Mitsubishi S6R MPTK Manual Collection

SERVICE MANUAL MITSUBISHI DIESEL ENGINE S&A,S&A2 May 2003 !!!T!Ms"!tt!.

INTRODUCTION This service manual describes the specifications of the Mitsubishi Diesel Engine and the maintenance and adjustment procedures. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before reassembling, inspecting, repairing or reassembling the engine. The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual. Pub.No.99419-12110

How 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. A short 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 service 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. (0) Inspections to be conducted during disassembly are indicated in a box I I 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: (5) The following marks are used in this manual to emphasize important safety cautions. & DANGER &WARNING & CAUTION CAUTION Note: · ... Indicates a highly hazardous situation which, if not avoided, can result in death or serious injury. · . . . Indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. · ... Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. · . . . Indicates a potentially hazardous situation which, if not avoided, can result in property damage. · . . . 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.

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/cm' 'Torque: 1 N·m = 0.10197 kgf-rn 'Force: 1 N=0.10197kgf 'Horsepower: 1 kW= 1.341 HP= 1.3596PS · Meter of mercury: 1 kPa = 0.7 cmHg · Meter of water: 1 kPa = 10.197 cmH 2 0 (cmAq) · Rotational speed: 1 min" = 1 rpm

GENERAL CONTENTS- Group No. Group Name Page 0 Safety Cautions 0-1 General 1-1 Maintenance Standards 1 -13 1 Basic and Special Tools 1 -33 Overhaul Instructions 1 -41 Preparation for Disassembly 1 -45 Disassembly 2-1 2 Engine Main Parts Inspection and Repair 2 -17 Reassembly 2 -47 Removal 3-1 .- 3 Fuel System Disassembly, Inspection and Reassembly 3 -11 Installation 3 -27 Removal 4-1 4 Lubrication System Disassembly, Inspection and Reassembly 4-5 Installation 4 -17 Removal 5-1 5 Cooling System Disassembly, Inspection and Reassembly 5-5 Installation 5 -19 Removal 6-1 6 Inlet and Exhaust Systems Disassembly, Inspection and Reassembly 6-5 Installation 6 -11 Removal 7-1 7 Electrical System Disassembly, Inspection and Reassembly 7-3 Installation 7 -17 Removal 8-1 8 Air Starter System Disassembly, Inspection and Reassembly 8-7 Installation 8 -17 Engine Inspection and Adjustment 9-1 Inspection, Adjustment, 9 Break-In Operation And Break-In Operation 9 -21 Performance Tests Performance Tests 9 -22 10 Others Disassembly and Reassembly of General Parts 10- 1 I Supplement I Engine inspection record sheet

SAFETY CAUTIONS WARNING Danger of Fire and CAUTION Cautions Regarding Engine Explosion · · · · · · · · · · · · · · .. 0-2 Oil and LLC · · · · · · · · · · · · .. 0-5 • Keep flames away· · · ...... .. 0-2 • Use only specified fuel, engine oil and • Keep surrounding area neat and clean 0-2 • coolant· ·.···.· ........... .. 0-5 • Do not open crankcase until engine cools 0-2 • Handle LLC (long life coolant) carefully· 0-5 • Check for fuel and oil leaks· 0-2 • Properly disposed of drained oil and coolant 0-5 • Use shatterproof light· 0-2 • Do not short-circuit electrical wires· 0-2 CAUTION Cautions Regarding Battery · · · · · · · · · · · · · · · · .. 0-6 • Keep fire extinguishers and first aid kit nearby· . 0-2 • Handle battery carefully .................. .. 0-6 • If engine overheats, conduct heating operation before stopping engine· .................. .. 0-6 • If engine stops due to abnormality, exercise caution when restarting 0-6 • If oil pressure drops, stop engine immediately 0-6 • If fan belt breaks-stop engine immediately····· 0-6 Other Cautions · · · · · · · · · .. 0-7 WARNING Danger of Entanglement· .. 0-3 • Install protective covers on rotating parts· .. .. 0-3 CAUTION • Check surrounding area for safety before starting engine· 0-3 • Stay clear of rotating parts while engine is in operation· ................................. 0-3 • Lock out and tag out ........................ 0-3 • Always stop engine before inspection and maintenance 0-3 • Always return turning tools to original position after use ............................... .. 0-3 CAUTION Response to Abnormalities 0-6 WARNING Danger of Burns· ······· .. 0-4 • Do not touch engine in operation or immediately after operation ............... .. 0-4 • Open radiator filler cap carefully· 0-4 • Add coolant after coolant temperature drops sufficiently· ................................ 0-4 • Do not remove heat shields· 0-4 WARNING Beware of Exhaust Gas Poisoning · · · · · · · · · · · · · · .. 0-4 • Operate engine in well-ventilated area 0-4 WARNING Danger of Hearing Problems· 0-4 • Wear ear plugs 0-4 WARNING Beware of Falling Equipment 0-5 • Lift engine carefully · · · · · · · · · · · · · · · · · · · · · · · · · 0-5 • Do not climb onto engine · · · · · · · · · · · · · · · · · · · · 0-5 • Watch footing when conducting maintenance .. 0-5 • Never modify engine· .................... .. 0-7 • Never break seals .......................... 0-7 • Always perform specified pre-operation inspections and periodic inspections· 0-7 • Break in new engine· 0-7 • Conduct warm-up operation 0-7 • Never operate engine under overload condition· 0-7 • Conduct cooling operation before stopping engine·············· ·········0-7 • Do not splash water on engine· 0-7 • Conduct proper maintenance of air cleaner 0-8 • Observe safety rules at workplace· ..... ·.· 0-8 • Wear proper work clothes and protective gear· ............................ 0-8 • Use appropriate tools for maintenance work 0-8 • Do not operate starter for prolonged time 0-8 • Do not turn off battery switch while engine is operating· · 0-8 • Cautions in transporting engine 0-8

