Mitsubishi S3L, S3L2, S4L, S4L2 Service Manual

FOREWORD

This service manual describes the specifications as well as the maintenance and adjustment procedures for Mitsubishi diesel engines. This manual also includes the detailed information on basic and special tools as the need arises.

The Mitsubishi diesel engines can offer highly efficient and reliable performance for many years to come, which, however, only can be achieved through the proper handling and the periodical inspection/maintenance work exercised in according to the procedures of disassembly, inspection/adjustment and reassembly described in this manual.

Before attempting any work on your engine, thoroughly read this manual to familiarize with the engine and the required procedures of the work.

All information contained in this manual is based on the engine produced at the time of publication and is subject to change as the engine improved without notice.

Pub. No. 99619-12140

HOW TO USE THIS MANUAL

This Service Manual describes the specifications of Mitsubishi diesel engines (land and standard applications) and relevant service standards, as well as the procedures for servicing the engines such as for disassembly, inspection, repair and reassembly. This manual is divided into Groups. Each Group covers a specific area of the engine. The fuel injection pump, the governor and the turbocharger are handled in a separate manual.

Major contents of Groups are listed on the “General Contents” page. Detailed contents of each Group are listed on the first page of that Group.

For information on the operations and recommended inspection/maintenance schedule of forklift trucks, please refer to the operator’s manual for the forklift truck. For information on components/parts and spares ordering procedures, refer to the parts catalogue. For information on structures and functions, refer to appropriate training materials.

1. Notes on descriptions

(1) Parts shown in Figures as well as in the text are numbered in the order of disassembly. (2) Inspecting points during disassembly are shown in the Disassembly figures by enclosing in the box. (3) Service standards for inspection and repair are listed on the appropriate pages of this manual where the

relevant descriptions are made. Also, a comprehensive listing of service standards is provided in Group

(4) Parts reassembly sequence is provided below the Figure of that reassembly in the form of ⑤→④→③

→②→①.

(5) In this manual, the following marks are provided to draw the reader’s attention to the safety notes

described under the marks.

････ This indicates a dangerous situation which can highly likely result in death or

serious injury unless avoided.

････ This indicates a potentially dangerous situation which may possibly lead to

death or serious injury unless avoided.

････ This indicates a potentially dangerous situation which may cause minor to

moderate injury unless avoided.

････This indicates a potential danger in which property damage may result unless

avoided.

(6) Wherever hardware tightening requires the application of engine oil, “WET” is mentioned. If not

Note: ････ This stresses important points or provides useful tips on engine operations and

service.

mentioned, tighten the hardware “dry” (engine oil should not be applied).

2. Terms

Nominal value ······This is the nominal dimension of the part being measured.

Standard value ······ This is the dimension of the individual part being measured, the clearance between the

parts in question, or the standard performance in question. Standard values have been arranged within the range appropriate for the inspection being carried out, and are not necessarily the design values.

Limit·····················Parts that have reached the limit value should be replaced or repaired whichever is

appropriate.

3. Abbreviations and standards

・BTDC = Before Top Dead Center ・ATDC = After Top Dead Center ・BBDC = Before Bottom Dead Center ・ABDC = After Bottom Dead Center ・TIR = Total Indicator Reading ・API = American Petroleum Institute ・ASTM = American Society for Testing and Materials ・JIS = Japan Industrial Standards ・LLC = Long Life Coolant ・MIL = Military Specifications ・MSDS = Material Safety Data Sheets ・SAE = Society of Automotive Engineers

4. Units

Values shown in this manual are based on SI units (International System of Units). The corresponding metric values are shown in ( ) immediately after the SI values. The SI to metric conversions are based on the following.

・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 ・Rotational speed: 1 min

-1

= 1 rpm

O (cmAq)

GENERAL CONTENTS

Group No. Group Name Page

0 SAFETY CAUTIONS 0 - 1

GENERAL 1 - 1 SERVICE STANDARDS 1 -11

2 Engine Main Parts

3 Fuel System

4 Lubrication System

5 Cooling System

7 Air starter System

TOOLS LIST 1 -21 OVERHAUL TIMING 1 -25 REMOVAL PREPARATIONS 1 -29

Inlet and Exhaust Systems

ENGINE MAIN PARTS - DISASSEMBLY 2 - 1 ENGINE MAIN PARTS - INSPECTION AND

CORRECTION ENGINE MAIN PARTS - REASSEMBLY 2 -33

FUEL SYSTEM - REMOVAL 3 - 1 FUEL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y FUEL SYSTEM - INSTALLATION 3 -25

OIL SYSTEM - REMOVAL 4 - 1 OIL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y OIL SYSTEM - INSTALLATION 4 - 9

COOLING SYSTEM - REMOVAL 5 - 1 COOLING SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y COOLING SYSTEM - INSTALLATION 5 - 9 INLET AND EXHAUST SYSTEMS -

REMOVAL INLET AND EXHAUST SYSTEMS DISASSEMBLY, INSPECTION AND REASSEMBLY INLET AND EXHAUST SYSTEMS INSTALLATION

ELECTRICAL SYSTEM - REMOVAL 7 - 1 ELECTRICAL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y ELECTRICAL SYSTEM - INSTALLATION 7 -25

2 -17

3 - 9

4 - 5

5 - 5

6 - 1

6 - 5

6 - 7

7 - 7

Engine -

9 Others

Supplement Engine Inspection Sheets

Inspection/Adjustment, Running-in Trial and Performance Test

ENGINE - INSPECTION / ADJUSTMENT 8 - 1 RUNNING-IN TRIAL 8 -12 PERFORMANCE TEST 8 -13

DISASSEMBL Y AND REASSEMBLY OF GENERAL PARTS

9 - 1

SAFETY CAUTIONS

Warning Risk of fire and explosion ···0-2

●Never use open fire ······························0-2

●Keep things tidy around the engine ··········0-2

●Do not open the crankcase until it has

cooled down

●Pay attention to fuel and oil leakage

●Use explosion-proof light

●Prevent short circuit

●Keep fire extinguisher and first-aid kit

at hand

········································0-2

·········0-2

························0-2

······························0-2

··············································0-2

Warning Risk of entanglement into

the machine························0-3

●Keep guards on the rotating parts ············0-3

●Ensure safety in the surrounding area

when starting the engine

●Keep away from rotating parts while the engine is running

●Lockout/tagout

●Always stop the engine before any

inspection/service

●Remove the turning gear after use

··································0-3

·····································0-3

·································0-3

························0-3

···········0-3

Warning Risk of burn ························0-4

●Do not touch the engine while it is running or for a while after it is stopped

●Be careful when opening/closing the radiator cap

●Replenish coolant only when the coolant in the system is cold

●Do not remove heat insulating material ·····0-4

·········································0-4

··············0-4

·····0-4

Warning Exhaust gas is

poisonous···························0-4

●Ensure good ventilation while the engine is running

··································0-4

Warning Hearing difficulty·················0-4

●Wear ear protector································0-4

Warning Beware of falling engine·····0-5

●Exercise caution when lifting the engine····0-5

●Do not climb on the engine

●Secure your foothold when carrying out

service

···············································0-5

·····················0-5

Caution Use correct engine oil

and LLC······························0-5

●Only use the specified fuel, engine oil and coolant (LLC)

