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Mitsubishi Heavy Industries S4S User Manual

Mitsubishi Heavy Industries S4S
220 pages
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Printed in Japan
Pub. No.
Pub. No.
SERVICE MANUAL
SERVICE MANUAL
July 2016
July 2016
99616-101A0
99616-101A0

Table of Contents

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Mitsubishi Heavy Industries S4S Specifications

General IconGeneral
Engine ModelS4S
CategoryEngine
ManufacturerMitsubishi Heavy Industries
Cylinders4
AspirationNaturally Aspirated
Fuel SystemDirect Injection
Fuel TypeDiesel
Displacement3.331 L
FuelDiesel
Type4-cycle, water-cooled diesel engine

Summary

Introduction

How to Use This Manual

Guidance on navigating and utilizing the service manual effectively.

General Safety Precautions

Essential safety guidelines covering fire, electrical, thermal, mechanical, and operational hazards.

General Engine Information

External View and Component Identification

Diagrams illustrating engine component locations and external views.

System Flow Diagrams

Visual representations of fuel, lubrication, cooling, and exhaust systems.

Main Engine Specifications

Key technical parameters and data for engine models S4S and S4S-DT.

Tips on Disassembling and Reassembling

Recommended procedures and basic safety advice for engine service tasks.

Service Data and Specifications

Maintenance Service Data

Specifications and tolerance limits for engine component inspection and maintenance.

Tightening Torque Table

Torque values for various engine bolts and nuts to ensure proper assembly.

Service Tools

Special Tool List

Identification and usage of specialized tools required for engine maintenance and repair.

Engine Overhaul Determination

Determining Overhaul Timing

Guidelines for assessing when an engine requires a complete overhaul based on symptoms.

Testing Compression Pressure

Procedure and standards for measuring engine cylinder compression pressure.

Disassembly of Basic Engine Components

Cylinder Head and Valve Mechanism Disassembly

Steps for removing and inspecting cylinder head and valve train components.

Flywheel Disassembly and Inspection

Procedures for removing and inspecting the engine flywheel.

Gear Case, Timing Gear, and Camshaft Disassembly

Steps for disassembling and inspecting timing gears and camshaft assembly.

Piston, Connecting Rod, Crankshaft, and Crankcase Disassembly

Procedures for dismantling major internal engine components.

Inspection and Repair of Basic Engine

Cylinder Head and Valve Mechanism Inspection and Repair

Methods for inspecting and repairing cylinder head and valve components.

Flywheel Inspection and Repair

Procedures for inspecting and repairing the engine flywheel.

Timing Gear and Camshaft Inspection and Repair

Methods for inspecting and repairing timing gears and camshaft.

Piston, Connecting Rod, Crankshaft, and Crankcase Inspection and Repair

Inspection and repair procedures for key engine rotating and stationary parts.

Reassembly of Basic Engine Components

Reassembling Piston, Connecting Rod, Crankshaft, and Crankcase

Steps for reassembling the engine's bottom end components.

Reassembling Timing Gear and Camshaft

Procedures for reinstalling timing gears and camshaft assembly.

Reassembling Flywheel

Steps for installing the engine flywheel.

Reassembling Cylinder Head and Valve Mechanism

Procedures for reinstalling the cylinder head and valve train.

Fuel System Service

Removing Fuel System Components

Steps for safely removing fuel system parts like filters and pipes.

Fuel System Disassembly, Inspection, and Reassembly

Detailed procedures for servicing fuel system components, including nozzles.

Installing Fuel System Components

Steps for correctly installing fuel system parts after service.

Lubrication System Service

Removing Lubrication System Components

Procedures for removing oil filter, oil cooler, oil pump, and oil pan.

Lubrication System Disassembly, Inspection, and Reassembly

Detailed steps for servicing the oil pump, oil cooler, and oil filter.

Installing Lubrication System Components

Procedures for reinstalling lubrication system parts.

Cooling System Service

Removing Cooling System Components

Steps for removing fan, thermostat, and water pump.

Cooling System Disassembly, Inspection, and Reassembly

Detailed procedures for servicing the thermostat and water pump.

Installing Cooling System Components

Steps for reinstalling cooling system parts like water pump and fan.

Inlet and Exhaust Systems Service

Removing Turbocharger, Inlet, and Exhaust Systems

Steps for removing turbocharger, inlet, and exhaust manifolds.

Inlet and Exhaust Systems Disassembly, Inspection, and Reassembly

Procedures for inspecting and repairing exhaust manifold distortion.

Installing Turbocharger, Inlet, and Exhaust Systems

Steps for reinstalling turbocharger, inlet, and exhaust manifolds.

Electrical System Service

Removing Electrical System Components

Steps for removing starter, alternator, and glow plugs.

Electrical System Disassembly, Inspection, and Reassembly

Detailed procedures for servicing starter and alternator components.

Installing Electrical System Components

Steps for reinstalling starter, alternator, and glow plugs.

Engine Adjustment and Operation

Engine Adjustment Procedures

Instructions for adjusting valve clearance and V-belt tension.

Break-in Operation Guidelines

Procedures and timeframes for engine break-in after overhaul or installation.

Performance Test Procedures (JIS Standard)

Methods for conducting engine performance tests and output adjustments.

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