Mitsubishi 6D1 Service Manual

601 diesel engine Shop Manual

GROUP INDEX
HOW TO READ THIS MANUAL
GENERAL ......................	•

{for

industrial

use)

ENGINE .........................	•
LUBRICATION ..................	·lfl

	.	FOREWORD
	This Shop Manual is published for the information and guid-
	ance of personnel responsible for maintenance of Mitsubishi
	601 series diesel engine, and includes procedures for ad-
	justment and maintenance services.
	We earnestly look forward to seeing that this manual is made
	full use of in orderto perform correct service with no wastage.
(	For more details, please consult your nearest authorized
	Mitsubishi dealer or distributor.
	Kindly note that the specifications and maintenance service
	figures are subject to change without prior notice in line with
	improvement which will be effected from time to time in the
	future.
	Applicable models
	6014	6014-T
	6015-T	6016
	6016-E	6016-T
	6016-TE 6016-TL
	6016-TLE ··············SK330(N)LC-6E

FUEL AND ENGINE CONTROL	... •
ELECTRONICALLY	mf.11
CONTROLLED FUEL SYSTEM	......
COOLING .......................	•
INTAKE AND EXHAUST ..........	•
CLUTCH ........................	•
ELECTRICAL SYSTEM ...........	•
SPECIAL EQUIPMENT ...........	•
NOTE; The parts marked"*" are deleted as
they are not applicable to the SK330(N)LC-6E.

©

2001

Mitsubishi Motors Corporation Printed in Japan

From the library of Barrington Diesel Club

HOW TO

RE.AD

THIS MANUAL

HOW THIS MANUAL IS COMPILED . • • • • • . • • . • . .			• • . • . .	• . . . .
GENERAL EXPLANATION OF THIS MANUAL . . • • • . . . . .				. . . . .
TERMS AND UNITS . . . . • . • • . • • • • • • • • . .	• . .	• • • . .	• • . • . • . • • . •

ii iii vii

2. Service standards table Only the relevant service· standards are shown.

	Service standards
	Location		Maintenance item
	1'11	Clearance between strap bolt and strap plate
	7	Pressure spring	Installed load
			(Installed length 49.1)
			lilt·

t This shows the key No. of the relevant part.

Standard value 0.01 to 0.16 835 N {85 kgf}

2.9 or less

Limit

0.3

710 N {72.3 kgf}

5.0

Unit: mm Remedy Replace Replace

Replace

3. Tightening torque table

	This shows specified tightening torque.
0	t
	Tightening torque
Location		Parts to be tightened
	1	Strap bolts (Strap bolt mounting)
	4	Bolt (Lock plate mounting)

t This shows the key No. of the relevant part.

4. Lubricant, fluid and sealant table

Tightening torque 39 to 59 {4 to 6} 5.9 to 7.8 {0.6 to 0.8}

Unit: N ·m {kgf ·m}

Remarks

-

Wet

t

This shows that the item is to be tightened wet.

Only the relevant lubricant, fluid and sealant are shown. This shows the application point.

~	Lubricant, fluid and sealant

Location	Points of application	1
1	Thread area of bolt
10,16	Friction surfaces of release lever plate a!ld release lever

t This shows the key No. of the relevant part.

Kinds

LOCTITE272

Molybdenum·disulfidegrease [NLGI No.2 (Li soap)]

t This shows the specified brand.

Quantity As required As required

v

Terms

and

Units

The terms and units in this manual are defined as follows.
e	This service manual contains important cautionary instructions and supplementary	information under the following four
	.headings which identify the nature of the instructions and information:

DANGER,&.

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING_&.---

Precautionary instructions, which,

if not observed, could

result

in

serious injury or death.

CAUTION,&.

