This is the service manual for the Mitsubishi S4K and S6K diesel engines, including the turbocharged S4K-T and S6K-T, publication 99499-10190 in English. These four and six cylinder engines are widely used in excavators and other heavy equipment, and this 148 page book is written for workshop level repair rather than routine operation.Mechanics can use it to work through testing and adjusting, valve clearance and injection timing, accessory removal, and full engine teardown covering cylinder heads, timing gears, camshaft, pistons and connecting rods. It also details the lubrication, cooling, fuel and electrical systems, plus the air inlet and exhaust.The maintenance standards and tightening torque sections give the wear limits, clearances and torque values you need for a correct rebuild, and a maintenance chart lists the service intervals. It is delivered as a downloadable PDF you can read on any device or print at the bench.
What's Inside This Mitsubishi S4K, S6K Manual
| System | Pages | Key Topics |
|---|---|---|
| Main Page | 1-4 | Introduction, How to Use This Manual, Fuel Injection Pump, Governor, And Turbocharger Coverage, Manual Sections and Contents in Index, References for Operation, Parts |
| - General Information | 5-12 | General (S4K-T Diesel Engine - External Views, S6K-T Diesel Engine - External Views, Engine Serial Number Location, Engine Model and Application Codes), Specifications |
| - Maintenance Standards | 13-23 | Maintenance Standards, Important Bolts and Nuts, Standard Bolts, Standard Stud Bolts, Standard Plugs, Sealants |
| - Special Tools | 24-27 | - |
| - General Instructions | 28-30 | S4K-T Diesel Engine - External Views, S6K-T Diesel Engine - External Views, Engine Serial Number Location, Engine Model and Application Codes |
| - Testing and Adjusting | 31-42 | Adjustments (Valve Clearance Inspection and Adjustment, Fuel System Priming, Fuel Injection Timing Inspection and Adjustment, No-Load Minimum Speed and Maximum Speed Setting Inspection and Adjustment, Fan Drive Belt Inspection and Adjustment) |
| - Engine Accessory Removal and Installation | 43-49 | Preparatory Steps, Engine Accessory Removal, Engine Accessory Installation |
| - Engine Proper | 50-95 | Cylinder Heads and Valve Mechanism (Disassembly, Repair, Reassembly), Flywheel, Timing Gears and Camshaft (Disassembly, Pistons, Connecting Rods |
| - Air Inlet and Exhaust System | 96-98 | Paper-Element Type Air Cleaner (Disassembly and Inspection), Exhaust Manifold (Inspection) |
| - Lubrication System | 99-107 | Oil Pump (Disassembly, Repair, Reassembly), Oil Filter (Disassembly and Inspection), Pressure Relief Valve (Inspection), Relief Valve (Inspection) |
| - Cooling System | 108-114 | Water Pump (Disassembly, Inspection, Reassembly), Thermostat (Inspection), Radiator, Fan and Fan Belt (Inspection) |
| - Fuel System | 115-119 | Fuel Filter (Disassembly and Inspection), Fuel Injection Nozzles (Disassembly, Repair, Reassembly) |
| - Electrical System | 120-133 | Starter (Disassembly, Repair, Reassembly), Alternator (Disassembly, Inspection, Heater Relay (Inspection), Air Heater (Inspection) |
| - Workshop Theory | 134-137 | Heater Relay, Air Heater |
| -Maintenance Chart | 138-148 | Every 50 Service Hours, Every 250 Service Hours, Every 500 Service Hours, Every 1000 Service Hours, Every 2 Years, As Required |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Cylinder head bolts tightening torque | 12±0.5 kgf·m (87±3.6 lbf·ft) [118±5 N·m] | p. 21 |
| Fuel filter replacement interval | every 500 hours | p. 116 |
| Fuel filter element tightening torque | 39±5 N·m (4±0.5 kgf·m) | p. 117 |
| Fuel injection nozzle valve opening pressure (Nominal Value) | 220 (3128) [21.6] kgf/cm² (psi) [MPa] | p. 15 |
| Fuel injection nozzle spray angle | 155° | p. 15 |
| Air cleaner element replacement interval | every 1000 hours | p. 97 |
| Air cleaner clamp tightening torque | 0.5±0.1 kgf·m (3.6±0.7 lbf·ft) [4.9±1.0 N·m] | p. 97 |
