Mitsubishi S6R Series Service Manual

SERVICE MANUAL August 2010 Pub. No. 99419-12120 199419-12120

I FOREWORD This service manual describes the maintenance and adjustment procedures, and specifications for Mitsubishi diesel engines. 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 scheduled inspection and maintenance, and it may also be necessary to take appropriate measures which involve in disassembly, inspection, repair and assembly work of the engine and engine parts. Read through this manual carefully and understand the work procedures fully before dis- assembling, inspecting, repairing or assembling the engine. The contents of this manual are based on the engine model produced at the time of publi- cation. Please note that the contents of this manual may change due to improvements made thereafter.

II FOREWORD HOW TO USE THIS MANUAL This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel engines. A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed table of contents at the beginning of each chapter. Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man- ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func- tion of the engine are described in the relevant training manuals. If you have an inquiry, please check the engine model and serial number, and contact our service department. Description format (1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica- tion of the sequence of disassembly. (2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views. (3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They are also collectively indicated in the Chapter 2. (4) The tightening torque with engine oil applied on the thread, is specified [Wet]. Unless otherwise specified, the tightening torque is of dry condition. (5) In this manual, important safety or other cautionary instructions are emphasized with the following head marks. Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. Note Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

III FOREWORD Terms used in this manual Nominal value means the basic nominal size of a part to be measured. Standard value means the quantitative requirement for dimension of a part, clearance between parts and performance. The values are rounded off for the inspection job, and do not necessarily conform to the design values. Limit value means the limit value, which the measured value reaches, the part needs repair or replacement with a new one. 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 : Japanese Industrial Standards LLC : Long Life Coolant MIL : Military Specifications and Standards (U.S.A.) MSDS : Material Safety Data Sheet SAE : Society of Automotive Engineers (U.S.A.) P/N : Part Number Unit of Measurement Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and U.S. customary values are in [ ]. For metric conversion, the following rates are used. Pressure :1 MPa = 10.197 kgf/cm 2 Torque :1 N•m = 0.10197 kgf•m Force :1 N = 0.10197 kgf Output power :1 kW = 1.341 HP = 1.3596 PS Pressure (mercury column) :1 kPa = 0.7 cmHg Pressure (watercolumn) :1 kPa = 10.197 cmH2O (cmAq) Rotation speed: 1 min -1 = 1 rpm

IV FOREWORD Safety Cautions Fire and Explosion Precautions Keep Flames Away Do not use flames near the engine (in the engine room). The flame is dan- gerous to ignite combustibles and cause a fire. Wipe off spilled fuel, oil and LLC immediately and thoroughly. Spilled fuel, oil and LLC may ignite and cause a fire. Store the fuel and engine oil in a well ventilated area. Make sure that the fuel and engine oil container caps are tightly fastened. Keep Engine Surrounding Area Tidy and Clean Do not place combustible or explosive material, such as fuel, engine oil, LLC or explosive powder near the engine. Such substances can cause a fire or explosion. Thoroughly remove dust, dirt and other foreign material collected on the engine and the area around the engine. Such material can cause a fire or the engine to overheat. In particular, clean the top surface of the battery thoroughly. Dust can cause a short-circuit. Always place the engine at a position at least 1 m [3.28 ft.] apart from buildings and other equipment to prevent a possible fire caused by engine heat. Do Not Open Side Covers Until Engine Cools Do not try to open the side cover of crankcase before the engine cools down. Wait at least 10 minutes after stopping the engine. Opening the cover when the engine is hot allows fresh air to flow into the crankcase, which can cause oil mist to ignite and explode. Pay Attention to Fuel, Oil and Exhaust Gas Leak If any fuel, oil or exhaust gas leakage is found, immediately take corrective measures to stop it. Such leak- ages, if left uncorrected, can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable material, may results in a fire, personal injury and damage to the equipment. Use Explosion-proof Light When inspecting fuel, engine oil, coolant, battery electrolyte, etc., use an explosion-proof light. If the lighting is not an explosion-proof type, it may ignite and cause an explosion. Prevent Electrical Wires From Short Circuit Avoid inspecting or servicing the electrical system with the battery cable connected to the battery. Otherwise, a fire could result from short circuit. Be sure to disconnect the battery cable from the negative (-) terminal before starting work. A loose terminal and a damaged cable or wire may result in a short circuit and a fire. Inspect, and if any defect is found, repair or replace it before starting work. Keep Fire Extinguishers and First-aid Kit Handy Keep fire extinguishers handy, and become familiar with their usage. Keep a first-aid kit at the designated place to be ready for use in an emergency. Make counteract procedures against a fire or an accident. Provide the contact person and means of communication in case of emergency.