·································0-5

●Handle LLC with care

●Lawful disposal of waste oil and

coolant

···············································0-5

····························0-5

Caution Handling of battery··············0-6

●Handle the battery with care····················0-6

Caution How to handle

emergencies·······················0-6

●Engine overheat - Idle to cool down, then stop the engine

●Never restart the engine after a su dden stop unless the cause is eliminated

●Stop the engine immedia t ely upon oil pressure drop

●Stop the engine immedia t ely upon broken fan belt

···············································0-6

······································0-6

·····························0-6

··········0-6

Caution How to handle

emergencies·······················0-6

●Engine overheat - Idle to cool down, then stop the engine

●Never restart the engine after a su dden stop unless the cause is eliminated

●Stop the engine immedia t ely upon oil pressure drop

●Stop the engine immedia t ely upon broken fan belt

···············································0-6

······································0-6

·····························0-6

··········0-6

Caution Other considerations···········0-7

●Never alter or modify the engine ··············0-7

●Do not tamper with sealing

●Daily and periodical inspection

●Running-in period

●Warming up the engine

●Do not overload the engine·····················0-7

●Cooling down the engine

●Do not spill water onto the engine ···········0-7

●Air cleaner maintenance precautions

●Observe safety rules at work sites

●Wear appropriate clothes and protective

gear

···················································0-8

●Use appropriate tools when carrying out service

·································0-7

·····················0-7

················0-7

··························0-7

························0-7

········0-8

············0-8

0-8

●Do not operate the starter continuously

●The battery switch must be kept ON while

the engine is running

●Precautions for road transport

·····························0-8

·················0-8

·····0-8

SAFETY CAUTIONS

W arning Risk of fire and explosion

●Never use open fire

When topping up or replacing fuel or engine oil, or cleaning parts in wash oil, do not light a match, smoke or use any other open fire nearby. Doing these is extremely dangerous as fuel and oils can catch fire. Completely wipe off any spilt fuel or engine oil as they are flammable and can be a fire hazard. Store fuel and engine oil in a well-ventilated place. Firmly tighten the cap of the container.

●Keep things tidy around the engine

Keep fuel, engine oil or any other flammables as well as explosives and other dangerous materials away from the engine. These materials can ignite and explode. Keep the engine and the surrounding area free of waste, dirt, foreign matter, etc. These substances can be a fire hazard and invite overheating. In particular, ensure that the top of the battery is clean after service operations. Any waste left on the battery can cause short circuit. Keep a running engine at least 1 m (3.3 ft.) away from the surrounding building or equipment to eliminate the risk of fire.

●Do not open the crankcase until it has cooled down

Do not attempt to open the crankcase side cover immediately after the engine is stopped. Wait at least 10 minutes until the engine has sufficiently cooled down. If fresh air flows into the crankcase with the engine still hot, the remaining mist of oil may ignite and cause explosion.

●Pay attention to fuel and oil leakage

If leakage of fuel or oil is found, immediately take measures to stop it. If leaking fuel or engine oil spills over the heated engine, fire may start, possibly leading to bodily injury or equipment damage.

●Use explosion-proof light

When checking fuel, engine oil, coolant, battery electrolyte, etc., use explosion-proof light. If ordinary light is used, these fluids may ignite and explode.

●Prevent short circuit

Before inspecting or servicing the electrical/electronic system, disconnect the negative (-) cable from the battery terminal. Failure to observe this can cause the circuit to short, possibly starting a fire. Loose terminals and damaged cables/wires can cause short circuit or even fire. Before carrying out service operation, check for loose or damaged components and repair or replace as required.

●Keep fire extinguisher and first-aid kit at hand

Keep a fire extinguisher at hand. Become familiar with the handling of the fire extinguisher. Store a first-aid kit at the designated place. The kit should be kept fully supplied so that it can serve the purpose at any time. Establish a set of actions to take in the event of fire or accident, including emergency contact numbers and means of communication.

0 - 2

W arning Risk of entanglement into the machine

SAFETY CAUTIONS

●Keep guards on the rotating parts

Ensure that all guards are correctly installed over the rotating parts of the engine. Damaged or loose guards should be repaired. Never attempt to remove the camshaft cover, rocker cover or any other guards form rotating parts while the engine is running. Never leave exposed the drive belts and related couplers for auxiliaries and radiator. They should also be covered with guards. Never remove these guards.

●Ensure safety in the surrounding area when starting the engine

Before starting the engine, ensure that no one is near the electric power generator and that no tools or foreign matter are left behind. Shout to people around you so that they will know you are starting the engine. Never start the engine if a “Do not start” tag or any other similar message is posted on the starter switch, etc.

●Keep away from rotating parts while the engine is running

Never stand near the rotating parts while the engine is running. Do not place objects near the rotating parts that are likely to be caught by these parts. Should any part of human body (or tool) is caught by the rotating parts, dismemberment or other bodily injury will result.

●Lockout/tagout

Perform lockout/tagout before carrying out any inspection/service. Lockout/tagout is an ideal way of disconnecting the machine/equipment from the power source. To lockout/tagout, remove the starter switch key, place the battery switch in the “OFF” position, and post a “Do not start” tag or other similar message on the starter switch. The starter switch key should then be carried by the person who is going to perform inspection/service. If an air start system is used, close the air tank source valve and post a “Do not open” tag or other similar message.

●Always stop the engine before any inspection/service

Always stop the engine before performing any inspection/service. Never attempt to adjust belt tension while the engine is running. Otherwise, the operator runs a great risk of becoming entangled into the rotating parts and seriously injured.

●Remove the turning gear after use

Be sure to remove the turning gear after use. Never start the engine with the turning gear still installed or “engaged.” Otherwise, the engine will break and possibly someone may become injured.