| Thermostat valve opening temperature | 71±2 (159.8±3.6) °C (°F) | p. 15 |
| Thermostat temperature at which valve lifts more than 10 mm (0.4 in.) | 85°C (185°F) | p. 15 |
| Fan drive belt tension (deflection) | 12 (0.473) mm (in.), approx. | p. 14 |
| S4K | ||
| Water pump delivery capacity at 1800 rpm | 130 (34.3) liter (U.S. gal)/min | p. 15 |
| S4K-T | ||
| Water pump delivery capacity at 1800 rpm | 145 (38.3) liter (U.S. gal)/min | p. 15 |
Mitsubishi S4K, S6K Common Problems This Manual Covers
Hard starting, smoke, low power
Hard starting, rough running or white and black smoke on these engines usually trace to the fuel system: worn injectors, air in the lines, or clogged filters. The fuel system section covers the fuel filter and injection nozzle service.
Manual Section: Fuel System p. 115Overheating and temperature swings
Overheating or unstable running temperature is a recurring service need, often from a tired water pump, stuck thermostat, or radiator restriction. The cooling system section covers the water pump, thermostat, radiator and fan belt inspection.
Manual Section: Cooling System p. 108Low oil pressure or knocking
Low oil pressure, knocking or abnormal noise signals lubrication trouble such as a worn oil pump, relief valve fault, or bearing wear. The lubrication system section covers oil pump disassembly, repair and the pressure relief valve inspection.
Manual Section: Lubrication System p. 99Blow-by and high oil consumption
Excessive crankcase blow-by or oil use points to worn rings, cylinders or valve seals and calls for teardown inspection. The engine proper section covers cylinder head, piston, connecting rod and timing gear disassembly, repair and reassembly.
Manual Section: Engine Proper p. 50Rough idle and out of spec adjustments
Rough idle, poor throttle response or a hunting speed often come from valve clearance, injection timing or speed settings that have drifted. The testing and adjusting section covers valve clearance, fuel injection timing and idle and maximum speed setting.
Manual Section: Testing and Adjusting p. 31Charging and starting problems
No crank, weak cranking or a dead battery can trace to the starter, alternator or the cold start air heater on these diesels. The electrical system section covers starter, alternator, heater relay and air heater service.
Manual Section: Electrical System p. 120Frequently Asked Questions
Which engines does this manual cover?
It covers the Mitsubishi S4K and S6K diesel engines, including the turbocharged S4K-T and S6K-T variants used in excavators and other machines. It is publication 99499-10190.
What are the cylinder head bolt torque values?
The maintenance standards section lists the tightening torques for the cylinder head, main bearing caps, connecting rod caps and other important bolts, so you can reassemble the engine to spec. p. 13
Does it cover valve clearance and injection timing?
Yes. The testing and adjusting section walks through valve clearance inspection and adjustment, fuel system priming, injection timing, and the idle and maximum speed settings. p. 31
Does it include full engine overhaul procedures?
Yes. The engine proper section covers disassembly, repair and reassembly of the cylinder heads and valve mechanism, flywheel, timing gears, camshaft, pistons and connecting rods for a complete rebuild. p. 50
What do I get after purchasing this Mitsubishi S4K, S6K manual?
Immediate download of the complete 148-page searchable Service Manual. Open it on any device, from the laptop at your desk to a phone in the field.
Is this Mitsubishi S4K, S6K Service Manual printable?
Yes. The PDF carries no DRM restrictions, so you can print any page or section you need on any standard shop printer.
Can I find hydraulic circuit diagrams in this Mitsubishi S4K, S6K manual?
No, this Mitsubishi S4K, S6K Service Manual focuses on the engine base and does not include hydraulic system diagrams for the excavator.
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