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ENGINE BASE SERVICE MANUAL MITSUBISHI S4K,S6K REFERENCE ONLY - EXCAVATOR(10TON, -7SERIES)

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INTRODUCTION This service manual has instructions and procedures for the subject on the front cover. n that was The information, specifications and illustrations in this manual are on the basic of the informatio current at the time this issue was written. Before starting a test, Correct servicing, test and repair procedures will give the engine a long service life. all the components know to manual this repair or rebuild job, the serviceman must read the respective sections of he will work on. which are not included Continuing improvement of product design may have caused changes top your engine in this manual.

Whenever a question arises regarding your engine, or this manual, consult your Mitsubishi dealer available information. for the latest . Pub No. 99499-10190

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HOW TO USE THIS MANUAL This service manual covers standard specifications for the Mitsubishi Diesel Engine, and describes specifications, maintenance standards, adjustments, disassembly inspection and repair, and reassembly. Following is a brief summary of the system used in compiling this service manual. 1. The fuel injection pump, governor, and turbocharger are covered in the supplement of this manual. 2. The sections of the manual and their contents are listed in the index furnished at the beginning of the manual. The contents of each section are listed in the index furnished at the beginning of the section.

For operation and periodic maintenance, refer to OPERATION MAINTENANCE MANUAL; for component parts and ordering of replacement parts, refer to PARTS CATALOGUE; for systems operation, refer to TRAINING MANUALS. The parts read in the texts or shown in the disassembled views are numbered in the disassembly sequence. What to be inspected for during disassembly are indicated in [___] in the disassembled views. The maintenance standards or specifications to be referred to for inspection and repair: are indicated in easyto-refer passages of the texts and also in Section 2 in a tabulated form. The following symbols are used in this manual to emphasize important and critical instructions:

NOTE news ---- Indicates a condition that is essential to highlight. /A\CAUTION Indicates a condition that can cause engine damage. - WARNING Indicates a condition that can cause personal injury or death. Tighten Torque in “wet” condition isi indicated as [wet]. considered i in “dry” condition.— Unless indicated as such, the torque is to be The following terms are used in the dimensional and other specifications: Nominal Size ...............00 Is the named size which has no specified limits of accuracy. Assembly standard........... Is the dimension of a part to be attained at the time of assembly, or the standard performance.

Its value is rounded to the nearest whole number needed for inspection and is different from the design value. Standard clearance........... Is the clearance to be obtained between mating parts at the time of assembly. Repair limit ............cceeees Is the maximum or minimum dimension specified for a part. A part which has reached this limit must be repaired. Service limit ..............000 Is the maximum or minimum dimension specified for a part. A part which has reached this limit must be replaced.

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TABLE OF CONTENTS Contents No. External views; sectional views, engine serial number location; . Section General information specifications; engine model and application codes; on disassembly and reassembly suggestions 1 Maintenance standards Maintenance standards; tightening torques; sealants 2 Special tools Special tools list 3 General instructions Determining when to overhaul the engine; measuring the compression pressure 4 Testing and adjusting Adjusting; bench test; performance test 5 val Eneine acces soding tallati sory remo on Preparation removal and installation of turbocharger; exhaust manifold:

thermostat; fuel filter; fuel injection pipe; fuel injection nozzle; inlet manifold; fuel injection pump; fan; water pump; starter; alternator; oil filter; oil pan; oil cooler; 6 air heater Disassembly, inspection and reassembly of engine proper: Engine proper ’ Cylinder head and valve mechanism; flywheel; timing gears, camshaft, pistons, connecting rods, crankshaft, crankcase Disassembly; inspection; external views of inlet and Air inlet and exhaust system | exhaust system Air cleaner (paper-element type), exhaust manifold gs Lubrication system Disassembly; inspection, assembly; oil pump; oil filter; pressure relief valve; oil strainer; oil cooler; safety valve Coo :

7 / Disassembly; inspection; assembly; 8 9 ling system water pump; thermostat; radiator; fan; fan belt 10 ] bly; inspection; assembly; Disassem , fuel filter; fuel injection nozzles i Fuel system Electrical system Disassembly; inspection; assembly; starter; alternator; air heater 12 Workshop theory Precautions for disassembly and reassembly of general parts: Oil seals, O-rings, bearings, lock plates, pins 13

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