0 - 3

SAFETY CAUTIONS

W arning Risk of burn

●Do not touch the engine while it is running or for a while after it is stopped

Never touch any part of the engine while it is running or for a while after it is stopped. Otherwise, you may become burned. Use a coolant temperature gauge to confirm that the engine has sufficiently cooled down before performing any inspection/service.

●Be careful when opening/closing the radiator cap

Never attempt to open the radiator cap while the engine is running and for a while after it is stopped. Stop the engine and wait until the coolant temperature has sufficiently dropped before opening the cap. Slowly open the radiator cap to allow the internal pressure to escape. To prevent possible burn, wear thick rubber gloves or cover the cap with cloth to protect your hands from escaping vapor. Tighten the radiator cap firmly. Coolant is extremely hot while the engine is running or for a while after the engine is stopped. You may become burned by extremely hot vapor or coolant that will gush out if the radiator cap is opened.

● Replenish coolant only when the coolant in the system is cold

Do not replenish coolant for a while after the engine is stopped. Replenish coolant when the coolant in the system is sufficiently cold. Otherwise, you may become burned.

● Do not remove heat insulating material

The exhaust system components become extremely hot and therefore are covered with heat insulating material. Never remove the material. If the material needs to be removed at all for inspection/service, be sure to install it again after the operation.

W arning Exhaust gas is

poisonous

● Ensure good ventilation while the engine is running

If the engine is installed inside a building and the exhaust gas is directed outside through a duct, regularly check the duct for any leakage through the joints etc. Do not run the engine in a building (warehouse, tunnel, etc.), confined space, or other poorly ventilated places if the engine is used for a portable generator. If the engine needs to be run in a buildin g at all, ensure to direct the exhaust gas outside and provide sufficient ventilation. Also, take care not to direct the exhaust gas towards nearby plants or animals, if any. Engine exhaust gas contains carbon monoxide and other substances that are harmful to humans. Running the engine in a poorly ventilated place can cause exhaust gas poisoning.

Warning Hearing

difficulty

●Wear ear protector

W ear ear protector whenever entering the engine room. Otherwise, the combustion and mechanical noises may cause you to develop hearing difficulty.

0 - 4

SAFETY CAUTIONS

Warning Beware of

falling engine

● Exercise caution when lifting the engine

The wire rope used to lift the engine should have enough strength to withstand the weight of the engine. Attach the specified lifting gear onto the lifting hangers on the engine. Ensure that the engine is well balanced when it is lifted by taking into account the engine’s center of gravity. The angle of wire rope relative to the lifting hangers should be maintained at 60º or less. Above this, the hangers may be subjected to overload and break. If direct contact between the wire rope and the engine is anticipated, protect them from damage by covering them with cloth or other soft material.

● Do not climb on the engine

Do not climb onto the engine, nor place a foot on the components on the side of the engine. Otherwise, you may not only break the engine components but also fall and become injured. Use a stool or a platform to work on the top of the engine. Be careful not to slip and fall.

● Secure your foothold when carrying out service

Use a stable stool or platform when working on the top of the engine or other areas of the engine difficult to reach. Do not use a rickety stool nor substitute a box of parts. Otherwise, you may fall and become injured. Do not leave anything on the stool.

Caution Use correct

engine oil and LLC

● Only use the specified fuel, engine oil and coolant (LLC)

Only use the fuel, engine oil and coolant (LLC) that are specified in this manual. Handle them with sufficient care. Using fluids other than those specified in this manual or incorrect use of those specified in this manual will lead to many problems and may possibly cause failures. Use the specified engine oil and LLC according to the instructions of MSDS (Material Safety Data Sheets) issued by and available from the manufacturers.

● Handle LLC with care

LLC is a strong alkali. Be careful not to drink it by mistake or allow it to contact your eyes. Old coolant (containing LLC) that has been drained off is toxic. Do not dispose of it carelessly. Dispose of it in accordance with the applicable laws and regulations.

● Lawful disposal of waste oil and coolant

Do not dispose of waste oil or coolant carelessly. Doing so is harmful to the environment and is prohibited by law. Harmful substances such as waste oil and coolant should be disposed of in a manner that complies with the applicable laws and regulations.

0 - 5

SAFETY CAUTIONS

Caution Handling of

battery

● Handle the battery with care

・ Batteries emit hydrogen and

oxygen gases, both of which are flammable. Never use open fire or generate sparks near the battery. Otherwise, these gases may ignite and explode.

・ Do not use the battery if the electrolyte level has

dropped below the minimum line. Otherwise, the battery may explode.

・ Be careful not to inadvertently place a metal

object such as tool between the battery terminals.

・ Always disconnect the negative (-) terminal first,

then the positive (+) terminal, from the battery. Always connect the positive (+) terminal first, then the negative (-) terminal, to the battery.

・ Recharge the battery in a well ventilated place,

with all battery plugs removed.

・ The battery terminals should have a positive

connection. Loose terminals can generate sparks, possibly causing the battery to explode.

・ Before servicing or performing electric welding

on the electrical/electronic system, position the battery switch in the OPEN/OFF position or disconnect the negative (-) terminal of the battery to isolate the electrical/electronic circuit.

・ The battery electrolyte contains dilute sulfuric

acid. Incorrect handling may lead to loss of eyesight or burn. Never drink battery electrolyte.

・ Wear protective goggles and rubber gloves when

maintaining the battery (replenishing, recharging, etc.).

・ If your skin or clothing has come into contact with

battery electrolyte, immediately wash the affected area with plenty of water and then thoroughly clean with soap.

・ Should your eyes come into contact with battery

electrolyte, loss of eyesight may result. Immediately wash your eyes with plenty of fresh water and seek medical attention immediately.

・Should you inadvertently drink battery electrolyte,

repeatedly gargle with plenty of water and then drink plenty of water. Seek medical attention immediately.

Caution How to handle

emergencies

● Engine overheat - Idle to cool down, then stop the engine

In the event of engine overheat, do not stop the engine immediately. Doing so may cause the coolant temperature to rise quickly and the engine may seize. Instead, run the engine at low idle for a while to cool it down. Then, stop the engine. Do not attempt to replenish coolant for a while after the engine is stopped. Otherwise, the cylinder head etc., which may still be hot, is cooled down rapidly and may break. Wait until the engine is sufficiently cold and then top up slowly.