---

Precautionary instructiqns, which, if not observed, could of equipment or parts.

result in damage to

or

destruction

NOTE

Suggestions or supplementary information for more efficient use of equipment or a better understanding.

e

Front and rear

The terms ''front"is the fan side and "rear''the flywheels side of the engine.

e

Left and right

The terms

"right" and "left" shall

be

used to indicate the side as viewed from the flywheel side of the engine.

e

Terms of service standards

(1) Standard value Standard value dimensions in designs indicating: the design dimensions. of individual parts, the standard clearC\nce between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [ ] is the basic diameter. (2) Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired.

e Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque.

vii

GENERAL SPECIFICATIONS

Item

Specifications

Engine model

Type Combustion chamber type Valve mechanism Bore x Stroke mm

Total displacement cc Compression ratio Empty mass kg*

6014	6014		6015	601616016			6016160161601616016
	-T		-T			-E	-T	-TE	-TL	-TLE
		6-cylinder in-line, water-cooled 4-cycle diesel
				Direct injection type
			Overhead valve (OHV) type
110x115			113 X				118x115
			115
6557			6919				7545
17.5			16	17.5	1	19		16	1	17.5
								I
500		540		500			550		560

*

Empty

mass

as

measured according to Mitsubishi Motors Corporation standard.

Engine

Outputs

~lassified

By

Application

~n Intermittent rated output kW (HP)

Continuous rated output kW (HP)

		6014
59 (79)/1500
70 (94}/1800
77	(1	03)/2000
82 (110)/2200
87 (117)/2500
92	(123}/2800
53	(72)/1500
64	(86)/1800
70 (93}/2000
74 (99)/2200
79	(106)/2500
83 {111)/2800

	6014-T					6016		6016-T
Middle-speed		High-speed					Middle-speed		High-speed
specification		specification					specification		specification
83 (111)/1500		79 (106)/1500		71	(95)/1500		106 (142)/1500		101	(136)/1500
98 (132)/1800		95 (127)/1800		85 (114}/1800			123 (165)/1 BOO		121	(163}/1800
106 (143)/2000		103 (139)/2000		93 (125)/2000			131	(176}/2000	131	(175)/2000
111	(150)/2200	111	(150)/2200	101		(135)/2200	140 (188)/2200		139 (186)/2200
		120 (161)/2500		111		(149}/2500			147 (197)/2500
		126 (168)/2800		120 (161)/2800					151	(203}/2800
75 (101)/1500		72 (96)/1500		65 (87)/1500			96 (129)/1500		92 (123)/1500
89 (120)/1800		86 (115}/1800		77 (103)/1800			111	(149)/1800	110	(148)/1800
96 (129}/2000		94 (126)/2000		84 (113}/2000			119	(160}/2000	118	(158)/2000
101	(136)/2200	101	(136)/2500	93 (125)/2200			127 (170)/2200		125 (168)/2200
		109 (146)/2500		101		(135)/2500			133 {178)/2500
		114 (153)/2800		110		(147)/2800			137 (184)/2800

NOTE

1. The

output

(SAE,

gross)

Is

corrected

to

standard

ambient

conditions

based

on

SAE J1349.

2.

The

continuous

rated

output

allows

10% {one

hour)

overload operation.

00-2

ENGINE NUMBER AND NAME PLATE

00

The serial number for engine is assigned to the respective engine in manufacturing	sequence: every
number. This number is required for incidental inspection of the engine. Please do not fail to mention
dealers when ordering spare parts.

engine has its own this number to the

Engine Number

1

Engine number 1 is punch-marked on the left of the crankcase.

Example: 6016-DDDDDD
1	LEngine
	Engine	number
	model

Name Plate

Name plate

The name plate is-attached to the portion shown in the illustration, and indicate the following items.

~ I

							18779
				1
				I
AI			I	I			2
TOTAL CYL VOL. 6557cc (400cu.					In)	_....	3
OUT PUT		c::::::::J CJ ;c=J			rpm-	-
MITSUBISHI		MOTORS		CORPORATION
		TOKYO	JAPAN
VALVE	CLEARANCE			(COLD)			4
INLETS. EXHAUST			0.4mm(O.OI61n)			j--
FIRING	ORDER			1-5-3-6-2-4		r----	5
FUEL INJEcTioN TIMINGO;sTDc
				\
				6			18780

1 2 3 4 5 6

Engine model Total displacement Maximum output Valve clearance Firing order Fuel injection timing

00-3

PRECAUTIONS FOR MAINTENANCE OPERATION

In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the. customer'sdemand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.

Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual.

0

18770

Perform maintenance work at a level area.

Prepare the following.

•Prepare general and special tools necessary for the maintenance work.

WARNING& --------------
	Do not attempt to use tools other than special tools where use of
	special tools is specified in this manual. This will avoid injury or
	damage.
Pay special attention to safety when removing or installing heavy items
such as engines, transmissions.
When lifting up heavy items using cables, pay special attention to the fol-
lowing points:
•	Check the mass of the item to be lifted and use a cable capable of lifting
	that mass.
14194
•	If you do not have the specified lifting hanger, secure the item using
	cable taking the point-of-balance of the item into consideration.

14195

•You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls.

00-4

00

Be particularly careful not to slippery. When working as a vance and keep confirming switches or levers.

work in shoes that have oily soles and are team of two or more, arrange signals in adsafety. Be careful not to accidentally bump

00012

Check for oil leakage before cleaning the area having the fault otherwise you might miss detecting the leakage. Prepare replacement part(s) beforehand.

/~

					00014
	'	~		/
'	""-	;..		/
.........				-
		~~1r~w~~~m~
		[f[][J~[[)		--
/	/			'
					00015
([>C) 8~~
""'\		f	•		~
			"/

Replace oil seals, packing, 0-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

00016

00-5

PRECAUTIONS FOR

MAINTENANCE

OPERATION

Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where performance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust. CAUTION,& . --------------

• •

Take care and right, Keep new arate.

to avoid etc. parts for

mixing up numerous parts, similar parts, left replacement and original (removed) parts sep-

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oil, grease, etc. for lubricant, remove the excess immediately after application with a piece of waste, etc. CAUTION _ & -------------- When the specified lubricant, fluid and sealant is not available, you may use an equivalent.

00018

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries to prevent them from short-circuit- ing and burning-out. CAUTION_&-----------------

Be sure to turn starter and lighting switches, connecting or connecting battery terminals, conductors can be damaged.

etc. off before dis because the semi

- -

00-6

00

Take care when .handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit.

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.

When washing the vehicle, cover the electric system parts and instruments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00023

When using an electric welder, such electronic parts that are directly con-
nected to the batteries might be damaged due to the flow of current from
the welder that flows through the negative circuit. Parts that have switches
might be subject to the same danger if the switches are left on.
Therefore, do not fail to observe the following.
•	Connect the negative terminal of the welder as near as possible to the
	area that is to be welded.
•	Disconnect the negative terminals of batteries.

To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt. Do not apply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always fed the battery voltage.

14185

00-7

PRECAUTIONS FOR MAINTENANCE OPERATION

When using testers test probes to touch

or the like for continuity tests, be careful not to allow the wrong terminals.

Measurement Procedures Using Connectors

Test with

connectors engaged (continuity through

circuit

obtained)

<Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connector.

02587

<Non-waterproof connector> Insert test probe C from the harness side of the units, etc. have connectors that are too small to not force the test probe into them.

connector. Where control accept the test probe, do

c

02588

Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

00-8

00

Using male pins Touch the pins directly using test probes. CAUTION . &_ --------------

Be sure that you do not short circuit the connector use the test probe because this could damage the of the electronic control unit.

pins when you internal circuit

02590 Connector Inspection Procedures

Visual inspection Check for loose connection and

poor

engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

Check for a decrease in contact pressure between the male and female terminals.

02593

Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles.

00-9

00

•While the engine is running, do not remove the battery terminals. If the battery terminals are removed at that time, a surge voltage is gener-

ated and the

diode or

regulato~

might be weakened.

•Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.

02371

•Do not splash water over the alternator.

