Mitsubishi S6R, S6R2 Service Manual
SERVICE MANUAL
199419-12120
August 2010
Pub. No. 99419-12120
FOREWORD
This service manual describes the maintenance and adjustment procedures, and specifi-
cations 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 mainte-
nance, and it may also be necessary to take appropriate measures which involve in disas-
sembly, 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.
I
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.
Note
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.
Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II
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
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 cmH
-1
Rotation speed: 1 min
= 1 rpm
2
2O (cmAq)
III
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 explo-
sion. 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-cir-
cuit. 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 crank-
case, 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, imme-
diately 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 con-
tact 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 elec-
trolyte, 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 discon-
nect 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 emer-
gency. Make counteract procedures
against a fire or an accident. Provide the contact per-
son and means of communication in case of emer-
gency.
IV
Stay Away From Rotating and Moving Parts
FOREWORD
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 immedi-
ate area when starting the engine. When the starter
device is tagged with the warning sign saying DO NOT
RUN, never start the engine.
Lockout and Tagout
Be sure to lockout and tagout before starting inspec-
tion 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 Inspection 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
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.
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 turn-
ing tool inserted or turning condition, it can not only
cause damage to the engine, but also lead to a per-
sonal injury.
V
FOREWORD
Be Careful of Exhaust Gas Poisoning
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 poison-
ing.
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.
VI
FOREWORD
Be Careful When Handling Fuel,
Engine Oil or LLC
Use Specified Fuel, Engine Oil and LongLife 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, irritation 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 run-
ning 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 imme-
diately 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.
VII
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 reconnecting 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 current.
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 cloth-
ing, 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 immedi-
ately, 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 seri-
ous 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 sys-
tem 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.
VIII
Other Cautions
FOREWORD
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 Inspections and Scheduled Inspections
Conduct the daily inspection and scheduled inspec-
tion/maintenance as described in this manual.
Failure to conduct the specified inspections may cause
various engine problems, damage to parts, and a seri-
ous 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, oper-
ate 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.
IX
FOREWORD
Warm-up the Engine Before Use
After starting the engine, run the engine at a low idling
speed for 5 to 10 minutes for warming-up. Start the
work after this operation is completed. Warm-up oper-
ation circulates lubricant in the engine, and works for
the longer service life and economical operation. Do
not continue the warm-up operation for a longer time
than necessary. Long warm-up operation causes car-
bon deposits in the cylinders, and may lead to incom-
plete combustion.
Do Not Operate the Engine in an Overloaded Condition
If the engine shows an overloaded condition such as
black exhaust smoke, reduce the load immediately to
an appropriate load condition. Overloading causes not
only high fuel consumption but also excessive carbon
deposits inside the engine. Carbon deposits cause
various problems and will shorten the service life of the
engine.
Cool Down the Engine Before Stop
Cool down the engine at low idling for five to six min-
utes before stopping it. Stopping the engine immedi-
ately after high-load operation will cause local heat up
of engine parts and shorten the service life of the
engine. During the cooling operation, check the engine
for abnormalities.
Do Not Continue Low Load Operation
Low load continuous operation (less than 30%) must
be limited within one hour. Long warm-up operation
causes carbon deposits in the cylinders, and may lead
to incomplete combustion. Also, after low load opera-
tion for approx one hour, run the engine at a 30% or
higher load for five minutes or more.
Use Care to Protect Engine From Water
Use care to protect engine from water such as rain
entering through the air inlet or exhaust openings. Do
not wash the engine while it is running. Cleaning fluid
or water can be sucked into the engine. Starting the
engine with water inside the combustion chambers
can cause the water hammering, and may result in
engine inner parts damage and serious accident.
Air Cleaner or
Pre-cleaner is to be Properlly Maintained.
With foreign material in the intake air, excessive wear
of the engine can result. Worn parts produce many
problems such as increase of oil consumption,
decrease of output and starting difficulties. For effec-
tive removal of dust from intake air, maintain the air
cleaner/pre-cleaner according to the following instruc-
tions.