● Never restart the engine after a sudden stop unless the cause is eliminated

If the engine has suddenly stopped with some alert signals, do not restart immediately. Otherwise, the engine may seriously become damaged. Locate and eliminate the cause before restarting.

● Stop the engine immediately upon oil pressure drop

If the oil pressure has dropped, immediately stop the engine. Otherwise, bearings etc. may seize. Inspect the oil system and components.

● Stop the engine immediately upon broken fan belt

If the fan belt has broken, immediately stop the engine. Otherwise, the engine will overheat. Also, coolant vapor will gush out from the reserve tank and radiator and you may get burned.

0 - 6

Caution Other considerations

SAFETY CAUTIONS

● Never alter or modify the engine

Altering or modifying the engine in any way will nullify the warranty. A modified engine may not only break but also lead to injury.

● Do not tamper with sealing

To help ensure trouble-free operation of the engine, the fuel control link has been sealed to achieve the correct fuel injection volume and engine speed. If the sealed setting is tampered with, the following will result and the correct functioning of the engine is no longer guaranteed.

・ Sliding and rotating parts will wear faster. ・ Various parts will seize/become damaged. ・ The engine will consume more fuel and oil. ・ The governor and fuel injection volume go out of

balance, reducing the engine performance.

● Daily and periodical inspection

Perform the daily and periodical inspection in accordance with the Operation and Maintenance Manual. Failure to observe the instructions of the manual may lead to many problems, and the various engine parts may eventually fail, possibly causing a serious accident.

● Running-in period

A brand new engine requires a running-in period of 50 hours, during which never put the engine under severe load. Otherwise, the service life of the engine will be reduced.

● Warming up the engine

Before starting work, warm up the engine by running it at low idle for 5 to 10 minutes. Warming up the engine will not only smoothen the operation of various engine parts but also help extend its service life. It also helps maximize the performance and achieve economical running of the engine. Do not warm up the engine longer than necessary. Doing so facilitates carbon deposit on the cylinders, possibly leading to poor combustion.

● Do not overload the engine

Do not continue to run the engine if it emits black smoke. Overloaded running of the engine (accompanied by black smoke) not only consumes excessive fuel but also facilitates carbon deposit and thus shortens the service life of the engine.

● Cooling down the engine

Before stopping the engine, cool it down (by running it at low idle) for 5 to 6 minutes. Stopping the engine suddenly while it is heavily loaded will result in some areas of the engine remaining extremely hot for a while, which is detrimental to the long service life of an engine. While the engine is being run at low idle for cooling, check the engine for any problems.

● Do not spill water onto the engine

Ensure that no rainwater etc. enters into the engine from the exhaust or inlet manifold, or via any other routes. Do not run the engine while at the same time washing it. Otherwise, cleaning fluid (water) may be sucked into the engine. If the engine is started with water trapped in the combustion chambers, water hammering will result, causing the engine to fail and possibly leading to a serious accident.

0 - 7

SAFETY CAUTIONS

● Air cleaner maintenance precautions

Wear of engine parts is accelerated largely by the dust contained in the intake air. Worn engine parts will lead to various problems such as increased oil consumption, reduced power and poor starting. Air cleaner is effective in removing dust in the intake air. When maintaining the air cleaner, observe the following precautions. ・ Never attempt to service the air cleaner while the

engine is running.

・ When removing the air cleaner, take care not to

allow the dust trapped on the air cleaner to enter into the inlet port.

・ If the engine is equipped with the dust indicator,

clean the air filter only when the indicator shows clogging. Unnecessary maintenance (removal/ installation of the filter element) runs the risk of allowing dust into the inlet port or damaging/ deforming the filter element.

● Observe safety rules at work sites

Whenever running or servicing the engine, always observe the relevant safety rules in place. If you are not in good shape, do not operate the engine. Consult the site supervisor. Poor physical conditions are accompanied by reduced attention. Do not operate the engine if you are not feeling well. Otherwise, you may incorrectly handle the engine and cause an accident. When working jointly with other people on the same task, use signals to coordinate actions involved.

● Wear appropriate clothes and protective gear

Whenever appropriate, including when using compressed air, wear protective gear such as helmet, face mask, safety shoes, dust mask, goggles and gloves. Working without appropriate protective gear may lead to serious injury.

● Use appropriate tools when carrying out service

When carrying out any service, use appropriate tools and in correct ways. Damaged tools should be replaced with new ones.

● Do not operate the starter continuously

Do not operate the starter more than 10 seconds per starting attempt. If the engine fails to start at the first attempt, wait for at least 30 seconds before trying again. Do not run the starter continuously if the engine will not start. Otherwise, the battery will go flat or the starter will seize.

● The battery switch must be kept ON while the engine is running

Do not turn off the battery switch while the engine is running. Otherwise, the instruments will become inoperative and the diode or transistor of the alternator may deteriorate.

● Precautions for road transport

When transporting the engine on public roads, the weight, width and height of the electric power generator should be taken into account while observing the relevant laws regarding road traffic and haulage, and vehicle restrictions and requirements.

