Mitsubishi S4Q2 User manual

Service Manual

99719-77100

For use with FD10N, FD15N, FD18N, FD20CN

Chassis Service Manual.

S4Q2 Diesel Engine

24467-up

FD10N F16D-00011-up, F16D-10001-up

FD15N F16D-50001-up, F16D-60001-up

FD18N F16D-70001-up, F16D-80001-up

FD20CN F16D-85001-up, F16D-87001-up

FOREWORD

This service manual covers S4Q2 Diesel Engine of Mitsubishi Forklift Trucks and gives

detailed maintenance and repair information. The instructions are grouped by systems to serve

the convenience of your ready reference.

Long productive life of your forklift trucks depends to a great extent on correct servicing – the

servicing consistent with what you will learn from this service manual. We hope you read the

respective sections of this manual carefully and know all the components you will work on

before attempting any work.

All descriptions, illustration, specifications, and serial numbers in this manual are effective as

of the date printing of this manual. Mitsubishi reserves the right to change specifications or

design without notice and without incurring obligation.

Pub. No. 99719-77100

Hou 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.

Ashort summary of each Group is given in the General Contents, and there is also a table of contents at the

beginning of each Group.

Regarding engine operation and periodical maintenance, refer to the Operation & Maintenance Manual. For

component parts and ordering of servie parts, refer to the Parts Catalogue. Structure and function of the engine are

described in various training manuals.

1. 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 in disassembled views.

(3) Maintenance standards for inspection and repair are described in text where they are relevant, are also listed in

Group 1 in the General Contents.

(4) The sequence in which parts are to be assembled is summarized below each assembled view.

Such as: trewq.

(5) The following marks are used in this manual to emphasize important safety cautions.

…Indicates a potentially hazardous situation which, if not avoided, can result in death or serious

injury.

…Indicates a potentially hazardous situation which, if not aboided, can result in minor or

moderate injury.

…Indicates important information or information which is useful for engine operation or

maintenance.

(6)Tightening torque under wet conditions is indicated as “[Wet]”. 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.

←←←←

WARNING

CAUTION

NOTE

2. Terms Used in This Manual

Nominal value: Indicates the standard dimension of a part to be measured.

Standard: 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.

Limit: A part must be repaired or replaced with a new part when it reaches the limit value.

3. 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

•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/cm2

•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 cmH2O (cmAq)

•Rotational speed: 1 min−1= 1 rpm

GROUP INDEX Items

GROUP INDEX

GENERAL

GENERAL INSTRUCTIONS

ENGINE MAIN PARTS

INLET AND EXHAUST

SYSTEM

COOLING SYSTEM

FUEL SYSTEM

OIL SYSTEM

ELECTRICAL SYSTEM

TESTING AND ADJUSTING

TROUBLESHOOTING

MAINTENANCE STANDARD

SPECIAL TOOL

Determination of Engine Overhaul Timing, Testing Compression Pressure, Tips

on Disassembly and Reassembly, Precautions for Disassembly and Reassembly

Cylinder Heads and Valve Mechanism, Flywheel, Timing Gears, Camshaft and

Oil Pan, Pistons, Connecting Rods, Crankshaft and Crankcase

Description, Disassembly, Inspection and Reassembly

Description, Water Pump, Fan, Thermostat

Description, Fuel System Bleeding, Disassembly, Fuel Filter (Paper-Element

Cartridge Type), Fuel Injection Nozzles

Description, Oil Pump, Oil Filter, Pressure Relief Valve

Starter, Alternator, Glow Plugs

Bench Test, Idling Speed and Maximum Speed Seting Inspection and

Adjustment, Performance Test

Outline, Spcifications

Causes of Engine Problems and Remedies

Maintenance Standards Table, Tightening Torques, Thread Sealants,

Maintenance Schedule

Special Tool List

Table of contents

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