Mitsubishi Heavy Industries S4S Manuals

Manuals and User Guides for Mitsubishi Heavy Industries S4S. We have 2 Mitsubishi Heavy Industries S4S manuals available for free PDF download: Service Manual

Mitsubishi Heavy Industries S4S Service Manual (220 pages)

Brand: Mitsubishi Heavy Industries | Category: Engine | Size: 8 MB

General Contents

15
- Table of Contents
  15
- General
  17
Service Data

37
- 1 Maintenance Service Data
  
  38
  - General
    38
  - Basic Engine
    39
  - Cooling System
    43
  - Fuel System
    43
  - Lubrication System
    43
  - Electrical System
    44
  - Inlet and Exhaust System
    44
  - Basic Engine
    45
  - Fuel System
    45
  - Major Bolt Tightening Torque
    45
- 2 Tightening Torque Table
  
  45
  - Cooling System
    46
  - Electrical System
    46
  - Inlet and Exhaust Systems
    46
  - Lubrication System
    46
  - Metric Automobile Screw Thread
    47
  - Metric Course Screw Thread
    47
  - Standard Bolt and Nut Tightening Torque
    47
  - Standard Stud Tightening Torque
    47
  - Service Tools
    49
  - Determination of Overhaul
    53
  - Determining Overhaul Timing
    54
  - Testing Compression Pressure
    55
Disassembly of Basic Engine

57
Inspection and Repair of Basic Engine

73
Reassembly of Basic Engine

103
- 1 Reassembling Piston, Connecting Rod, Crankshaft and Crankcase
  
  104
  - Installing Main Bearing
    104
  - Installing Thrust Plate
    104
  - Installing Tappet
    104
  - Installing Crankshaft
    104
  - Installing Main Bearing Caps
    105
  - Inserting Side Seal
    105
  - Installing Main Bearing Cap Bolt
    105
  - Measuring Crankshaft End Play
    106
  - Reassembling Piston and Connecting Rod
    106
  - Installing Piston Ring
    107
  - Preparation for Installing Pistons
    107
  - Installing Connecting Rod Bolt and Connecting Rod Bearing
    108
  - Installing Pistons
    108
  - Installing Connecting Rod Cap
    109
- 2 Reassembling Timing Gear and Camshaft
  
  110
  - Installing Oil Pump
    110
  - Installing Front Plate
    110
  - Installing Camshaft Gear and Thrust Plate
    111
  - Installing Camshaft
    111
  - Installing Idler Gear
    111
  - Installing Oil Pump Gear
    112
  - Installing Fuel Injection Pump
    112
  - Inspecting and Adjusting Timing Gear after Installation
    112
  - Inspecting Backlash and End Play
    112
  - Installing Front Oil Seal
    113
  - Installing Timing Gear Case
    113
  - Installing Oil Strainer
    113
  - Installing Oil Pan
    114
  - Installing Cover
    115
  - Installing Crankshaft Pulley
    115
- 3 Reassembling Flywheel
  
  116
  - Installing Oil Seal
    116
  - Installing Flywheel Housing
    116
  - Installing Flywheel
    116
- 4 Reassembling Cylinder Head and Valve Mechanism
  
  117
  - Cleaning Cylinder Head Bottom Surface
    117
  - Installing Valve Stem Seal
    117
  - Installing Valve and Valve Spring
    117
  - Installing Cylinder Head Gasket
    118
  - Installing Cylinder Head Assembly
    118
  - Tightening Cylinder Head Bolts
    118
  - Inserting Pushrod
    119
  - Reassembling Rocker Shaft Assembly
    119
  - Installing Rocker Shaft Assembly
    119
  - Determining Top Dead Center of No.1 Cylinder Compression Stroke
    120
  - Adjusting Valve Clearance
    120
  - Installing Rocker Cover
    121
Fuel System