Never perform maintenance of the air cleaner or pre-
cleaner during operation. Foreign material enters the
turbocharger and may result in a serious failure.
When removing the air cleaner or pre-cleaner, be
careful to prevent dust and foreign material collected
on the cleaner from entering the engine. After
removing the air cleaner or pre-cleaner, immediately
cover the opening (inlet port of engine or turbo-
charger silencer) with plastic sheet or similar means
to prevent foreign materials from entering the
engine.
An air cleaner with a dust indicator gives an alarm
when it is clogged. Conduct maintenance when the
alarm is given.
X
FOREWORD
Observe Safety Rules at Work Site
Observe the safety rules established at the workplace
when operating and maintaining the engine. Do not
operate the engine if you are in bad health. Consult
your supervisor about your condition. Operation of the
engine with decreased attention may cause improper
operation and results in an accident. When working in
a team of two or more people, use specified hand sig-
nals to communicate among workers.
Use Proper Tools for Maintenance Work
Always keep in mind to select most appropriate tools
for the work and use them correctly. If a tool is dam-
aged, replace with new tool.
Do Not Operate Starter for a Long Time
Do not use the starter for more than 10 seconds at a
time. If the engine does not start, wait for at least 1
minute before starting again. Continuous operation of
the starter to start a stubborn engine may lead to a flat
battery or starter burning out.
Cautions for Engine Trans portation
To road-transport the engine, consider the engine
weight, width and height, and obey applicable laws
and regulations such as road traffic laws, vehicle road
acts and vehicle restriction ordinances.
Be Careful of Engine Room Ventilation
Always keep the engine room well-ventilated. Insuffi-
cient intake air amount of the engine can cause an
increase in the engine temperature, and could result in
a decrease in the output power and poor performance.
It is highly recommended to calculate the required
amount of air supply to the engine and install an ade-
quate ventilation system before installing the engine.
Do Not Touch High Pressure Fuel Jet
Do not touch fuel jet leaked or sprayed from the high
pressure injection pipe. Fuel in the fuel injection pipe
has a high pressure and if the fuel impinges your skin,
it goes through the skin and can cause serious injury.
Do Not Turn Off the Battery Switch During
Operation
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the diodes and transistors in the starter can be
damaged.
XI
FOREWORD
Warning Labels
Maintenance of Warning Labels
Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other
chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part sticked with a warning label is replaced with a new one, attach a new identical warning label to the
new part.
To get new warning labels, contact our approved dealer.
XII
Warning labels
Points on Disassembling and Assembling
This service manual contains the recommended practices to
service the engine. The manual also contains dedicated spe-
cial tools made for the work, and the basic safety cautions to
obey when working. Note that this manual does not cover
all potential hazards that could occur during maintenance,
inspection and service works of the engine.
When working on the engine, follow the related instructions
in this manual and also be careful of the following:
Points on Disassembling
Use correct tools and instruments. Or serious damage or
accident may result.
Do not use jack bolts having sharp edge, as they may cause
damage to the surface.
Use a footing and workbench to place disassembled parts if
necessary, and obey the disassembling procedures
described in this manual. Do not place the parts on the
floor directly. Place them on a workbench or the like.
Place the engine parts in the order of removal to prevent
from missing. Place the parts in the serial order for reas-
sembling.
When reusing the engine parts, unless there are special rea-
sons, install them to their original positions.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which can not be
found after disassembling or cleaning.
Pay attention to the safety, especially for the balancing of
disassembled parts and carrying of heavy parts. (Get help,
and use jacks, chain blocks and guide bolts as necessary.)
Use protective gloves when you touch overheated or fro-
zen parts. Touching the part with a bear hand can cause
burns.
