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ENGINE BASE SERVICE MANUAL MITSUBISHI $4S, S6S REFERENCE ONLY - EXCAVATOR(16-18TON, -7SERIES) - FORK LIFT(HDF35-70, -7SERIES)

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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 differ partially from the one described in this manual. Pub.No.99616-10180

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How 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. f at A short summary of each Group is given in the General Contents, and there is also a table of contents at the beginning of each Group. o_o Regarding engine operation and periodical maintenance, refer to the Operation & Maintenance Manual.

For component parts and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are described in various training manuals. 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 [| _ G) in disassembled views. they are relevant, are- also Maintenance standards for inspection and repair are described in: text where ae mes Group | in the General Contents. (4) The sequence in which parts are to be assembled is summarized below each assembled view.

(5) The following marks are used in this manual to emphasize important safety cautions. listed in — Such as: ©-@-@-@—-@. /\ DANGER -+++ Indicates a highly hazardous situation which, if not avoided, can result in death or serious injury. ” - +++ Indicates a potentially hazardous situation which, if not avoided, can result in death or AN CAUTION CAUTION Note: (6) +++ Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. case Indicates a potentially hazardous situation which, if not avoided, can result in property amage. - ++ Indicates important information or information which maintenance. is useful for engine operation or | .

Tightening torque under wet conditions is indicated as "TWet]." 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. . ~

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2. Terms Used in This Manual Nominal value ° +++ Indicates the standard dimension of a part to be measured. Standard Limit 3. ++*++++** 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. +++++++++++ A part must be repaired or replaced with a new part when it reaches the limit value. 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... - e ee * 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/cm? *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 cmH,O (cmAq) -Rotational speed: 1 min! = 1 rpm

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