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SERVICE MANUAL MITSUBISHI DIESEL ENGINE DO4FD-TAA for HYUNDAI HEAVY INDUSTRIES CO.,LTD. November 2006 MITSUBISHI HEAVY INDUSTRIES, LTD.

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INTRODUCTION This service manual describes the specifications, maintenance and service procedures 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 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 disassembling, 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.99616-H0100

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INTRODUCTION How to use this manual This service specifications, manual consists maintenance of several Groups, standards, which are arranged adjustment procedures so as to allow and service procedures you to make reference including methods quickly to for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use). A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table of contents at the beginning of each Group. Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance Manual.

For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are described in the relevant training manuals. Methods of presentation (1 )Index numbers alloted to parts in exploded views are not only a call-out of part names listed in the text but also an indication 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 Group 2, the General Contents group.

(4)Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating with engine oil. (5)In this manual, important safety or other cautionary instructions are emphasized with the following marks headed. 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, can result in property damage.

Note: Indicates important information or information useful for operation or maintenance of the engine.

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INTRODUCTION Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured. Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance. Therfore, the values shown are not in agreement with the design values. Limit means that, if this value is reached, the part must be repaired or replaced with a new part. Abbreviations * BTDC: e ATDC: ¢ BBDC: * ABDC: Before Top Dead Center After Top Dead Center Before Bottom Dead Center After Bottom Dead Center ¢ TIR: Total Indicated Runout ¢ API: American * ASTM: e JIS:

Petroleum Institute American Society for Testing and Materials 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.) Units of Measurement Measurements are based on the International System of Units parentheses {}. For metric conversion, the following rates are used. ¢ Pressure: 1 MPa = 10.197 kgf/cm? * Torque: 1 N-m = 0.10197 kgf-m ¢ Force: 1 N = 0.10197 kgf ¢ Horsepower: 1 kW = 1.341 HP = 1.3596 PS * Meter of mercury: 1 kPa = 0.7 cmHg ¢ Meter of water: 1 kPa = 10.197 cmHzO (cmAq) ¢ Rotational speed:

1min'’ = 1 rpm (SI), and their converted metric values are indicated in

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