Points on Assembling
Wash all engine parts, except such parts as oil seals, O-
rings and rubber seats, in cleaning oil and dry them with
compressed air.
Use correct tools and instruments.
Use only high-quality lubricating oil and grease of the
appropriate type. Be sure to apply oil, grease or adhesive
to specified surfaces.
Use a torque wrench to tighten parts correctly when their
tightening torques are specified. Refer to "Tightening
torque table."
Replace Gaskets, packings and O-rings with new ones.
Apply adhesive as required. Do not apply adhesive too
much.
Use protective gloves when you touch overheated or fro-
zen parts. Touching the part with a bear hand can cause
burns.
FOREWORD
XIII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. Outline of Systems
3. Contents of Plate and Label
4. Specifications
Chapter 2 SERVICE DATA
1. Maintenance Service Data
2. Tightening Torque Table
Chapter 3 SERVICE TOOLS
1. Special Tools
Chapter 4 OVERHAUL INSTRUCTIONS
1. Determining Overhaul Timing
2. Compression Pressure - Measure
Chapter 5 DISASSEMBLY OF BASIC ENGINE
1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect
2. Rear Mechanism - Disassemble and Inspect
3. Front Mechanism - Disassemble and Inspect
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE
1. Cylinder Head and Valve Mechanism - Inspect and Repair
2. Rear Mechanism - Inspect and Repair
3. Front Mechanism - Inspect and Repair
4. Piston and Connecting Rod - Inspect and Repair
5. Crankcase and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE
1. Crankshaft and Main Bearing - Install
2. Cylinder Liner, Piston and Connecting Rod - Assemble
3. Front Mechanism - Assemble
4. Rear Mechanism - Assemble
5. Cylinder Head and Valve Mechanism - Assemble
Chapter 8 FUEL SYSTEM
1. Fuel System - Remove and Inspect
2. Fuel System - Disassemble, Inspect and Assemble
3. Fuel System - Install
Chapter 9 LUBRICATION SYSTEM
1. Lubrication System - Remove and Inspect
2. Lubrication System - Disassemble, Inspect and Assemble
3. Lubrication System - Install
Chapter 10 COOLING SYSTEM
1. Cooling System - Remove and Inspect
2. Cooling System - Disassemble, Inspect and Assemble
3. Cooling System - Install
Chapter 11 INLET AND EXHAUST SYSTEMS
1. Inlet and Exhaust Systems - Remove and Inspect
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble
3. Inlet and Exhaust Systems - Install
Chapter 12 AIR START SYSTEM
1. Air Start System - Remove and Inspect
2. Air Start System - Disassemble, Inspect and Assemble
3. Air Start System - Install
Chapter 13 ADJUSTMENT AND OPERATION
1. Engine - Adjust
2. Break-in Operation
3. Engine-Test and Adjustment
Chapter 1 GENERAL
1. External View ...........................................................................................................1-3
2. Outline of Systems................................................................................................1-13
2.1 Outline of Fuel System ........................................................................................................... 1-13
2.2 Outline of Lubrication System................................................................................................. 1-13
2.3 Outline of Cooling System ...................................................................................................... 1-14
2.4 Outline of Inlet and Exhaust System....................................................................................... 1-17
3. Contents of Plate and Label .................................................................................1-19
3.1 Name Plate ............................................................................................................................. 1-19
3.2 Caution Plate .......................................................................................................................... 1-19
3.3 Emissions Certification Label.................................................................................................. 1-19
4. Specifications ........................................................................................................1-20
1-1
Chapter 1 GENERAL
Tension pulley
Engine coolant outlet
Water pump
S6R-PTA with fan spec
Thermostat case
Oil pan
Note: Configuration varies depending on the destination and specifications.
Damper
Flywheel
Engine oil discharge port
Rotation direction
Rotation direction
Timing gear case
S6R-PTA with fan spec
Note: Configuration varies depending on the destination and specifications.