0 - 8

GENERAL

1. Overview ····························································································· 1 - 2

1.1 Outline Drawing··················································································· 1 - 2

1.2 Fuel System Schematic ········································································ 1 - 4

1.3 Oil System Schematic··········································································· 1 - 4

1.4 Cooling System Schematic···································································· 1 - 5

1.5 Inlet / Exhaust System Schematic··························································· 1 - 5

1.6 Engine Serial Number··········································································· 1 - 6

1.7 Engine Model and Application Codes ······················································ 1 - 6

2. Specifications ······················································································ 1 - 7

3. Disassembly / Reassembly Notes······················································· 1 - 9

3.1 Disassembly ······················································································· 1 - 9

3.2 Reassembly························································································ 1 - 9

GENERAL

1. Overview

1.1 Outline Drawing S3L, S3L2

Thermostat

Alternator

Fan

Hanger

Oil filler

Exhaust manifold

Starter

Front end

V belt

Oil pan

Left-hand side

Rear end

Flywheel

Engine LH side view

Fuel injection nozzle

Fuel injection pump

Stop solenoid

Coolant drain plug

Water pump

Inlet cover

1 - 2

Rear end

Flywheel housing

Oil level gauge

Oil drain plug

Right-hand side

Engine RH side view

Front end

Crankshaft pulley

Oil filter

S4L, S4L2

Thermostat

Alternator

Fan

Hanger

GENERAL

Oil filler

Exhaust manifold

Starter

Fuel injection pump

Coolant drain plug

Front end

V belt

Stop solenoid

Oil pan

Left-hand side

Engine LH side view

Rear end

Flywheel

Fuel injection nozzle

Water pump

Inlet cover

Flywheel housing

Rear end

Oil filter

Oil drain plug

Right-hand side

Engine RH side view

Front end

Crankshaft pulley

Oil level gauge

1 - 3

GENERAL

1.2 Fuel System Schematic

To fuel tank

Fuel injection nozzle

Fuel pump

Fuel leak-off pipe

Fuel injection pipe

Fuel injection pump

From fuel tank

1.3 Oil System Schematic

Oil pressure switch

Oil main gallery

Oil filter

Relief valve

Fuel filter

Fuel system schematic

1 - 4

Oil pump

Oil drain plug

Oil strainer

Oil system schematic

1.4 Cooling System Schematic

Radiator

Water pump

GENERAL

Water bypass valve

Thermostat

Cooling fan

Cooling system schematic

1.5 Inlet / Exhaust System Schematic

Exhaust gas

Intake air

Air breather pipe (positive crankcase ventilation)

Intake air

(from air cleaner)

Inlet cover

Blow-by gas

Exhaust gas

(to muffler)

Exhaust manifold

Inlet / exhaust system schematic

1 - 5

GENERAL

1.6 Engine Serial Number

The engine serial number is stamped on the top face of the fuel injection pump bracket on the right-hand side of the cylinder block.

1.7 Engine Model and Application Codes

(1) The engine model code is embossed on the side

of the fuel injection pump mount on the right-hand side of the cylinder block.

(2) The engine model code consists of the following

alphanumerical digits.

Model coding

(Example) S

4 L 2

Type (2 = Type 2)

Series [L = bore size 78 mm (3.07 in.)]

No. of cylinders (4 = 4 cylinders)

S = Sagamihara Machinery Works

Engine serial number

Engine serial number location

Engine model code

1 - 6

2. Specifications

Engine Type S3L S3L2 S4L S4L2

Type Water-cooled; 4-stroke cycle; Diesel powered No. of cylinders 3 4 Combustion Swirl chamber type Valve mechanism Overhead valve type

Cylinder bore×stroke mm (in.)

Total displacement l (U.S. gal)

Compression ratio 22.0 : 1

General

Fuel Diesel fuel (JIS K2204 Special 1 - 3)

78×78.5

(3.07×3.09)

1.125

(0.297)

Firing order 1-3-2 1-3-4-2 Direction of rotation Counterclockwise when viewed from the flywheel end

Overall length mm (in.) 536 (21.10) 620 (24.40)

Dimensions

Overall width mm (in.) 433 (17.04) 433 (17.04) Overall height mm (in.) 572 (22.52) 572 (22.52)

Dry mass kg (lb) 135 (297.6) 155 (341.7)

Piston ring No. of rings

Va l ve

Inlet valve timing (hot engine)

Engine mounting 4 mounts

Engine main parts

Starting method Starter

Exhaust valve

Open BTDC 15° Close ABDC 41° Open BBDC 54° Close ATDC 10°

Type Bosch M

Manufacturer DENSO

Injection pump

Plunger

diameter

MS retard

mm (in.)

(crank angle)

Cam lift mm(in.) 15 (0.59) Governor Governing method Centrifugal fly-weight type

Type Throttle nozzle

Fuel system

Injection nozzle

Manufacturer Bosch Automotive Systems Corporation

Spray angle mm (in.) 15°

Opening

pressure

MPa

(kgf/cm

[psi]

)

Fuel filter Type Paper-element cartridge; Separate type w/ cock Lubrication method Forced circulation (pressure feed by trochoid pump)

Grade CD Class (API Classification) Engine oil

Capacity (entire engine)

l (U.S. gal)

3.7 (1.0) 4.2 (1.1) 5.4 (1.4) 6.0 (1.6)

Type Gear pump Oil pump

Oil system

Relief valve

Displacement

Type Piston valve

Opening

pressure

l (U.S. gal)

/min

MPa

(kgf/cm

)

[psi]

Oil filter Type Paper element (spin-on type)

78×92

(3.07×3.62)

1.318

(0.348)

78×78.5

(3.07×3.09)

1.500

(0.396)

Compression ring :2

Oil ring (w/expander) : 1

φ5.5 (0.21)

8°

14.22 to 15.00 (145 to 153) [2062 to 2176]

18 (4.8)

0.35±0.05 (3.6±0.5) [51±7]

GENERAL

78×92

(3.07×3.62)

1.758

(0.464)

1 - 7

GENERAL

Engine Type S3L S3L2 S4L S4L2

Cooling method Water-cooled, forced circulation Capacity (engine proper)

l (U.S. gal)

1.8 (0.5) 2.5 (0.7)

Type Centrifugal pump

Water pu m p

Displacement

l (U.S. gal)

/min

30 (8.0) up (@ 2000 min

Type Wax

Thermostat

Cooling system

Cooling fan

Opening temperature

℃ (°Ｆ)82±1.5 (179.6±2.7)

Type Pusher suction (PP fan)

No. of blades / OD

mm (in.)

5 / 340 (13.39), 6 / 320 (12.6), 6 / 340 (13.39),

6 / 360 (14.17), 6 / 380 (14.96), 7 / 380 (14.96)

Air cleaner Type Paper element

system

Voltage - Polarity

12 V - Θ ground, 24 V - Θ ground

Type M001T68281, M008T70471A, M008T81071A Manufacturer Mitsubishi Electric Corporation

Starter

Pinion engagement Output V-kW 12 V-1.7, 12 V-2.0, 24 V-3.2

Pinion shift (reduction)

No. of units 1 Reduction ratio

(pinion / ring gear)

13 / 120

Type 3-phase alternator w/ built-in IC regulator Manufacturer Mitsubishi Electric Corporation Output V-A 12-50, 24-25

Alternator

Speed at which rated voltage is

min

-1

5000 (@ 13.5 V, 47 A), 5000 (@ 27.0 V, 22 A)

generated Regulated voltage V

Electrical system

Glow plug

Type Sheathed plug

Rated voltage current

voltage

Stop solenoid

Insulation resistance

Stroke mm (in.) Working

ambient temperature

V-A

℃ (°Ｆ)

(30-second application)

12 V-ETR 12 V-ETS 24 V-ETR 24 V-ETS Operating

8 or less 10 to 15 16 or less 20 to 30

-40 to 120

(-40 to 248)

14.7±0.3 (12-50), 26.5±0.5 (24-25)

12 V plug 24 V plug

10.5-9.7 (25-second application)

100 MΩ or more at DC500 V

(at ordinary temperature and humidity)

13.5±0.5 (0.53±0.01)

-30 to 120

(-22 to 248)

-40 to 120

(-40 to 248)

-1

engine speed)

22.5-5

-30 to 120

(-22 to 248)

1 - 8

3. Disassembly / Reassembly Notes

This Service Manual specifies various procedures recommended by Mitsubishi Heavy Industries, Ltd. for servicing Mitsubishi diesel engines. These procedures include, wherever appropriate, required special tools and related safety precautions. The instructions provided in this manual, however, cannot fully guarantee safety as potential risks beyond ordinary imagination are hidden everywhere. When conduct any work, the following points should also be observed in addition to the instructions this manual.

