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S6R Series
Mitsubishi S6R Series User Manual
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1-13
Chapter 1 GENERAL
2.
Outline of Systems
2.1
Outline of Fue
l System
Outline of Fuel System
2.2
Outline of Lubrica
tion System
Outline of Lubrication System
Fuel injection nozzle
Fuel leak-off pipe
Fuel injection pump
Fuel feed pump
From fuel tank
T
o fuel tank
Fuel filter
Fuel injection pipe
Oil pressure governor spec
Governor
T
urbocharger
Camshaft
Oil thermostat
Oil cooler
T
iming gear
Fuel injection pump
Oil pump
Safety valve
Bypass oil filter
Oil strainer
Oil filter
Relief valve
Crankshaft
W
ater pump
Piston
cooling nozzle
Piston
Rocker shaft
Oil filter
Governor oil filter
27
29
Table of Contents
Section 1
17
How to Use this Manual
3
Warning Labels
13
Table of Contents
17
External View
18
Chapter 1 GENERAL
28
Outline of Fuel System
28
Outline of Lubrication System
28
Outline of Systems
28
Outline of Cooling System
29
Outline of Inlet and Exhaust System
32
Contents of Plate and Label
34
Name Plate
34
Caution Plate
34
Emissions Certification Label
34
Specifications
35
Overlap
35
Section 2
36
Chapter 2 Service Data
40
Maintenance Service Data
41
Maintenance Service Data of Engine General
41
Overlap
41
Maintenance Service Data of Basic Engine
42
Overlap
44
Maintenance Service Data of Fuel System
47
Maintenance Service Data of Lubrication System
49
Maintenance Service Data of Cooling System
50
Maintenance Service Data of Electrical System
52
Air Start System
55
Tightening Torque Table
56
Tightening Torque Spec for Basic Engine
56
Tightening Torque Spec for Fuel System
57
Tightening Torque Spec for Lubrication System
57
Tightening Torque Spec for Cooling System
58
Tightening Torque Spec for Inlet and Exhaust System
58
Tightening Torque Spec for Electrical System
59
Tightening Torque Spec for Air Start System
59
Tightening Torque for Standard Bolts
60
Tightening Torque for Standard Eyebolts
61
Tightening Torque for Standard Union Nuts
61
Tightening Torque for Fuel Injection Pipe
61
Special Tools
63
Chapter 5 Disassembly of Basic Engine
71
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect
72
Fuel Inlet Connector - Remove
73
Nozzle Assembly - Remove
73
Valve Clearance - Inspect
73
Fuel Injection Timing - Inspect
74
Rocker Shaft Assembly - Remove
74
Clearance between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
74
Valve Bridge - Remove
75
Rocker Case - Remove
75
Cylinder Head Assembly - Remove
75
Valve Sinkage - Measure
75
Valve and Valve Spring - Remove
76
Nozzle Gland Stud Bolt and Bridge Guide - Remove
76
Rear Mechanism - Disassemble and Inspect
77
Flywheel Face and Radial Runout - Measure
78
Flywheel - Remove
78
Timing Gear Case - Remove
78
Timing Gear Backlash - Measure
79
Idler Gear End Play - Measure
79
Idler Gear - Remove
79
Governor Drive and Fuel Injection Pump Accessory Drive - Remove
79
Camshaft End Play - Measure
80
Camshaft Gear - Remove
80
Camshaft - Remove
80
Idler Shaft - Remove
80
Rear Plate - Remove
81
Front Mechanism - Disassemble and Inspect
82
Coupling - Remove
83
Damper Face and Radial Runout - Measure
83
Front Pulley, Damper and Crankshaft Pulley - Remove
84
Tension Pulley - Remove
84
Front Cover - Remove
84
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect
85
Piston Protrusion - Measure
86
Connecting Rod End Play - Measure
86
Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove
86
Connecting Rod Cap - Remove
86