Rotation direction
1. External View
Chapter 1 GENERAL
Engine Front View
Engine Rear View
1-3
Chapter 1 GENERAL
Oil level gauge
Governor
Governor oil filter
Fuel injection pump
Fuel filter
Oil cooler
Engine coolant inlet
Oil filler
Stop solenoid
Fuel outlet
Fuel inlet
Rear
Front
Damper
Oil filter
Bypass oil filter
Front hanger
Fuel feed pump
Breather
Rear hanger
Water pump
S6R-PTA with fan spec
Note: Configuration varies depending on the destination and specifications.
Engine coolant outlet
Starter
Air cooler
Turbocharger
Front
Rear
Air inlet
Exhaust manifold
Exhaust pipe, exhaust outlet
Relief valve
Alternator
S6R-PTA with fan spec
Note: Configuration varies depending on the destination and specifications.
Left Side View
1-4
Right Side View
Chapter 1 GENERAL
Tension pulley
Engine coolant outlet
Thermostat case
Oil pan
S6R-PTK
Note: Configuration varies depending
on the destination and specifications.
Water pump
Damper
Flywheel
Timing gear case
Note: Configuration varies depending
on the destination and specifications.
S6R-PTK
Engine oil drain port
Rotation directionRotation directionRotation direction
Engine Front View
Engine Rear View
1-5
Chapter 1 GENERAL
Governor
Governor oil filter
Fuel injection pump
Fuel filter
Oil cooler
Oil filler
Rear
Front
Front hanger
Breather
Rear hanger
Water pump
Note: Configuration varies depending on the destination and specifications.
S6R-PTK
Fuel feed pump
Stop solenoid
Oil level gauge
Fuel return port
Fuel inlet
Damper
Oil filter
Bypass oil filter
Starter
Engine air cooler
coolant outlet
Air cooler
Engine air cooler
coolant inlet
Turbocharger
Front
Rear
Exhaust manifold
Alternator
S6R-PTK
Note: Configuration varies depending on the destination and specifications.
Exhaust pipe, exhaust outlet
Air inlet
Relief valve
Left Side View
Right Side View
1-6
Chapter 1 GENERAL
Tension pulley
Engine coolant outlet
Thermostat case
Oil pan
Note: Configuration varies depending on the destination and specifications.
S6R-Y2PTAW
Water pump
Damper
Water pump
for air cooler cooling
Flywheel
Timing gear case
S6R-Y2PTAW
Note: Configuration varies depending on the destination and specifications.
Engine oil drain port
Rotation directionRotation direction
Rotation direction
Engine Front View
Engine Rear View
1-7
Chapter 1 GENERAL
Oil level gauge
Governor
Fuel injection pump
Fuel filter
Oil cooler
Engine coolant inlet
Oil filler
Fuel return port
Fuel inlet
Rear
Front
Front hanger
Breather
Rear hanger
Water pump
S6R-Y2PTAW
Note: Configuration varies depending on the destination and specifications.
Fuel feed pump
Stop solenoid
Damper
Oil filter
Bypass oil filter
Alternator
Starter
Air cooler coolant outlet
Air cooler
Turbocharger
Front
Rear
Exhaust manifold
S6R-Y2PTAW
Note: Configuration varies depending on the destination and specifications.
Exhaust pipe, exhaust outlet
Air inlet
Relief valve
Air cooler coolant inlet
Left Side View
Right Side View
1-8
Chapter 1 GENERAL
Thermostat case
Note: Configuration varies depending on the destination and specifications.
S6R2-PTAA
Water pump
Damper
Coolant inlet
Coolant outlet
Air outlet for air cooler
Air inlet for air cooler
Flywheel
Timing gear case
S6R2-PTAA
Note: Configuration varies depending on the destination and specifications.