123
Lubrication System

147
Cooling System

161
- 1 Removing Cooling System
  
  162
  - Removing Cooling Fan, Fan Pulley and V-Belt
    162
  - Removing Thermostat
    163
  - Removing Water Pump
    164
- 2 Disassembling, Inspecting and Reassembling Cooling System
  
  165
  - Disassembling and Inspecting Thermostat10-5
    165
  - Inspecting Thermostat
    166
  - Disassembling Water Pump
    167
  - Inspecting Water Pump
    167
- 3 Installing Cooling System
  
  168
  - Installing Water Pump
    168
  - Installing Thermostat
    169
  - Installing Cooling Fan, Fan Pulley and V-Belt
    170
Inlet and Exhaust Systems

171
Electrical System

179
- 1 Removing Electrical System
  
  180
  - Removing Starter
    180
  - Inspection before Removing Alternator
    181
  - Inspecting Alternator Operation
    181
  - Handling Precaution
    181
  - Removing Alternator (12V-50A)
    182
  - Removing Alternator (12V-75A, Option)
    183
  - Removing Glow Plug
    184
- 2 Disassembling, Inspecting and Reassembling Electrical System
  
  185
  - Inspection before Disassembling Starter
    185
  - Inspecting Magnetic Switch
    185
  - No Load Test
    186
  - Disassembling and Inspecting Starter
    187
  - Removing Pinion Set
    188
  - Removing Magnetic Switch
    189
  - Removing Rear Bracket
    189
  - Removing Armature and Yoke
    189
  - Removing Overrunning Clutch
    189
  - Inspecting and Repairing Starter
    190
  - Inspecting Brushes for Wear
    190
  - Measuring Brush Spring Load
    190
  - Inspecting Brush Holder for Insulation
    190
  - Measuring Commutator Radial Runout
    190
  - Measuring Commutator Outside Diameter12-13
    191
  - Measuring Undercut Depth
    191
  - Checking Armature Coil
    191
  - Inspecting Field Coil
    192
  - Inspecting Rear Bracket
    192
  - Inspecting Overrunning Clutch
    192
  - Inspecting Front Bracket
    192
  - Inspecting Gears of Starter
    192
  - Inspecting Magnetic Switch
    193
  - Reassembling Starter
    194
  - Installing Gear Shaft
    194
  - Disassembling and Inspecting Alternator12-17
    195
  - Separating Front Bracket from Stator
    196
  - Removing Pulley
    196
  - Removing Rear Bearing
    196
  - Removing Front Bearing
    196
  - Removing Stator
    197
  - Removing Regulator Assembly
    197
  - Removing Rectifier Assembly
    197
  - Inspecting and Repairing Alternator
    198
  - Inspecting Rectifier
    198
  - Inspecting Rotor Assembly
    198
  - Inspecting Stator
    199
  - Inspecting Brushes for Wear
    199
  - Replacing Brushes
    200
  - Reassembling Alternator
    201
  - Installing Rectifier Assembly and Regulator Assembly
    201
  - Installing Stator
    202
  - Installing Front Bearing
    202
  - Installing Rear Bearing
    202
  - Installing Pulley
    202
  - Assembling Stator and Front Bracket
    203
  - Heating Test of Glow Plug
    204
  - Inspecting Air Heater
    204
  - Inspecting Magnetic Valve (Stop Solenoid, Distributor-Type)
    205
  - Continuity Test of Magnetic Valve
    205
  - Inspecting Magnetic Valve (Stop Solenoid) Operation
    205
  - Installing Magnetic Valve (Stop Solenoid)12-27
    205
  - Installing Stop Solenoid (RUN-ON Type, for In-Line Pump Type)
    206
- 3 Installing Electrical System
  
  207
  - Installing Glow Plug
    207
  - Installing Alternator (12V-50A)
    208
  - Installing Alternator (12V-75A, Option)
    209
  - Installing Starter
    210
Adjustment and Operation

211
- 1 Adjusting Engine
  
  212
  - Inspecting and Adjusting Valve Clearance13-2
    212
  - Inspecting Valve Clearance
    212
  - Adjusting Valve Clearance
    212
  - Draining Fuel Filter
    213
  - Draining Fuel System
    213
  - Bleeding Fuel Filter
    214
    
