type ‘3167671. ‘M8T60373 Pinion mesh type Pinion shift Starter | Output | V-KW] 123 L 24-5 Piniowing gear bing ioniz2 [ype 3 phase altemating-curent generator, builtin vecifier Output —__V-A 12:50 l 2425 Working: eee 1000 to 18000. Rated output oe venga 000 Maximam permissible speed 22000 min” Speed ratio a crankshaft = ‘Type Sheathed Eloi sug Rated age 10397 2330 & v-a[ _ G0-second application) (@0-second application) g (Operating i voltage 80 14 (for 2V) 16 t027 (for 24 V) v ig EE] Operating S|temperature 30 to 90 [-22 to 194] & $C PF] {Rated time 0orless see! eeeeena| 22.6 or less 11.7 or less Stop solenoid Rated voltage een a 2 24 Rated 20 [68] sc] BS Rated jobserving Bel 35 29 A Raed hold current 1 06 A 1-27GENERAL 2.3. S4S distributor-type fuel injection pump specification (may differ in detail) i Engine type 3S SEDI ripe ‘iisubihiaisel engine (Cooling method ‘Watercooling [No.of strokes “stroke cycle No. of cylinders~ cylinder arrangement 4 inline (Combustion method ‘Switlchamber | __Direet injection "Valve mechanism Overhead 2 [Cylinder bore x stoke mm fin] 345120 [3.701 x47] [otal displacement “feu in] 3331 [05] & [Compression ratio Dl I 1s = [Ruel Diesel fuel GIS No. 2 equivalent) & [Firing onder 1342 & [Rotational direction ‘Counterclockwise a5 viewed from flywheel side = oreatiagh mai bon Dimension ene 567 [223] Crea [tirana asta Dry weight kg ib] 245 [540] 230/55) [Cylinder sleeve Tipe ‘Dry Gategral with cylinder block) ston ri 5 ‘Compression rng: 2 § [Pstonring No. ofrings ‘ing wth expander 5 Tavane [OPS BIDCI0" BDC BY save an (Close "ABDC 50" ABDC 54 iS eecannee Exhaust [Open ‘BBDC 74" BBDC 66° 2 [valve [close ‘AIDC 30" ‘AIDC22° Staring sytem Blestc ater Starting aid Glow plug Tipe Distributor (Bosch Type VE anaes beeen 101039] 11 [043] Feed pump Type. ‘Vane pump (Bosehy ‘Speed control . [Governor |sysem Centrifugal § ‘Type “All 3 [ype ‘Tiarottle nozzle (Bosch) Hoole nozzle (Bosch) 3 (No. oF spray holes 1 5 a Spray hole diameter 1.0 [0.039] $0.20 [0.008] Injection nozzle 2m fin pray anale © TSO (wares with specification) ‘Valve opening pressure 11.77 (120) (17071 1765 (180) [2561] ‘MPa (kgm! [sil Fuel iter "Type Paper-clementcarridge 1-28GENERAL — Engine ype SS SDT Tabricating method Foreedsirculation oil pump pressure feed) os eee (Class CF (SAE30O equivalent) ae Capacity Entire engine: 10 (264), 2{US.gal) (Oi pan: Maximum of 9 [2.38] ofl filter: 1 [026] Type “roche Speed ratio fo aaa Oil pump crankshaft Discharge capacity | 286 [7.6] at 03MPa G katom') [43 psi] discharge pressure of 2{US.gal] / in ‘pump running at 2230min" Type Piston valve : Valve opening pene pressure 0.35#0.05 (.640.5) [5127] ‘MPa (kgfiem?) [psi] Valve opening Safety valve pressure - 1.1 (11) 156) MPa (ket/em?) [ps (Oil cooler Type = ‘Waier-cooled, multi-plate Oil filter Type Paper-clement cartridge [Cooling method ‘Water-cooled, forced circulation [Coolant capacity (engine water jacket) Cae 55 [143] $1.32] Centrifugal volute Speed ratio to a Water pump crankshaft & [Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kgffem*) [107 psi] discharge 3 ‘{{US.gal] / min ‘ressure of pup running at 3600min 2 —Type Pusher (PP fan) 5 | coslt No, of blades 6 Oana: Outside diameter euntGal ‘mm {in & Webalt Type Raw-edge cog V-belt Type B= 1 ‘Type ‘Wax Thermostat, valve opening 76,521.5 (169.742.7] ‘Approx.90 [194] when fully opened) $c i & | air cleaner Type Paper element i 2 | Rebocharger Type i ‘Too =GENERAL Engine ype MS SDT Voliage~ polarity T2V = negative @) ground | 24 V- negative C) ground [ype MBT7SI71 M2TSSO7L ion mesh type Pinion shift Starter ‘Output VW. 12-22 I 2432 Eee a 1on22 [ype ~3;phae altemating-ourent generator, bul-in rectifier Output VA 1250 1 24-25 eee ier 1000 to 18000 Rated output ase generating speed. 