Piston - Remove
87
Piston Ring - Remove
88
Piston Pin and Piston - Remove
88
Cylinder Liner Inside Diameter - Measure
89
Cylinder Liner Flange Protrusion - Measure
89
Cylinder Liner - Remove
89
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect
90
Crankcase - Turn over (Upend)
91
Crankshaft End Play - Measure
91
Piston Cooling Nozzle - Remove
91
Main Bearing Cap - Remove
91
Crankshaft - Remove
92
Chapter 6 Inspection and Repair of Basic Engine
93
Cylinder Head and Valve Mechanism - Inspect and Repair
95
Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure
95
Rocker Bushing - Replace
95
Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
96
Valve Guide - Replace
96
Valve Face - Inspect
97
Valve Face - Reface
97
Valve Seat - Reface
98
Valve Seat - Replace
98
Valve and Valve Seat - Lap
100
Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect
100
Squareness and Free Length of Valve Spring - Measure
101
Tappet - Inspect
102
Pushrod Runout - Measure
102
Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace
102
Distortion of Cylinder Head Bottom Surface - Measure
103
Rear Mechanism - Inspect and Repair
104
Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure
104
Idler Bushing - Replace
104
Cam Lift of Cam Shaft Lobe - Measure
105
Camshaft Runout - Measure
105
Camshaft Journal Outside Diameter - Measure
105
Overlap
105
Camshaft Bushing - Inspect
106
Camshaft Bushing - Replace
106
Front Mechanism - Inspect and Repair
108
Damper - Inspect Visually
108
Pulley - Inspect
108
Piston and Connecting Rod - Inspect and Repair
109
Piston - Inspect Visually
109
Piston Weight
109
Piston Outside Diameter - Measure
109
Piston Ring Groove - Inspect
110
Piston Pin Bore Inside Diameter - Measure
110
Piston Ring - Inspect Visually
110
Piston Ring End Gap - Measure
110
Piston Pin Outside Diameter - Measure
111
Connecting Rod Bushing Inside Diameter - Measure
111
Connecting Rod Bushing - Replace
112
Connecting Rod Assembly Weight Rank
114
Bore Diameter and Roundness of Connecting Rod Big End - Measure
114
Side Face Width of Connecting Rod Big End - Measure
115
Connecting Rod Big End Serration and Bolt Holes - Inspect
115
Connecting Rod Bearing - Inspect
115
Connecting Rod Bearing Thickness - Measure
116
Connecting Rod Bend and Twist - Inspect
116
Crankcase and Crankshaft - Inspect and Repair
117
Crankcase Top Surface Distortion - Measure
117
Inside Diameter of Main Bearing Housing Bore - Measure
117
Cylinder Liner Fitting Bore in Crankcase - Inspect
117
Counterbore in Crankcase - Repair
118
Crankpin and Journal Outside Diameters - Measure
119
Width of Crankpin and Rearmost Crank Main Journal - Measure
120
Crankshaft Gear - Inspect
121
Crankshaft Gear - Replace
121
Crankshaft Runout - Measure
121
Oil Seal Slinger - Inspect
122
Oil Seal Slinger - Replace
122
Main Bearing - Inspect
123
Thickness of Main Bearing Shell - Measure
124
Thrust Plate - Inspect
124
Piston Cooling Nozzle - Inspect
125
Thickness of Thrust Plate - Measure
125
Chapter 7 Assembly of Basic Engine
126
Crankshaft and Main Bearing - Install
128
Crankcase - Turn over (Upend)
128
Piston Cooling Nozzle - Install
128
Upper Main Bearing - Install
129
Rear Upper Thrust Plate - Install
129
Crankshaft - Install
130
Front Upper Thrust Plate - Install
130
Lower Main Bearing Shell and Lower Thrust Plate - Install
131
Main Bearing Cap - Install
131
Crankshaft End Play - Measure
132
Crankcase - Turn over
132
Cylinder Liner, Piston and Connecting Rod - Assemble
133