V FOREWORD Stay Away From Rotating and Moving Parts Install Protective Covers Over Rotating Parts After Inspection and Maintenance Work Check the covers over engine rotating parts for correct installation. Repair any damaged or loosed covers. Never remove the protective covers over rotating parts during operation. When the engine is coupled to a radiator or other equipment, install protective covers over the exposed connecting belt and coupling. Check Work Area for Safety Before Starting Before starting the engine, make sure that no one is near the engine and that tools are not left on or near the engine. Verbally notify persons within the immediate area when starting the engine. When the starter device is tagged with the warning sign saying DO NOT RUN, never start the engine. Stay Away From Moving Parts While Engine Operates Keep away from the rotating parts during operation. Do not leave any objects that may get caught in rotating parts. If clothes or a tool gets caught in rotating parts, serious injury will result. Lockout and Tagout Be sure to lockout and tagout before starting inspection and maintenance. Lockout and tagout are effec- tive methods of cutting off machines and equipment from energy sources. To accomplish the lockout/ tagout, remove the starter switch key, set the battery switch to OFF position and attach a DO NOT RUN or equivalent caution tag to the starter switch. The starter switch key must be kept by the person who performs inspection and maintenance work. Be Sure to Stop the Engine Before Inspec- tion and Maintenance Be sure to stop the engine before proceeding to inspection and maintenance work. Never try to make adjustments on the engine parts while the engine is running. Rotating parts such as belt can reel in your body and cause serious injuries. Always Put Back Engine Turning Tool After Use Be sure to remove the turning tool used for inspection and maintenance work. Make sure to pull back the turning gear to the engine running position before starting the engine. If the engine is started with a turning tool inserted or turning condition, it can not only cause damage to the engine, but also lead to a personal injury.

VI FOREWORD Be Careful of Exhaust Gas Poison- ing Be Careful of Ventilation to Operate Engine If the engine is installed in an enclosed area, and the exhaust gas is ducted outside, make sure that duct joints are free from gas leak. Exhaust gas from the engine contains harmful components such as carbon monoxide. Operating the engine in an ill-ventilated area can cause gas poisoning. Be Careful of Hearing Loss Wear Ear Plugs Always wear ear plugs when entering the machine room (engine room). Combustion sound and mechanical noise of engine can cause hearing loss. Be Careful of Falling Lift Engine Carefully Use slings or wire ropes strong enough to lift the load considering the engine weight. To lift the engine, hitch the proper slings to the lifting hangers prepared on the engine. To lift the engine, keep the engine in a well-bal- anced position, thinking carefully of the engine center of gravity. The hangers prepared on the engine are designed for lifting the weight of engine only. In the case where the generator, marine gear, and others are installed to the engine, consideration that the additional weight will not affect the hangers of the engine. Keep the angle formed by slings attached to hangers within 60°. If the angle exceeds this limit, excessive load may be applied to the hangers and damage the hangers. If the wire rope contacts the engine directly, place a cloth or other soft pad to avoid damage to the engine and sling. Do Not Climb Onto the Engine Do not climb onto the engine, nor step on any engine parts on the engine sides. To work on parts located high on the engine, use a ladder, footing, and others to prevent from slipping and falling. Climbing onto the engine may result in engine part damage and your injury by falling down. Always Prepare a Stable Footing When working on the upper part of the engine and other hard-to-reach places, use a stable footing. Stand- ing on an old footstool or parts box may result in personal injury. Do not put any unnecessary objects on a footing.

VII FOREWORD Be Careful When Handling Fuel, Engine Oil or LLC Use Specified Fuel, Engine Oil and Long- Life Coolant (LLC) Only Use the fuel, oil and LLC specified in this manual only, and handle them carefully. Use of any other fuel, oil or LLC, or improper handling may cause various engine defects and malfunctions. Get the MSDS issued by the fuel, oil and LLC suppliers, and follow the directions in the MSDS for proper handling. Handle LLC Carefully When handling LLC, wear rubber gloves and a protective face mask. If LLC or coolant containing LLC comes into contact with your skin or eyes, or if it is swallowed, you would suffer from inflammation, irrita- tion or poisoning. If LLC is accidentally swallowed, induce vomiting immediately and seek medical attention. If LLC enter your eyes, flush them immediately with plenty of water and seek medical attention. If LLC contact your skin or clothing, wash it away immediately with plenty of water. Keep flames away from LLC. LLC can catch flames and cause a fire. Drained coolant containing LLC is a hazardous material. Do not discard it in an unauthorized procedure. Practice the applicable law and regulations when discard drained coolant. Proper Discarding of Waste Oil, LLC and Coolant Do not discard waste engine oil, LLC and coolant in an unauthrized procedure. Such a way of disposal is strictly prohibited by laws and regulations. Discard waste oil, LLC, coolant and other environmentally hazardous waste in accordance with the applicable laws and regulations. Be Careful of Burns Do Not Touch the Engine During or Immedi- ately After Operation Do not touch any parts of the engine during or immediately after operation. You can get burned. Before starting the maintenance and inspection work, check the water temperature meter to make sure that the engine is cooled down. Be Careful to Open and Close the Radiator Cap Never open the radiator cap while the engine is running or immediately after the engine stops. Stop the engine and give a sufficient time to allow the coolant to cool down before opening the cap. When opening the radiator cap, slowly open the cap so as to release internal pressure. To prevent hot steam scalds, wear thick rubber gloves or cover the cap with a cloth. When closing the radiator cap, tightly close the cap. Do not open the radiator cap during engine running or immediately after engine stop. Otherwise hot steam and coolant gush out and can cause burns. Refill Coolant Only After the Coolant Tem- perature Dropped Do not refill coolant immediately after the engine stops. Wait until the coolant temperature lowers suffi- ciently to avoid risk of burns. Do Not Remove Heat Shields The exhaust system, which becomes extremely hot while the engine is operating, is provided with various heat shields. Never remove the heat shields. If any of these heat shields were inevitably removed for the inspection and maintenance, be sure to install them after the work. Be Careful of Burns When Changing Oil Wear gloves when draining oil or changing oil filters. If your skin contacts hot oil or hot parts, you get burn injury.