Engine oil drain port
Rotation directionRotation direction
Rotation direction
Turbocharger
Engine Front View
Engine Rear View
1-9
Chapter 1 GENERAL
Fuel return port
Oil level gauge
Fuel inlet
Breather
Stop lever
Actuator (governor)
Fuel injection pump
Fuel feed pump
Stop solenoid
Water pump
Damper
Bypass oil filter
Oil filter
Oil filler
Oil cooler
Fuel filter
Fan
Front hanger
Front
Rear
Exhaust pipe, exhaust outlet
S6R2-PTAA
Note: Configuration varies depending on the destination and specifications.
Starter
Relief valve
Radiator
Air cooler
Air duct
Front
Rear
Rear hanger
S6R2-PTAA
Note: Configuration varies depending on the destination and specifications.
Oil pan
Left Side View
Right Side View
1-10
Chapter 1 GENERAL
Tension pulley
Thermostat case
Oil pan
Water pump
Damper
Note: Configuration varies depending on the destination and specifications.
S6R-Z3MPTAW
Engine coolant outlet
Flywheel
Timing gear case
Silencer
S6R-Z3MPTAW
Note: Configuration varies depending on
the destination and specifications.
Engine oil drain port
Rotation directionRotation directionRotation direction
Engine Front View
Engine Rear View
1-11
Chapter 1 GENERAL
Oil level gauge
Governor
Governor oil filter
Fuel injection pump
Fuel filter Oil cooler
Engine coolant inlet
Oil filler
Fuel return port
Fuel inlet
Rear
Front
Damper
Front hanger
Fuel feed pump
Breather
Rear hanger
Water pump
S6R-Z3MPTAW
Note: Configuration varies
depending on the destination
and specifications.
Starter
Oil filter
Oil filter
Bypass oil filter
Air cooler coolant outlet
Air cooler
Air cooler coolant inlet
Turbocharger
Front
Rear
Pre-cleaner air inlet
Exhaust manifold
Exhaust pipe, exhaust outlet
Alternator
S6R-Z3MPTAW
Note: Configuration varies depending on the destination and specifications.
Left Side View
1-12
Right Side View
2. Outline of Systems
Fuel injection nozzle
Fuel leak-off pipe
Fuel injection pump
Fuel feed pump
From fuel tank
To fuel tank
Fuel filter
Fuel injection pipe
Oil pressure governor spec
Governor
Turbocharger
Camshaft
Oil thermostat
Oil cooler
Timing gear
Fuel injection pump
Oil pump
Safety valve
Bypass oil filter
Oil strainer
Oil filter
Relief valve
Crankshaft
Water pump
Piston
cooling nozzle
Piston
Rocker shaft
Oil filter
Governor oil filter
2.1 Outline of Fuel System
Chapter 1 GENERAL
2.2 Outline of Lubrication System
Outline of Fuel System
Outline of Lubrication System
1-13
Chapter 1 GENERAL
Turbocharger
Camshaft
Oil thermostat
Oil cooler
Electronic governor spec
Timing gear
Fuel injection pump
Oil pump
Safety valve
Bypass oil filter
Oil strainer
Oil filter
Relief valve
Crankshaft
Water pump
Piston
cooling nozzle
Piston
Rocker shaft
Oil filter
Water outlet pipe (rocker case)
Oil cooler
Air cooler
PTA spec
Thermostat
Radiator
Water pump
2.3 Outline of Cooling System
Outline of Lubrication System
1-14
Outline of Cooling System
Chapter 1 GENERAL
Water outlet pipe (rocker case)
Oil cooler
PTK spec
Thermostat
Air cooler
Water pump
Air cooler,
Engine coolant inlet
Air cooler,
engine coolant outlet
Water outlet pipe (rocker case)
Oil cooler
PTAW spec (Outside of water pump for air cooler cooling)
Thermostat
Air cooler
Water pump
Exhaust manifold
Air cooler coolant inlet Air cooler coolant outlet
Engine coolant outlet
Outline of Cooling System
Outline of Cooling System
1-15
Loading...