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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:

65kW/ 88 Hp 6

Bore x Strole (mm):

94 x 120

Displacement (cc):

4996

Compression ratio:

19.5 : 1

Intercooler:

N/A

Rated power (kW/rpm):

65kW/2200

Peak torque (Nm/rpm):

348/1400

Low idle speed (rpm):

2400 +/- 50

High idle speed (rpm):

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 / 30°c) • 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  90°C • 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 *

- Adjust valves

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

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  90°C - 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 76.5°C it circulates via a by-pass to the water pump and back into the cylinder block. -When the coolant goes over 76.5°C the thermostat gradually opens and the coolant flows direct into the radiator. (thermostat max. open at 90°C)

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