SAFETY CAUTIONS & WARNING Danger of Fire and Explosion 1 • Keep flames away Do not use flames or smoke at a site where fuel or engine oil is handled or cleaning solvent is used for washing parts. Flames can ignite such materials and result in a dangerous situation. Spilled fuel and oil should be wiped immediately and thoroughly. Spilled fuel and oil can ignite and cause fire. When storing fuel or engine oil, make sure that the storage area is well ventilated and the caps of containers are tightly closed. • Keep surrounding area neat and clean Do not leave combustible or explosive materials, such as fuel and engine oil, near the engine. They can cause fire or explosion. Remove dust, dirt and other foreign materials accumulated on or near the engine. They can cause fire or engine overheating. Be sure to remove dust from the top side of the battery after maintenance. Dust can cause a short-circuit. The engine must be positioned at least 1 m [3.28 ft] away from buildings and other equipment to prevent possible fire caused by engine heat. • Do not open crankcase until engine cools After the engine stops operation, let the engine cool for at least 10 minutes before opening the side cover of the crankcase. Inflow of fresh air into the crankcase of a hot engine can cause oil mist to ignite and explode. 0-2 • Check for fuel and oil leaks When fuel or oil leaks are found, repair the leakage immediately. Fuel or engine oil spilled on a hot surface of the engine can cause fire and result in personal injury or equipment damage. • Use shatterproof light Use a shatterproof light when inspecting the fuel system, lubrication system, cooling system or battery fluid leveL A non-shatterproof light may catch fire and explode. • Do not short-circuit electrical wires Do not inspect or repair the electrical system with the battery cables connected to the battery, since it can cause accidental short-circuiting and lead to fire. Be sure to disconnect the negative (-) battery cable from the battery before conducting work. Loose terminals and damaged cables/wires can result in a short-circuit and cause fire. Inspect the terminals, cables and wires before servicing, and repair or replace when damage is found. • Keep fire extinguishers and first aid kit nearby Always keep fire extinguishers nearby, and be familiarized with their usage. Keep a first aid kit at a designated place, and make sure it is easily accessible whenever needed. Also, establish emergency response procedures to follow in the event of a fire or accident, and post emergency contact locations and contact methods.

SAFETY CAUTIONS & WARNING Danger of Entanglement • Install protective covers on rotating parts Make sure the protective covers of the engine are installed correctly at rotating parts. If protective covers are loose or damaged, repair. Never remove the covers guarding rotating parts, such as the camshaft cover and rocker covers, when the engine is operating. When the engine is coupled to other equipment or connected to a radiator, be sure to install covers on the exposed connecting belt and coupling. Never remove protective covers. • Check surrounding area for safety before starting engine Before starting the engine, check to make sure no one is near the generator and tools are not left on or near the engine. Always verbally notify people within the immediate area when starting the engine. When the starter switch is posted with a sign that prohibits startup operation, do not operate the engine. • Stay clear of rotating parts while engine is in operation Do not approach rotating parts while the engine is in operation. Keep items that can be easily entangled away from rotating parts. Rotating parts can entangle a persons' body or tools to cause serious. • Lock out and tag out Be sure to lock out and tag out before starting inspection and maintenance. Lockout and tagout are effective methods of cutting off machines and equipment from energy sources. To lock out and tag out, pull out the key from the starter switch, turn off the battery switch, and post a "Do Not Operate" tag or a similar sign on the starter switch. The starter switch key should be kept by the person performing the inspection and maintenance. If the engine is installed with an air starter system, close the main valve of the air tank, and post a "Do Not Open" tag on the main valve. • Always stop engine before inspection and maintenance Before inspection and maintenance, be sure to stop the engine. Never attempt to adjust the belt tension while the engine is operating. Operating belt can entangle your body and result in serious injury. • Always return turning tools to original position after use Be sure to remove all turning tools used in inspection and maintenance. Return the turning gear in the original position before 'starting the engine. Starting the engine with the turning tools inserted or turning gears engaged may not only cause engine damage but personal injury as well. 0-3

Mitsubishi S6R MPTK Manual Collection

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