    (Distributor-Type Fuel Injection Pump)
    215
  - Bleeding Fuel Filter (In-Line Fuel Injection Pump)
    214
  - Bleeding Fuel Injection Pump
    214
    
    (In-Line Fuel Injection Pump)
    214
  - Bleeding Fuel System
    214
  - Adjusting V-Belt Tension
    216
  - Inspecting V-Belt
    216
  - Inspecting V-Belt and Adjusting V-Belt Tension
    216
- 2 Break-In Operation
  
  217
  - Starting up
    217
  - Break-In Operation Time
    217
  - Inspection and Adjustment after Break-In
    217
    
    Operation
    217
- 3 Performance Test (JIS Standard)
  
  218
  - Engine Equipment Condition
    218
  - Test Items and Purposes
    218
  - Operation Load Test
    218
  - Continuous Load Test
    218
  - Low Idle Test
    218
  - Other Inspections
    218
  - Engine Output Adjustment
    218
  - Standard Atmospheric Conditions
    218
  - Calculation of Corrected Power
    219

Mitsubishi Heavy Industries S4S Service Manual (170 pages)

SS Series

Brand: Mitsubishi Heavy Industries | Category: Engine | Size: 6 MB

How to Use this Manual
2
Table of Contents
3
General

8
- Engine Model and Application Codes
  12
- Engine Serial Number Location
  12
1 Outline

8
- External View
  8
2 Specifications

13
- Model Designation
  17
3 Tips on Disassembly and Reassembly

19
- Disassembly
  19
- Reassembly
  20
Maintenance Standards

21
4 Maintenance Standards Table

22
5 Tightening Torques

29
- Important Bolts and Nuts
  29
- Standard Bolts
  30
- Standard Studs
  30
- Standard Plugs
  31
6 Sealants and Lubricants Table

32
Special Tools Special Tool List

34
Overhaul Instructions

37
8 Determination of Overhaul Timing

38
9 Testing the Compression Pressure

39
Adjustments, Bench Test, Performance Tests 10 Adjustments

42
11 Bench Testing

50
12 Performance Tests

52
- Engine Equipment Condition
  52
- Tests and Their Purposes
  52
- Other Inspections
  52
- Adjustment Engine Output
  52
Engine Auxiliaries Removal and Installation

55
13 Preparation

56
14 Engine Auxiliaries Removal

57
15 Engine Auxiliaries Installation

63
Engine Main Parts

65
16 Cylinder Heads and Valve Mechanism

66
- Disassembly
  66
- Inspection
  68
- Reassembly
  75
17 Flywheel

79
- Disassembly
  79
- Inspection
  80
- Reassembly
  82
18 Damper, Timing Gears and Camshaft

84
- Disassembly
  84
- Inspection
  88
  - Timing Gears
    90
  - Crankshaft Pulley
    91
- Reassembly
  92
19 Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets

98
- Disassembly
  98
- Inspection
  101
- Main Bearings
  113
- Reassembly
  115
Inlet and Exhaust System

121
20 Description

122
21 Exhaust Manifold

123
- Inspection
  123
Lubrication System

125
22 Description

126
23 Oil Pump

127
- Disassembly
  127
- Inspection
  127
- Reassembly
  130
24 Oil Filter

131
- Disassembly and Inspection
  131
25 Oil Cooler (Engine with Oil Cooler)

132
- Disassembly and Inspection
  132
26 Oil Pressure Relief Valve

133
- Inspection
  133
27 Safety Valve (Engine with Oil Cooler)

134
- Inspection
  134
Cooling System

135
- Cooling System 28 Description
  136
28 Description

136
29 Water Pump (According to Engine Specification)

137
- Inspection
  137
30 Thermostat

138
- Inspection
  138
Fuel System

139
31 Description

140
32 Fuel Filter (Paper-Element Cartridge Type)