If water is directly splashed over the alternator, individual components will be short-circuited and might be destroyed.

05165

•

Do not short-circuit tor. If the terminals are diode trio might be

terminal Band terminal L

short-circuited while the destroyed.

while running the alterna-

alternator is running, the

f

04749

•	Disconnect the	battery terminals before quick-charging the battery.
	Quick-charging	without disconnecting the battery terminals might
	damage the diode or regulator.		·

I

/

05166

00-11

TABLE OF STANDARD TIGHTENING TORQUES
Tightening torque for flare nut for general purpose
Pipe diameter	Q>4.76 mm	<j>6.35 mm	Q>8mm	Q>10mm	Q>12mm
Tightening torque	17{1.7}	25 {2.6}	39 {4.0}	59 {6.0}	88 {9.0}

Unit: N ·m {kgf ·m}

Q>15mm 98 {10.0}

Tightening torque for anr piping nylon tube for general purpose
{DIN type}
Standard diameter		6x1mm		10 x 1.25 mm				12 x 1.5 mm
Tightening torque	6	{ 2.0	~g·6}	29+10	{ 3.0 ~·	0	}	49+10	{ 5.0 ~~.0}
	2o+
	-0			-0				-0

	Unit: N ·m {kgf ·m}
	15 x 1.5 mm
54+	5	{ 5.5	~~.0}
-0

Tightening torque for air piping nylon tube for general purpose

{SAE type}

Standard diameter

1/4 in.

3/8 in.

1/2 in.

Tightening torque

4

{

1.3

~g.4}

29+

5

{

3.0

~g-5}

49+

5

{

5.0

~g-5}

13+

-0

-0

-0

	Unit: N ·m {kgf ·m}
		5/8 in.
64+	5	{	6.5	~g-5}
-0

00-14

STR·UCTURE AND OPERATION

11

1. Cylinder Head and Crankcase <Engines with wet type cylinder liners: 6014, 14-T, 15-T>

1 9

2

1	Connecting plate
2	Glow plug
3	Cylinder liner
4	o~ring
5	Crankcase
6	Water jacket
7	Piston
8	Injection nozzle
9	Cylinder head
A: Cylinder liner size mark:

A,

B, C

•

•

•

A

01924

The cylinde~ liners 3 are a removable wet type liners. They are press-fitted into the top of the crankcase 5 and the bottom of the water jacket 6.

The 0-rings 4 are provided to prevent the ingress of coolant. The cylinder liners 3 and pistons 7 have size marks. The liner and piston that are paired should be of the same size mark.

<Engines with

dry type cylinder liner: 6015-T, 16, 16-E, 16-T, 16-TE, 16-TL,I16-TLEI>

-c--1

/-"-"lt'"H'~-""'~

1 2 3 4 5 6 7 8

Connecting plate Glowplug Cylinder liner Crankcase Water jacket Piston Injection nozzle Cylinder head

7

A

•

•

A: Cylinder liner size mark Outer diameter mark: 1, 2, 3 Inner diameter mark: A, B

The cylinder liners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fitted into the crankcase 4.

The cylinder liners 3, crankcase 4, and pistons 6 have size marks. They should be combined as specified according to the size marks. CD P.11-28

3

01925

11-3

STRUCTURE AND OPERATION
6.	Flywheel
	1
	I l!!!!l!!lll!!l!l!!!!l 1'

3

2

		A
		-	5	1
	I		1
		l!!!l!l!!!lnnlm!l

1 2 3

A:

Flywheel

Pilot bearing

Ring gear

Angle scale, cylinder number

01934

7.

Flywheel

PTO

1 2 3 4 5 6 7 8 9

Flange PTO shaft PTO idler shaft Flywheel housing Crank!;lhaft gear No. 1 idler gear PTO idler gear PTO idler gear PTO gear

. The flywheel PTO is fitted onto the top of the flywheel housing 4 and is driven by the crankshaft

gear

5.

01935

11-6