Cylinder Liner Protrusion - Measure
133
Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed)
133
Cylinder Liner - Install
134
Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)
135
Cylinder Liner Inside Diameter - Measure
135
Piston and Connecting Rod - Assemble
136
Piston Ring - Install
136
Crankshaft - Turn
137
Piston Installation - Prepare
137
Upper Connecting Rod Bearing - Install
137
Piston- Install
139
Connecting Rod Cap - Install
140
Connecting Rod End Play - Measure
141
Piston Protrusion - Measure
142
Front Mechanism - Assemble
143
Front Cover - Install
143
Tension Pulley - Install
143
Front Oil Seal - Install
143
Crankshaft Pulley, Damper and Front Pulley - Install
144
Damper Face and Radial Runout - Measure
144
Pointer - Install and Adjust
144
Fan Drive Gear - Install
144
Coupling - Install
145
Rear Mechanism - Assemble
146
Rear Plate - Install
146
Idler Shaft - Install
146
Camshaft - Install
146
Camshaft Gear - Install
147
Camshaft End Play - Measure
147
Fuel Injection Pump Accessory Drive - Install
147
Idler Gear - Install
148
Idler Gear End Play - Measure
148
Timing Gear Backlash - Measure
148
Timing Gear Case - Install
149
Rear Oil Seal - Install
149
Flywheel - Install
150
Governor Drive - Install
150
Flywheel Face and Radial Runout - Measure
150
Pickup - Install
150
Cylinder Head and Valve Mechanism - Assemble
151
Cylinder Head - Assemble
151
Valve Sinkage - Measure
152
Tappet - Install
152
Liquid Gasket - Apply
152
Cylinder Head Gasket - Install
153
Cylinder Head Assembly - Install
153
Cylinder Head Bolt - Tighten
153
Rocker Case - Install
154
Bridges and Bridge Caps - Install
154
Valve Bridge and Adjusting Screw - Adjust
154
Clearance between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
155
Rocker Shaft Assembly - Install
155
Valve Clearance - Check and Adjust
156
Fuel Injection Timing - Check and Adjust
156
Valve Timing - Inspect
158
Fuel Injection Nozzle Assembly - Install
160
Chapter 8 Fuel System
161
Fuel Injection Pipe and Fuel Leak-Off Pipe - Remove and Inspect
162
Fuel System - Remove and Inspect
162
Fuel Filter and Fuel Pipe - Remove and Inspect
166
Stop Solenoid - Remove and Inspect
168
Fuel Control Link - Remove and Inspect
171
Governor and Actuator - Remove and Inspect
175
Fuel Injection Pump - Remove and Inspect
177
Fuel System - Disassemble, Inspect and Assemble
178
Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble
178
Fuel Injection Nozzle - Disassemble and Inspect
182
Fuel Injection Nozzle - Inspect and Adjust
184
Fuel Injection Nozzle - Assemble
188
Fuel Injection Pump Accessory Drive - Disassemble and Inspect
192
Outside Diameter and Inside Diameter of Accessory Drive Bearing Fit - Inspect
193
Fuel Injection Pump Accessory Drive - Assemble
194
Governor Drive - Disassemble and Inspect
195
Outside Diameter and Inside Diameter of Bearing Fit
196
Governor Drive - Assemble
197
Fuel System - Install
198
Fuel Injection Pump - Install
198
Fuel Control Link - Install
202
Stop Solenoid - Install
203
Chapter 9 Lubrication System
207
Lubrication System - Remove and Inspect
208
Lubrication System - Remove and Inspect (1)
208
Lubrication System - Remove and Inspect (2)
209
Lubrication System - Remove and Inspect (3)
209
Governor Oil Filter - Remove and Inspect
211
Lubrication System - Disassemble, Inspect and Assemble
212
Oil Pump and Safety Valve - Disassemble and Inspect
212
Oil Pump and Safety Valve - Inspect
213
Oil Pump and Safety Valve - Assemble
215