3.1 Disassembly

(1) Use tools and equipment that are appropriate for

the work being carried out.

(2) Whenever necessary, use workbenches to work

on or sort parts out. Disassemble in accordance with the disassembly sequence given in the manual.

(3) As parts are disassembled, place them neatly in

the order of removal to eliminate missing parts on reassembly.

(4) During disassembly, note the assembly marks.

Remember to respect these marks on reassembly. Whenever appropriate, put additional assembly marks to aid reassembly.

(5) Before and during disassembly as well as during

subsequent washing, carefully check for any abnormality or other fault which otherwise may likely remain unnoticed afterwards.

(6) Pay sufficient attention to ensure safety,

especially when lifting or carrying heavy components and parts. (Use a jack or a chain block as required.)

3.2 Reassembly

(1) Parts excluding oil seals, O-rings, rubber sheets,

etc. should be thoroughly washed in wash oil and completely dried using compressed air.

(2) Use appropriate tools and equipment. (3) Use good-quality oil and grease. Never fail to

apply oil, grease, sealant and adhesive to the relevant locations if so instructed in the manual.

GENERAL

1 - 9

GENERAL

(4) Tighten hardware to the specified torque, if

provided in the manual. Be sure to use a torque wrench.

(5) Gaskets, packing and O-rings should be replaced

with new parts unless specified otherwise.

1 - 10

SERVICE STANDARDS

1. Service Standards Table····································································· 1 -12

2. Tightening Torques Table···································································· 1 -16

2.1 Major Bolts and Nuts ··········································································· 1 -16

2.2 Standard Bolts and Nuts······································································· 1 -17

2.3 Standard Eyebolts··············································································· 1 -17

2.4 Standard Union Nuts ··········································································· 1 -18

2.5 Taper Bolts ························································································ 1 -18

3. Sealants List······················································································· 1 -19

SERVICE STANDARDS

1. Service Standards Table

Unit: mm (in.)

Item

Group

Max. speed (based on the rated speed)

Min. speed

Compression pressure (at 290 min

-1

)

Rated speed

pressure

Engine oil

Low idle speed

Inlet valve

Engine general

Valve timing [with 2 mm (0.079 in.) clearance on the valve side; cold engine]

open Inlet valve closed Exhaust valve open Exhaust valve closed

Valve clearance

Inlet valve 0.25 (0.01) Exhaust valve 0.25 (0.01)

Fuel injection timing (BTDC)

Rocker arm inner diameter

Rocker shaft diameter

Rocker

Arm-to-shaft clearance (oil clearance)

Inlet

Valve stem diameter

Exhaust

Valve guide inner diameter

Va l ve

Valve stem-to-guide

Engine main parts

clearance

Inlet

Exhaust

Inlet

Exhaust

Valve seat angle

Valve head sinkage 0

Valve seat width

Valve head margin

Valve seat and valve

Installed valve guide protrusion

Nominal

value

φ19

(0.749)

φ19

(0.749)

φ6.6

(0.260)

φ6.6

(0.260)

φ6.6

(0.260)

φ6.6

(0.260)

1.6

(0.063)

1.5

(0.0591)

(0.394)

Standard value Limit Remarks

+30

2700

1000±25 min

-10

min-1

-1

2.9 MPa (30 kgf/cm [421 psi] or above

)

2.6 MPa

(27 kgf/cm

[377 psi]

or less

Both oil and coolant

)

temperatures at 20 to

30℃ (68 to 86°Ｆ)

0.29 to 0.39 MPa (3.0 to 4.0 kgf/cm2) [42.07 to 56.57 psi]

0.098 MPa

(1.0 kgf/cm

)

Oil temperature at

60 to 95℃ (140 to 194°Ｆ)

[14.22 psi]

BTDC 15

The theoretical valve

ABDC 41

timing figures for inspection vary from

BBDC 54

the actual valve timing.

ATD C 10

Cold engine

17°

18.910 to 18.930

(0.7450 to 0.7458)

18.880 to 18.898

(0.7438 to 0.7445)

0.012 to 0.050 (0.0004

to 0.0019)

6.565 to 6.580

(0.2586 to 0.2592)

6.530 to 6.550

(0.2572 to 0.2580)

6.600 to 6.615

(0.2600 to 0.2606)

6.600 to 6.615

(0.2600 to 0.2606)

0.020 to 0.050

(0.0008 to 0.0020)

0.050 to 0.085

(0.0020 to 0.0033)

0.25 to 0.75

(0.0098 to 0.0295)

1.30 to 1.80

(0.0512 to 0.0709)

1.35 to 1.65

(0.0531 to 0.0650)

9.5 to 10.5

(0.3743 to 0.4137)

―

0.200

(0.0079)

6.500

(0.256)

6.500

(0.256)

0.100

(0.004)

0.150

(0.006)

Valve seat width

1.5

(0.0591)

2.5

(0.0985)

0.5

(0.0197)

―

Replace rocker arm.

Replace valve and valve guide.

Val v e seat

Valve head

angle

sinka

Va l ve head

mar

1 - 12

SERVICE STANDARDS

Unit: mm (in.)