141
- Disassembly and Inspection
  141
33 Injection Nozzles (According to Engine Specification)

142
- Disassembly
  142
- Inspection
  143
- Reassembly
  146
Electrical System General

148
- Wiring Diagrams
  148
- Electrical System 34 General
  148
35 Starter

151
- Disassembly
  151
- Inspection
  152
- Reassembly
  156
- Inspection and Testing after Assembly
  156
36 Alternator

158
- Disassembly
  158
- Inspection
  159
- Reassembly
  161
37 Glow Plugs

162
- Inspection
  162
38 ETR Type Stop Solenoid

163
- General
  163
- Solenoid Specification
  164
- Inspection
  165
- Connecting Rod Adjustment
  165
Workshop Tips

167
39 Basic Recommended Assembly Procedures

168
- Oil Seals
  168
- O-Rings
  169
- Bearings
  169
- Split Pins and Spring Pins
  169

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Mitsubishi Heavy Industries S4S Manuals

Mitsubishi Heavy Industries S4S Service Manual (220 pages)

Table of Contents

General Contents

Service Data

1 Maintenance Service Data

2 Tightening Torque Table

Disassembly of Basic Engine

1 Disassembling and Inspecting Cylinder Head and Valve Mechanism

2 Disassembling and Inspecting Flywheel

3 Disassembling and Inspecting Gear Case, Timing Gear and Camshaft

4 Disassembling and Inspecting Piston, Connecting Rod, Crankshaft and Crankcase

Inspection and Repair of Basic Engine

1 Inspecting and Repairing Cylinder Head and Valve Mechanism

2 Inspecting and Repairing Flywheel

3 Inspecting and Repairing Timing Gear and Camshaft

4 Inspecting and Repairing Piston, Connecting Rod, Crankshaft and Crankcase

Reassembly of Basic Engine

1 Reassembling Piston, Connecting Rod, Crankshaft and Crankcase

2 Reassembling Timing Gear and Camshaft

3 Reassembling Flywheel

4 Reassembling Cylinder Head and Valve Mechanism

Fuel System

1 Removing Fuel System

2 Disassembling, Inspecting and Reassembling Fuel System

3 Installing Fuel System

Lubrication System

1 Removing Lubrication System

2 Disassembling, Inspecting and Reassembling Lubrication System

3 Installing Lubrication System

Cooling System

1 Removing Cooling System

2 Disassembling, Inspecting and Reassembling Cooling System

3 Installing Cooling System

Inlet and Exhaust Systems

1 Removing Turbocharger, Inlet and Exhaust Systems

2 Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems

3 Installing Turbocharger, Inlet and Exhaust Systems

Electrical System

1 Removing Electrical System

2 Disassembling, Inspecting and Reassembling Electrical System

3 Installing Electrical System

Adjustment and Operation

1 Adjusting Engine

2 Break-In Operation

3 Performance Test (JIS Standard)

Mitsubishi Heavy Industries S4S Service Manual (170 pages)

Table of Contents

General

1 Outline

2 Specifications

3 Tips on Disassembly and Reassembly

Maintenance Standards

4 Maintenance Standards Table

5 Tightening Torques

6 Sealants and Lubricants Table

Special Tools Special Tool List

Overhaul Instructions

8 Determination of Overhaul Timing

9 Testing the Compression Pressure

Adjustments, Bench Test, Performance Tests 10 Adjustments

11 Bench Testing

12 Performance Tests

Engine Auxiliaries Removal and Installation

13 Preparation

14 Engine Auxiliaries Removal

15 Engine Auxiliaries Installation

Engine Main Parts

16 Cylinder Heads and Valve Mechanism

17 Flywheel

18 Damper, Timing Gears and Camshaft

19 Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets

Inlet and Exhaust System

20 Description

21 Exhaust Manifold

Lubrication System

22 Description

23 Oil Pump

24 Oil Filter

25 Oil Cooler (Engine with Oil Cooler)