5000 ‘mi Maximum permissible speed 22000 § min 5 Speed ratio to 20 z crankshaft : : Type Sheathed i | Glow plug eee 105-97 23.30 -v-a| _ (0-second application) (G0-second application) eee 2 24 Power consumption 20 “4 al Ww. Start voltage Stop solenoid Fe 7 63 or less 1Borless BQ |Reoovey voltage 2.5 or more 5 ormore v coi resistance 8 37 a)GENERAL —_— 2.4 S85 distributor-type fuel injection pump specification (may differ in detail) Engine ype. So SEDT 7] Tipe ‘Mitsubishi diesel engin [Cooling method. ‘Water cooling No.of strokes a-sroke eycle [No.of cylinders eylinder arangement 6 in-line Combustion method Sor chamber [___ Diet injestion Valve mechanism Overhead Cylinder bore x sake ‘mm fia] 94 120 [3.701 «A724] "Total displacement feu in 4.996 [305] [Compression ratio Tal T cea Fuel ‘Diesel fel GIS No. 7 equivalent) Firing order, 153-624 Rotational recon Countetelociise as viewed fom fijwheel side Overall length 1033 (40.7) mm fin] Overall width Dimension ane 379 (22.8) omnicef aweea Eq Dry weight kg {ib} 345 [761] ‘355 [783] Cylinder sleeve ripe Dy ae wa Best Piston ri No. of in ‘Compress & [Pitonsing es Oisay toma s Tmecvave BIDCIO™ BIDCI Leer [Close ‘ABDCS0> ABDC 54 2 Exhaust [Open BBDC 74° BEDC 66° 3 valve [Close ‘AIDC30® ‘ATC 22° | Starting system Elecite starter Starting ad Glow plug Type Distributor Bosch Type VE) eee erate $10 [039] 11 [0.43] Feed pump os ‘Vane pump (Bosch) Speed control Governor | system Contrifuga! & Type ‘All $ [ype Throne norle Bosch) Hote nozzle ose) 3g No. of spray holes 1 3 g Spray hole diameter 2 ee a 61.0 (0.039) e020 (0.008) pray angle 5 TSOF(waries with specification) ‘Valve opening pressure 11.77 020) (17071 1765 (180) [2561] ‘MPa (ketem?) [oi] Fuel ter Type Paper clement cartridgeGENERAL Engine type 3S S6SDT Lubricating method Forced circulation (oil pump pressure feed) (Grade (APT service a i feoancaia Class CF (SAE30 equivalent) Erect [Capacity Entire engine: 12.5 330), £{US.zal] il pan: Maximum of 11.5 {3.04}, ol filter: 1 (0.26) ype Trochoid g Speed ratio to 3 |oit pump Jrankshaft ae s Discharge capacity | 38.7 [102] at 03MPa ( Kgffem [43 pal] discharge pressure of g #{US gal] min ‘pump running at 2230min" Type Piston valve 3 Valve opening 5 | Relief valve pressure 0.3540.05 (3.60.5) [5147] ‘MPa (kaflem’ [psi] Valve opening Safety valve pressure - 1.111) (156) MPa (kgflem [psi] Oil cooler Type = Water-cooled, multi-plate Oil iter [Type Paper-clement cartridge Cooling method ‘Waier-cooled, forced circulation ‘Coolant capacity (engine water jacket) oA) spa US; Type ‘Centrifugal volute pamp ‘Speed ratio to a ‘Water pump crankshaft g Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kaffem [107 psi] discharge ‘{{USgal]/ min pressure of pump runing a 3600mia" gz Type ‘Pusher (PP fan) 8 | cot No. of blades 7 Cooling fan hes g eee eel $500 [19.71 Webel Type Raw-edge cog V-belt Type BT [Type Wax Valve opening Thermostat T6.521.5 (169.42. Pee (Approx.90 [194] when fully opened) °C [°F] g & | Aircleaner Type Paper element g 2 | Torbocharger Type - ‘TEO6H