VIII FOREWORD Battery Be Careful with Battery Never use flames or generate sparks near the battery. The battery gives off highly flammable hydrogen gas and oxygen gas. Any flame or spark near a battery may cause an explosion. Do not use the battery if its fluid level is below the lower limit line. Long use of the battery may result in an explosion. Do not short the battery terminals with a tool or other metal object. When disconnecting battery cables, always remove first from negative (-) terminal first. When reconnect- ing the cables, always connect first to the positive (+) terminal. Charge the battery in a well-ventilated area, with all battery plugs removed. Make sure the cable clamps are securely fastened to the battery terminals. A loose terminal can cause sparks that may result in an explosion. Before servicing electrical components or conducting electric welding, set the battery switch to the [Open/ OFF] position or disconnect the cable from the negative (-) battery terminal to cut off the electrical cur- rent. Electrolyte (battery fluid) contains dilute sulfuric acid. Careless handling of the battery may lead to the loss of sight and/or skin burns. Also, do not swallow battery fluid. Wear protective goggles and rubber gloves when working with the battery (such as adding water or charging). If battery electrolyte is spilled onto the skin or clothing, immediately wash it away with lots of water. Use soap to clean thoroughly. Battery fluid can make you blind if splash into your eyes. Immediately flush it away with plenty of clean water, and seek immediate medical attention. If battery fluid is accidentally swallowed, gargle with plenty of water, then drink lots of water, and seek immediate medical attention. When Abnormality Occurs Do Not Add Coolant Immediately After a Sudden Stop Due to Overheating If the engine stops suddenly due to overheating, or you suddenly stop the engine by any reason, do not add coolant immediately. If water is added immediately, parts such as cylinder heads can be damaged due to the sudden drop of temperature. Add coolant slowly after the engine becomes cool. Be Careful to Restart After Abnormal Stop If the engine stops abnormally, do not restart the engine immediately. If the engine stops giving an emergency alert, inspect the engine and correct the cause of the defect before restarting. If the engine is kept operating in such a condition, it can result in serious engine failure. Immediately Stop the Engine When Engine Oil Pressure Drops If the engine oil pressure drops significantly, stop the engine immediately, and inspect the lubrication system to find the cause. Continuous engine operation with low oil pressure may cause bearings and other parts to seize. Stop the Engine Immediately When the Belt Break If the belt breaks, stop the engine immediately. Contin- uous engine operation with the broken belt can cause the engine to overheat. Steam of boiled coolant may gush out from the reserve tank or radiator, and results in burns.

IX FOREWORD Other Cautions Do Not Tamper If tampered, the warranty is totally void even in the warranty period. Tampering with the engine can not only damage the engine but also may lead to personal injury. Perform All Specified Pre-operation Inspec- tions and Scheduled Inspections Conduct the daily inspection and scheduled inspection/maintenance as described in this manual. Failure to conduct the specified inspections may cause various engine problems, damage to parts, and a serious accident. Wear Proper Work Clothing and Protective Gears Wear a hard hat, face shield, safety shoes, dust mask, gloves and other protective gears as needed. When using compressed air, wear safety goggles, a hard hat, gloves and other necessary protective gear. Works without wearing proper protective gears may result in serious injury. Never Break the Seals To ensure the proper engine operation, the fuel control link is provided with seals that protect the fuel injection volume and rotation speed settings against tampering. If the seal is tampered, no guarantee will be provided. If the seal is tampered, the defects shown below can occure. Rapid wear of moving and rotating parts Engine troubles such as seizure and damage of engine parts Sudden increase of fuel and lubricating oil consump- tion Deterioration of engine performance due to improper balance between fuel injection volume and governor control, or a serious accident due to overrunning of the engine Inspect the Engine After Operation After the engine operation, inspect each part of engine once again. If any defect is found, correct immediately. Break-in the Engine To break-in a new engine or overhauled engine, operate the engine at a speed lower than the rated speed in a light load condition during the first 50 hours of operation. Operating a new engine or overhauled engine in a severe condition during the break-in period shortens the service life of the engine.

Mitsubishi S6R Series Service Manual

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