Group

Item

Nominal

value

Standard value Limit Remarks

Free length 47 (1.85) 46 (1.81)

θ

Squareness

39.0 (1.536)/ 131 to 145

(13.3 to 14.7)

[29 to 33]

Valve spring

Installed length / load

mm (in.)/N (kgf) [lbf]

Push rod Bend

Cylinder head

Cylinder block top face distortion

Cylinder

Bore

Bottom face distortion

φ78

(3.07)

78.0

Out of roundness

STD

Diameter

0.25 OS

0.50 OS

Max. allowable variation in weight among pistons on the

Piston

same engine

Engine main parts

Piston pin diameter

Piston pin-to-boss clearance

Piston-to-cylinder clearance

No. 1 ring Piston ring-to-groove

No. 2 ring clearance

Oil ring

Piston ring

Piston ring gap

No. 1 ring

No. 2 ring

78.00 (3.07)

78.25 (3.08)

78.50 (3.09)

φ23

(0.9062)

±5 g (0.177 oz)

22.944 to 23.000

(0.9039 to 0.9062)

(0.0002 to 0.0007)

(0.0014 to 0.0034)

(0.0035 to 0.0043)

(0.0028 to 0.0043)

(0.0012 to 0.0028)

Oil ring

Bend and twist

rod

End play

Connecting

θ=2.0° Δ=0.2

(0.0079)

Lf=47

(1.8518)

30.1 (1.185)/ 279 to 309

(28.5 to 31.5)

[63 to 69]

―

0.05 (0.002) or less

+0.03 0

(3.07

+0.0012 0

±0.01 (0.0004)

or less

77.93 to 77.95

(3.070 to 3.071)

78.18 to 78.20

(3.080 to 3.081)

78.43 to 78.45

(3.090 to 3.090)

or less

0.006 to 0.018

0.035 to 0.086

0.09 to 0.11

0.07 to 0.11

0.03 to 0.07

0.15 to 0.30

(0.006 to 0.012)

0.15 to 0.35

(0.006 to 0.014)

0.20 to 0.40

(0.008 to 0.016)

0.05/100

(0.002/3.940)

0.10 to 0.35

(0.004 to 0.014)

△= 0.5

(0.0197) across the entire length

0.3 (0.011) Replace

0.10 (0.004) Correct

78.2 (3.08) Bore or replace

)

(0.006/3.940)

-15 %

―

77.80

(3.065)

78.05

(3.075)

78.30

(3.085)

―

0.050

(0.002)

0.300

(0.012)

0.300

(0.012)

0.200

(0.008)

0.200

(0.008)

1.50

(0.06)

0.15/100

0.50

(0.020)

Bore or replace

Replace piston ring

Replace

Replace connecting rod

1 - 13

SERVICE STANDARDS

Unit: mm (in.)

Item

Group

Crank journal diameter (STD)

Crank pin diameter

Nominal

value

φ52

(2.0488)

φ48

(1.8912)

Standard value Limit Remarks

51.985 to 52.000

(2.0482 to 2.0488)

47.950 to 47.964

(1.8892 to 1.8897)

Crankshaft bend 0.025 (0.0010)

Main bearings oil clearance

Crankshaft

Connecting rod bearings oil clearance

End play

0.030 to 0.077

(0.0012 to 0.0030)

0.025 to 0.072

(0.0010 to 0.0028)

0.050 to 0.175

(0.0020 to 0.0069) Crank gear to idler gear Idler gear to valve camshaft gear Idler gear to pump camshaft gear Valve camshaft gear to PTO gear Pump camshaft gear to oil

Timing gear backlash

Engine main parts

pump gear

Camshaft cam height (including lobe)

Fuel injection pump shaft cam height (including lobe)

Flywheel flatness

0.040 to 0.120

(0.0015 to 0.0047)

0.080 to 0.190

(0.0032 to 0.0075)

0.070 to 0.200

(0.0028 to 0.0079)

(1.4073±0.0394)

(1.7336±0.0039)

0.150 (0.0059)

Tappet-to-guide clearance

Camshaft journal-to-bushing clearance

Idler gear-to-shaft clearance

0.050 to 0.125

(0.0020 to 0.0049)

0.020 to 0.070

(0.0008 to 0.0028)

35.720±0.1

44±0.1

or less

―

0.050 (0.0020)

0.100

(0.0040)

0.150

(0.0059)

0.500

(0.0197)

0.300

(0.0120)

34.720

(1.3679)

(1.6942)

0.500

(0.0197)

0.150

(0.0059)

0.150

(0.0059)

0.200

(0.0079)

Correct or replace Replace main bearings Replace connecting rod bearings Replace flanged No. 3 main bearings

Replace

Correct

Replace tappet

Replace bushing

Replace idler gear or idler shaft

Injection valve opening pressure

MPa (kgf/cm

Fuel system

Relief valve opening pressure

MPa (kgf/cm

Oil pressure switch closing pressure

Oil system

MPa (kgf/cm

Valve opening temperature

Thermostat

8 mm (0.32 in.) valve lift temperature

Thermoswitch

Fan belt deflection {when pressed

Cooling system

with a force of approx. 98 N (10

At 111±3.5℃ (231.8±6.3°Ｆ)

kgf) [22] between crankshaft and alternator pulleys and between crankshaft and fan pulleys}

1 - 14

) [psi]

14.22 (145)

[2062]

14.22 to 15.00 (145 to 153)

[2062 to 2176]

0.35±0.05 (3.5±0.5) [50±7.2]

0.05±0.01 (0.5±0.1)

[7±1.4]

82±1.5℃

(179.6±2.7°Ｆ)

95℃

(203°Ｆ)

30 MΩ

[when dipped in oil of

105℃ (221°Ｆ)]

10 to 12

(0.4 to 0.5)

―

Adjust with washer

Replace

SERVICE STANDARDS

(

)

Unit: mm (in.)

Item

Group

Paper-element type air

aus

cleaner

stems

Inlet / exhaust manifold

an e

mounting face distortion

Pinion gap

No-load characteristics

Brush length

Starter

Brush spring load

Commutator radial runout

Commutator diameter

Electrical system

Mica undercutting depth IC regulator controlled voltage

[at 20℃ (68°Ｆ)]

2500 min or

-1

cs st

less

aracter

Alternator

5000

when hot

-1

min

utput c

or less

Nominal

value

Standard value Limit Remarks

Clean every 100 hours

―

0.5 to 2.0

(0.02 to 0.08)

Term inal voltage

Current

Rotation speed

M001T68281 M008T70471A M008T81071A

11 V 11 V 23 V

110 A

or less

2400 min

16.5

(0.65)

130 A

or less

3600

-1

min-1

80 A

or less

3000

min-1

18.0

(0.71)

17.5 to

23.7 N

(1.78 to

2.41 kgf)

[3.9 to 5.3

29.4 to 39.2 N

(3.0 to 4.0 kgf)

[6.6 to 8.8 lbf]

lbf]

0.05

(0.002)

29.4

(1.16)

0.03

(0.001)

32.0

(1.26)

0.5

(0.02)

