Training:

Mitsubishi TIER II, S6S-DT engine

(Fork-lift specification) Instructor: Jean Joris 1 Service Department

Mitsubishi:

- Mitsubishi was founded in 1870 - Sagamihara factory opened in 1970 - Since 1992 Joint Venture with Caterpillar for engines and forklifts - 2200 employees

Instructor: Jean Joris

2 Service Department

Engine specifications:

Rotation direction: Clockwise, viewed from the front (timing gear side)

Instructor: Jean Joris

3 Service Department

Engine specifications:
Engine output: Number of cylinders: Bore x Strole (mm): Displacement (cc): Compression ratio: Intercooler: Rated power (kW/rpm): Peak torque (Nm/rpm): Low idle speed (rpm): High idle speed (rpm):
65kW/ 88 Hp 6 94 x 120 4996 19.5 : 1 N/A 65kW/2200 348/1400 2400 +/- 50 875 +/- 50

Injection pump: Distributor (Bosch VE-type) Engine Oil Quantity: 17.5L Combustion method: Direct injection

Instructor: Jean Joris

4 Service Department

Engine specifications:
Firing order: 1-5-3-6-2-4 Nominal compression pressure at 300 Rpm: 2.94 MPa. (29.4 bar) (oil and water temp. at: 20 / 30c) Limit: 2.64 MPa. (26.4 bar) Lubricating oil pressure: At 1500 rpm: 0.29 0.49 MPa. (2.9 4.9 bar) Limit: 0.15 MPa (1.5 bar) Idling: 0.1MPa (1 bar). Limit: 0.05 MPa (0.5 bar) Oil temperature: 70 90C Oil pressure relief valve (piston) opening pressure: 0.35 +/- 0.05 MPa (3.5 +/- 0.5 bar)

Instructor: Jean Joris

5 Service Department

Engine serial position:

Engine serial number is stamped in the block under the exhaust manifold, close to the flywheel.

Instructor: Jean Joris

6 Service Department

Tightening Torque Tables:

Instructor: Jean Joris

7 Service Department

Tightening Torque Tables:

Instructor: Jean Joris

8 Service Department

Tightening Torque Tables:

Instructor: Jean Joris

9 Service Department

Maintenance intervals:
Every 10 Hrs / daily service:
- Engine oil level check / add - Air filter element check / clean

Every 50 Hrs service:

- Engine oil & oil filter change / replace (initial 50 hours only) - Water separator check / clean

Every 250 Hrs service:

- Engine oil & oil filter change / replace

Every 500 Hrs service:

- Air cleaner element * - Fuel filter
* = air cleaner element / fuel filter change interval may be determined by an air / fuel restrictor indicator

- Adjust valves

Instructor: Jean Joris

10Service Department

Maintenance interval & data:

Valve clearance (cold): 0.25 mm (inlet & exhaust) Every 500 Hrs ! Fan belt deflection: 10~12 mm

Engine oil spec. / interval: CH-4 15W-40 / 250 Hrs Instructor: Jean Joris 11Service Department

Fuel injection system:

Injector nozzle valve opening pressure:
17.65 MPa
(176.5 bar)

Fuel injection pump:

Instructor: Jean Joris

12Service Department

Fuel injection system: Injectors

Tightening toque for re-assembling injector: 24.5 34.3 Nm

Instructor: Jean Joris

13Service Department

Fitting the fuel injection system:

- Install the pump align the mark (3) on the pump gear with the mark (3) on the timing gear. (remove complete timing cover) - Or install the pump and align the mark (3) on the pump gear with the mark you made earlier on the timing gear. (remove
cover over fuel injection gear)

Instructor: Jean Joris

14Service Department

Adjusting the fuel injection system:

- Turn crankshaft clockwise until TDC - Pointer 0 - Inlet & exhaust rocker arm cylinder No.:1 = loose (not actuated)

- Check that the alignment mark (A) of the fuel injection pump is aligned with the alignment mark (B) of the flange plate.

Instructor: Jean Joris

15 15Service Department

Lubrication system:
Oil cooler

Lubricating oil pressure: - At 1500 rpm: 0.29 0.49 MPa. (2.9 4.9 bar) Limit: 0.15 MPa (1.5 bar) - Idling: 0.1MPa. (1 bar) Limit: 0.05 MPa (0.5 bar) Oil temperature: 70 90C - Oil relief valve (piston) opening pressure: 0.35 +/- 0.05 MPa
(3.5 +/- 0.5 bar)

- Safety valve opening pressure:

1.1 MPa.
(11 bar)

Instructor: Jean Joris

16Service Department

Lubrication system:
Position: relief & safety valves

Instructor: Jean Joris

17Service Department

Lubrication system:
Oil pressure relief valve:

Instructor: Jean Joris

18Service Department

Lubrication system: oil filter by-pass

By-pass valve opens: when filter is clogged and there is a

pressure difference of more then 0.1 +/- 0.02 MPa ( 1 +/- 0.2 bar) between the upstream and downstream oil pressure.

Instructor: Jean Joris

19Service Department

Lubrication system: oil cooling jets

Instructor: Jean Joris

20Service Department

Lubrication system:
What role has the oil in the engine:
It reduces friction of sliding surfaces and prevents seizures. It fills gaps between metal parts and seals the combustion chamber to prevent leaks of combustion energy. It rinses away carbon and impurities produced by combustion. It protects metal parts from corrosive products with oil film, thus preventing rust.

Instructor: Jean Joris

21Service Department

Cooling system:

- System is forced circulation type. - Coolant is sucked by the water pump out of the radiator via the cylinders through the cylinder head thermostat. - When the coolant is below 76.5C it circulates via a by-pass to the water pump and back into the cylinder block. -When the coolant goes over 76.5C the thermostat gradually opens and the coolant flows direct into the radiator. (thermostat max. open at 90C)

Instructor: Jean Joris

22Service Department

Cooling system:
Test procedure for thermostat:

Instructor: Jean Joris

23Service Department

Outline of inlet and exhaust system:

Boost pressure at 87HP/2200rpm : +/- 460mmHg = +/- 61 kPa (0.61 bar) In the Material Handling Equipment configuration, the engine is not equipped with an air to air intercooler.

Turbo: Mitsubishi TE06H

Instructor: Jean Joris

24Service Department

Mitsubishi S6S-DT with distributor VE inj. pump

Thank you for your attention, this is the end of the training presentation for this particular engine. More details on this engine can be found:
http://ce.hhi.co.kr/eng/parts/sm/ENGINE/3.pdf

Instructor: Jean Joris

25Service Department