Mitsubishi Diesel Engine Service Manual

FOREWORD This service manual describes the specifications as well as the maintenance and adjustment procedures for Mitsubishi diesel engines. This manual also includes the detailed information on basic and special tools as the need arises. The Mitsubishi diesel engines can offer highly efficient and reliable performance for many years to come, which, however, only can be achieved through the proper handling and the periodical inspection / maintenance work exercised in according to the procedures of disassembly, inspection / adjustment and reassembly described in this manual.

Before attempting any work on your engine, thoroughly read this manual to familiarize with the engine and the required procedures of the work. All information contained in this manual is based on the engine produced at the time of publication and is subject to change as the engine improved without notice. Pub. No. 99619-12140

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HOW TO USE THIS MANUAL This Service Manual describes the specifications of Mitsubishi diesel engines (land and standard applications) and relevant service standards, as well as the procedures for servicing the engines such as for disassembly, inspection, repair and reassembly. This manual is divided into Groups. Each Group covers a specific area of the engine. The fuel injection pump, the governor and the turbocharger are handled in a separate manual. Major contents of Groups are listed on the “General Contents” page. Detailed contents of each Group are listed on the first page of that Group.

For information on the operations and recommended inspection / maintenance schedule of forklift trucks, please refer to the operator’s manual for the forklift truck. For information on components / parts and spares ordering procedures, refer to the parts catalogue. For information on structures and functions, refer to appropriate training materials. 1. Notes on descriptions (1) Parts shown in Figures as well as in the text are numbered in the order of disassembly. (2) Inspecting points during disassembly are shown in the Disassembly figures by enclosing in the box.

(3) Service standards for inspection and repair are listed on the appropriate pages of this manual where the relevant descriptions are made. Also, a comprehensive listing of service standards is provided in Group 1. (4) Parts reassembly sequence is provided below the Figure of that reassembly in the form of . (5) In this manual, the following marks are provided to draw the reader’s attention to the safety notes described under the marks. This indicates a dangerous situation which can highly likely result in death or serious injury unless avoided. This indicates a potentially dangerous situation which may possibly lead to death or serious injury unless avoided.

This indicates a potentially dangerous situation which may cause minor to moderate injury unless avoided. This indicates a potential danger in which property damage may result unless avoided. Note: This stresses important points or provides useful tips on engine operations and service. (6) Wherever hardware tightening requires the application of engine oil, “WET” is mentioned. If not mentioned, tighten the hardware “dry” (engine oil should not be applied).

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2. Terms Nominal value ······This is the nominal dimension of the part being measured. Standard value ······This is the dimension of the individual part being measured, the clearance between the parts in question, or the standard performance in question. Standard values have been arranged within the range appropriate for the inspection being carried out, and are not necessarily the design values. Limit ·····················Parts that have reached the limit value should be replaced or repaired whichever is appropriate. 3.

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 = Japan Industrial Standards LLC = Long Life Coolant MIL = Military Specifications MSDS = Material Safety Data Sheets SAE = Society of Automotive Engineers 4. Units Values shown in this manual are based on SI units (International System of Units). The corresponding metric values are shown in ( ) immediately after the SI values. The SI to metric conversions are based on the following. Pressure:

1 MPa = 10.197 kgf / cm 2 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 cmH 2 O (cmAq) Rotational speed: 1 min -1 = 1 rpm

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GENERAL CONTENTS Supplement Engine Inspection Sheets Group No.

Group Name Page 0 SAFETY CAUTIONS 0 - 1 1 GENERAL 1 - 1 SERVICE STANDARDS 1 -11 TOOLS LIST 1 -21 OVERHAUL TIMING 1 -25 REMOVAL PREPARATIONS 1 -29 2 Engine Main Parts ENGINE MAIN PARTS - DISASSEMBLY 2 - 1 ENGINE MAIN PARTS - INSPECTION AND CORRECTION 2 -17 ENGINE MAIN PARTS - REASSEMBLY 2 -33 3 Fuel System FUEL SYSTEM - REMOVAL 3 - 1 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3 - 9 FUEL SYSTEM - INSTALLATION 3 -25 4 Lubrication System OIL SYSTEM - REMOVAL 4 - 1 OIL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 4 - 5 OIL SYSTEM - INSTALLATION 4 - 9 5 Cooling System COOLING SYSTEM - REMOVAL 5 - 1 COOLING SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 5 - 5 COOLING SYSTEM - INSTALLATION 5 - 9 6 Inlet and Exhaust Systems INLET AND EXHAUST SYSTEMS - REMOVAL 6 - 1 INLET AND EXHAUST SYSTEMS - DISASSEMBLY, INSPECTION AND REASSEMBLY 6 - 5 INLET AND EXHAUST SYSTEMS - INSTALLATION 6 - 7 7 Air starter System ELECTRICAL SYSTEM - REMOVAL 7 - 1 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 7 - 7 ELECTRICAL SYSTEM - INSTALLATION 7 -25 8 Engine - Inspection/Adjustment, Running-in Trial and Performance Test ENGINE - INSPECTION / ADJUSTMENT 8 - 1 RUNNING-IN TRIAL 8 -12 PERFORMANCE TEST 8 -13 9 Others DISASSEMBLY AND REASSEMBLY OF GENERAL PARTS 9 - 1

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