A007T02071C A007TA8571

Term inal voltage

13.5 V 27.0 V

14.7±0.3 V 28.5±0.5 V

Current 32 A or above 18 A or above

Term inal voltage

13.5 V 27.0 V

Current 47 A or above 22 A or above

Replace every

500 hours

0.15 (0.006) or less

―

― ―

M001T68281

10.0

(0.39)

6.90 N

(0.70 kgf)

[1.6 lbf]

0.10

(0.004)

28.8

(1.13)

0.2

(0.01)

―

M008T70471A,

M008T81071A

11.0

(0.43)

13.7 N

(1.40 kgf)

[3.1 lbf]

31.4

(1.24)

Grind or replace

Adjust with packing

Inspect

Replace

Correct or replace

Replace

Correct

Brush length 18.5 (0.73) 5.0 (0.20) Replace Clearance between stop solenoid plunger and rack Glow plug resistance 0.55 Ω

0.15 to 0.20

(0.006 to 0.008)

Correct

―

Replace

1 - 15

SERVICE STANDARDS

2. Tightening Torques Table

2.1 Major Bolts and Nuts

Thread

Fittings

Engine proper

Cylinder head bolt

Rocker cover bolt

Rocker shaft bracket bolt

Thrust plate bolt

Main bearing cap bolt

Connecting rod cap nut

Flywheel bolt

Crankshaft pulley nut

Rear plate mounting bolt

Fuel system

Hollow screw (fuel injection pump) Delivery valve holder (fuel injection pump) Air bleeder plug (fuel injection pump)

Nozzle retaining nut

Nozzle holder IDI

Fuel injection pipe nut

Fuel leak-off pipe nut

Sliding sleeve shaft

Torque spring set special nut

Oil system

Oil relief valve

Oil pan drain plug

Oil filter

Oil pressure switch PT1/8 7.85 to 11.8 0.8 to 1.2 5.8 to 8.7

Oil pan mounting bolt

Oil strainer nut

Cooling system

Thermoswitch

Thermostat cover bolt

Thermo case bolt

Inlet and exhaust systems

Inlet cover bolt

Exhaust manifold bolt

Electrical system

Starter terminal B

Stop solenoid fixing nut

Stop solenoid blind plug

Glow plug

IDI

diameter

×pitch

(mm)

M10×1.75

M8×1.25 M8×1.25 M8×1.25

M10×1.25

M9×1.0

M12×1.25

M18×1.5

M12×1.25

M14×1.5

―

M8×1.25

M16×0.75

M20×1.5 M12×1.5 M12×1.5

M10×1.25

M12×1.0

M22×1.5 M14×1.5 M20×1.5

M8×1.25 M16×1.5

M16×1.5 M8×1.25 M16×1.5

M8×1.25 M8×1.25

M8×1.25 M30×1.5 M30×1.5

M10×1.25

N･m kgf･m lbf･ft

83.4 to 93.2 8.5 to 9.5 61.5 to 68.7

9.81 to 12.7 1.0 to 1.3 7.2 to 9.4

9.81 to 19.6 1.0 to 2.0 7.2 to 14.5

9.8 to 11.8 1.0 to 1.2 7.2 to 8.7

49.0 to 53.9 5.0 to 5.5 36.2 to 39.8

32.4 to 37.3 3.3 to 3.8 23.9 to 27.5

127 to 137 13.0 to 14.0 94.0 to 101.3

147 to 196 15.0 to 20.0 108.5 to 144.6

53.9 to 73.5 5.5 to 7.5 39.8 to 54.2 Equivalent to 7T

19.6 to 24.5 2.0 to 2.5 14.5 to 18.1

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

9.81 to 13.7 1.0 to 1.4 7.2 to 10.1

34.3 to 39.2 3.5 to 4.0 25.3 to 28.9

49.0 to 58.8 5.0 to 6.0 36.2 to 43.4

24.5 to 34.3 2.5 to 3.5 18.1 to 25.3

20.6 to 24.5 2.1 to 2.5 15.2 to 18.1

29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

14.7 to 24.5 1.5 to 2.5 10.8 to 18.1

44.1 to 53.9 4.5 to 5.5 32.5 to 39.8

34.3 to 44.1 3.5 to 4.5 25.3 to 32.5

10.8 to 12.7 1.1 to 1.3 8.0 to 9.4

9.80 to 12.7 1.0 to 1.3 7.2 to 9.4 Equivalent to 4T

24.5 to 29.4 2.5 to 3.0 18.1 to 21.7

18.6 to 26.5 1.9 to 2.7 13.7 to 19.6

16 to 20 1.6 to 2.0 11.8 to 14.8

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

9.81 to 11.8 1.0 to 1.2 7.2 to 8.7

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

14.7 to 19.6 1.5 to 2.0 10.8 to 14.5

Tightening torque

Remarks

1 - 16

2.2 Standard Bolts and Nuts

Thread

diameter

×pitch (mm)

N･m kgf･m lbf･ft N･m kgf･m lbf･ft

SERVICE STANDARDS

4T 7T

M6×1.0

M8×1.25 M10×1.25 M12×1.25

2.94 to 4.90 0.3 to 0.5 2.2 to 3.6 7.85 to 9.80 0.8 to 1.0 5.8 to 7.2

9.80 to 12.7 1.0 to 1.3 7.2 to 9.4 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

17.7 to 24.5 1.8 to 2.5 0.7 to 1.0 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

29.4 to 41.2 3.0 to 4.2 21.7 to 30.4 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

Note: (a) The above table shows the tightening torques for standard bolts and nuts. (b) The values in the table apply when tightened together with spring washers.

(d) Unless otherwise specified, standard bolts and nuts should be tightened to the torques in the table. (e) Do not apply oil to threaded portions (Tighten under dry conditions).

2.3 Standard Eyebolts

Thread diameter

×pitch (mm)

M8×1.25 8±1 0.8±0.1 M10×1.25 15±2 1.5±0.2 M12×1.25 25±3 2.5±0.3

M14×1.5 34±4 3.5±0.4

M16×1.5 44±5 4.5±0.5

M18×1.5 74±5 7.5±0.5

M20×1.5 98±10 10.0±1.0

M24×1.5 147±15 15.0±1.5

M27×1.5 226±20 23.0±2.0

(Dry conditions)

N･m kgf･m lbf･ft

Property class

5.9±0.7

11.1±1.5

18.4±2.2

25.1±3.0

32.5±3.7

54.6±3.7

72.3±7.4

108.4±10.8

166.7±14.8

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