Relief Valve - Disassemble and Inspect
216
Relief Valve - Inspect
217
Relief Valve - Assemble
217
Oil Cooler and Oil Thermostat - Disassemble
218
Oil Thermostat - Inspect
219
Oil Cooler and Oil Thermostat - Assemble
219
Oil Filter - Disassemble and Inspect
220
Oil Filter - Inspect
222
Oil Filter Alarm - Inspect
222
Oil Filter - Assemble
222
Oil Filter Cartridge - Install
222
Governor Oil Filter - Disassemble and Inspect
223
Governor Oil Filter - Assemble
224
Lubrication System - Install
225
Oil Pump - Install
225
Oil Pan - Install
225
Chapter 10 Cooling System
226
Cooling System - Remove and Inspect
227
Water Pump, Thermostat and Water Pipe - Remove and Inspect
227
Heat Exchanger and Water Pipe - Remove and Inspect
228
Sea Water Pump and Water Pipe - Remove and Inspect
229
Air Cooler Coolant Pump, Thermostat and Water Pipe - Remove and Insp
230
Cooling System - Disassemble, Inspect and Assemble
231
Tension Pulley - Disassemble and Inspect
231
Thermostat - Disassemble and Inspect
232
Thermostat for Jacket Water and Air Cooler - Inspect
235
Heat Exchanger - Disassemble and Inspect
236
Water Pump - Disassemble and Inspect
237
Water Pump - Inspect
239
Water Pump Shaft - Inspect
239
Water Pump - Assemble
240
Air Cooler Water Pump - Disassemble and Inspect
243
Air Cooler Coolant Pump - Assemble
246
Sea Water Pump - Disassemble and Inspect
248
Sea Water Pump - Assemble
250
Fan Drive Assembly - Disassemble and Inspect
254
Fan Drive - Inspect
255
Bushing Ring, Friction Rubber and Grommet - Inspect
255
Oil Seal Sleeve - Inspect
255
Oil Seal Sleeve - Replace
255
Fan Drive - Assemble
256
Cooling System - Install
259
Water Pipe (Air Cooler) - Install
259
Water Pump and Sea Water Pump - Install
259
Chapter 11 Inlet and Exhaust Systems
260
Inlet and Exhaust Systems - Remove and Inspect
261
Inlet Ststem - Remove and Inspect
261
Exhaust System - Remove and Inspect
266
Inlet and Exhaust Systems - Disassemble, Inspect and Assemble
269
Air Cooler - Disassemble, Inspect and Assemble
269
Pre-Cleaner - Clean
274
Inlet and Exhaust Systems - Install
275
Exhaust Pipe and Exhaust Manifold - Install
275
Air Cooler - Install
275
Chapter 12 Air Start System
276
Air Start System - Remove and Inspect
277
Magnetic Valve - Remove and Inspect
277
Air Pipe, Starter Valve and Distributor Valve - Inspect
278
Air Starter - Remove and Inspect
279
Air Start System - Disassemble, Inspect and Assemble
280
Magnetic Valve - Disassemble and Inspect
280
Magnetic Valve - Assemble
281
Starter Valve - Disassemble and Inspect
282
Starter Valve - Inspect
283
Starter Valve - Assemble
284
Distributer Valve - Disassemble and Inspect
285
Distributer Valve - Inspect
286
Distributer Valve - Assemble
287
Air Start System - Install
287
Chapter 13 Adjustment and Operation
288
Engine - Adjust
289
Turning Gear - Use
289
Valve Bridge and Adjusting Screw - Check
290
Valve Clearance - Check
290
Fuel Injection Timing - Check
290
Fuel System - Bleed Air
290
Belt and Belt Tension - Inspect and Adjust
292
Break-In Operation
295
Preparation before Engine Starting
295
Engine Start-Up
295
Engine-Test and Adjustment
297
Engine Performance Test
297
Emission Gas Test
297
Governor Performance Test
297
Alarm Action and Emergency Stop Tests
297
Maximum Fuel Injection Volume - Set
297
Seal
298
4
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Mitsubishi S6R Series Specifications
General
Brand
Mitsubishi
Model
S6R Series
Category
Engine
Language
English
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