CAT / Mitsubishi S4S Diesel Engine Service Manual – PDF DOWNLOAD
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Factory CAT Lift Trucks S4S Diesel Engine Service Manual covering serial 194618-up for DP20N – DP35N and P4000 – P7000 models. Includes detailed engine disassembly, inspection, and reassembly procedures with full torque data, fuel-lubrication-cooling diagrams, and specifications—essential for complete overhaul of the Mitsubishi 3.331 L S4S engine.
Description
CAT / Mitsubishi S4S Diesel Engine Service Manual DP25N P5000 Forklift Overhaul & Repair – PDF DOWNLOAD
Description
Overview
This official service manual (Pub. No. 99729-88100) provides comprehensive maintenance, inspection, and repair data for the Mitsubishi S4S Diesel Engine used in CAT Lift Trucks (DP and P series). It is an indispensable guide for technicians performing detailed engine service, featuring torque tables, flow diagrams, and adjustment standards based on JIS specifications
📑 Table of Contents
Introduction
Purpose of the manual
How to use this manual
Terms and notations used
Methods of presentation and safety symbols
Group 1 – General
External views (Left and Right engine sides)
System flow diagrams
Fuel System Flow Diagram
Lubrication System Flow Diagram
Cooling System Flow Diagram
Inlet and Exhaust System Flow Diagram
Engine serial number location
Main specifications (Engine type, displacement, bore, stroke, compression ratio, firing order, rotation, weight, etc.)
Valve timing and fuel system overview
Lubrication, cooling, and electrical systems
Tips on disassembling and reassembling the engine
Group 2 – Service Data
Maintenance service data
General maintenance items
Basic engine data (clearances, tolerances, fits)
Fuel system service standards
Lubrication system service data
Cooling system service data
Tightening torque table (Standard and important bolts/nuts)
Group 3 – Service Tools
List of special tools required for disassembly, inspection, and reassembly
Tool usage illustrations and reference codes
Group 4 – Determination of Overhaul
Compression pressure measurement
Inspection criteria and overhaul timing
Evaluation of wear limits and performance thresholds
Group 5–7 – Basic Engine
Disassembly Procedures
Cylinder head removal
Piston, connecting rod, crankshaft disassembly
Camshaft and timing gear removal
Inspection Procedures
Cylinder block, head, crankshaft, and valve mechanism checks
Reassembly Procedures
Bearing installation, sealant application, torque sequence
Final assembly adjustment and clearance verification
Group 8 – Fuel System
Fuel injection pump service (Bosch VE type)
Fuel injection nozzle (Denso type) – inspection and calibration
Governor and fuel filter servicing
Air bleeding and timing procedures
Group 9 – Lubrication System
Oil pump (Trochoid type) inspection
Relief valve specifications
Oil passage cleaning and testing
Filter replacement procedure
Group 10 – Cooling System
Water pump (Volute type) service
Thermostat and cooling fan specifications
Coolant capacity, flow diagram, and bleeding procedure
Group 11 – Inlet & Exhaust System
Inlet and exhaust manifold removal
Gasket replacement and leak checks
Exhaust emission maintenance
Group 12 – Electrical System
Starter and alternator (12V 50A) servicing
Glow plug and stop solenoid operation check
Circuit testing and resistance values
Group 13 – Adjustment & Operation
Idle speed and timing adjustments
Governor and fuel control setup
Break-in operation and test running
Performance check according to JIS standard
⚙️ Engine Specifications
| Parameter | Value |
|---|---|
| Engine Model | Mitsubishi S4S |
| Type | Water-cooled, 4-cycle diesel |
| Cylinders | 4 in-line |
| Displacement | 3.331 L (203 cu in.) |
| Bore × Stroke | 94 × 120 mm (3.70 × 4.72 in.) |
| Compression Ratio | 22.0 : 1 |
| Firing Order | 1 – 3 – 4 – 2 |
| Compression Pressure | 3.2 MPa (33 kgf/cm²) [469 psi] or more 465682349-Service-Manual-Engine… |
| Lubricating Oil Pressure (1500 rpm) | 0.3 – 0.5 MPa [43 – 71 psi] |
| Oil Capacity | ≈ 10 L (2.64 US gal.) |
| Coolant Capacity | ≈ 5.5 L (1.45 US gal.) |
| Starter Output | 12 V – 2.2 kW |
| Alternator Output | 12 V – 50 A |
🔩 Major Tightening Torques (Highlights)
| Component | Torque (N·m) | Notes |
|---|---|---|
| Cylinder Head Bolt | 118 ± 5 | [Wet] – Apply engine oil |
| Connecting Rod Cap | 54 ± 5 | Standard torque range |
| Main Bearing Cap | 103 ± 5 | Critical bearing fit |
| Flywheel Bolt | 83 ± 5 | Use Loctite if reused |
| Fuel Nozzle Holder | 58.8 ± 5.9 | Critical sealing pressure |
| Thermostat Cover | 18.5 ± 1.5 | Cooling system service |
🔧 Key Highlights
Complete factory procedures for engine disassembly, inspection, and reassembly
Detailed specifications for fuel, lubrication, and cooling systems
Torque tables, service limits, and overhaul criteria included
Ideal for CAT and Mitsubishi technicians servicing DP/P-series forklifts
Covers 194618-up S4S engine serial range
📂 File Details
| Detail | Specification |
|---|---|
| Manual Name | Service Manual – Mitsubishi S4S Diesel Engine |
| Publication Number | 99729-88100 |
| Models Covered | DP20N, DP25N, DP30N, DP35N, P4000, P5000, P6000, P7000 |
| Engine Serial No. | 194618-up |
| PDF Quality | OEM factory scan – searchable text + diagrams |
| Pages | ≈ 190 pages |
| Publisher | Mitsubishi Caterpillar Forklift Co., Ltd. |
| Language | English |
