Mitsubishi 6M60 Manuals

Manuals and User Guides for Mitsubishi 6M60. We have 1 Mitsubishi 6M60 manual available for free PDF download: Service Manual

Mitsubishi 6M60 Service Manual

Mitsubishi 6M60 Service Manual (331 pages)

Brand: Mitsubishi | Category: Engine | Size: 27 MB

Table of Contents

Group Index
3
Table of Contents
4
Group 00 General
4
General Inspection and Adjustment
5
How to Read this Manual
5
- Inspection
  5
- Service Procedure
  5
- Terms and Units
  5
- Tightening Torque
  6
- Units
  6
Engine Number
10
Precautions for Maintenance Operation
11
- Electrical
  13
- Inspection of Connectors
  15
- Inspections on Male Terminals
  15
- Visual Inspection
  15
- Checking for Loose Terminals
  16
- Inspections When a Fuse Blows
  16
- Service Precautions for Alternators
  16
- Precautions for Arc Welding
  19
1 Using Multi-Use Tester

20
- Connecting Multi-Use Tester
  20
- Diagnostic Codes
  20
2 Use of Blinking Warning Lamp for Diagnostic Code

22
- Erasing Diagnostic Codes
  23
- Table of Standard Tightening Torques
  24
3 Up-Time Service Tool Functions

24
- Menu
  24
- Input Monitor and Output Monitor
  25
- VCM-3 Input Monitor and Output Monitor
  25
- Fault Status
  30
- Fault History
  31
- Troubleshooting
  32
- General Information
  32
- Before Replacing Controllers
  32
- Connection of Service Tool
  32
- How to Clean Harness Connectors and System Components
  33
- Hexagon Head Bolts and Stud Bolts (Unit: N·M {Kgf·M})
  34
- Hexagon Head Flange Bolts (Unit: N·M {Kgf·M})
  34
- Hexagon Nuts
  35
- Hexagon Flange Nuts
  35
- Tightening Torque for General-Purpose Flare Nut
  36
- Tightening Torque for General-Purpose Air Piping Nylon Tube
  36
- Engine
  37
- Specifications
  38
- Structure and Operation
  39
- Engine Proper
  39
- Valve Mechanism
  40
- Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket
  40
- Connecting Rod
  41
- Piston
  41
5 Piston

42
- Timing Gears
  42
  - No. 3 Idler Gear
    42
  - Non-Backlash Mechanism
    43
- Flywheel
  43
- Troubleshooting
  44
- Measuring Compression Pressure
  46
  - Service Standards
    46
  - Special Tools (Unit: MM)
    46
- General Inspection and Adjustment
  46
- Inspection and Adjustment of Valve Clearances
  48
- Rocker Cover, Rocker Bracket and Camshaft
  52
  - Disassembly Sequence
    53
  - Assembly Sequence
    53
  - Work before Removal
    53
  - Lubricant And/Or Sealant
    53
  - Releasing Valve Spring Force
    54
  - Removal: Camshaft
    54
  - Installation: Rocker Case
    54
  - Installation: Packing
    55
  - Installation: Rocker Case Upper Gasket
    55
  - Installation: Rocker Cover Gasket
    55
  - Rocker and Bracket Assembly
    56
  - Inspection: Radial Clearance of Rocker (Roller)
    57
  - Inspection: Clearance between Rocker Shaft and Bushing
    57
  - Replace of Rocker Bushing
    57
  - Camshaft
    58
  - Removal: Camshaft Gear
    58
  - Inspection: Camshaft
    59
  - Cam Lift
    59
  - Bend
    59
  - Oil Clearance at Journal
    59
- Cylinder Head and Valve Mechanism
  60
- Piston and Connecting Rod, Cylinder Liner
  76
- Flywheel
  90
  - Inspection before Removal
    92
  - Inspection: Flywheel Friction Surface Runout When Fitted
    92
  - Removal: Flywheel
    92
  - Removal: Ring Gear
    92
  - Inspection: Flywheel
    93
  - Friction Surface Height
    93
  - Friction Surface Distortion
    93
  - Rectiﬁcation of Friction Surface
    93
  - Installation: Flywheel Housing
    94
  - Installation: Rear Oil Seal
    94
  - Installation: Air Compressor
    95
  - Installation: Ring Gear
    95
  - Installation: Flywheel
    95
- Timing Gears
  98
- Crankshaft and Crankcase
  104
  - Removal: Front Oil Seal Slinger
    107
  - Removal: Rear Oil Seal Slinger
    107
  - Removal: Crankshaft Gear
    107
  - Inspection: Main Bearing
    107
  - Inspection: Crankshaft
    108
  - Main Bearing-To-Crankshaft Clearance
    108
  - Grinding of Crankshaft
    109
  - Crankshaft Undersize Dimensions
    109
  - Inspection: Distortion of Crankcase Top Surface
    109
  - Installation: Rear Plate
    110
  - Installation: Crankshaft Gear
    110
  - Installation: Front Oil Seal Slinger
    110
  - Installation: Rear Oil Seal Slinger
    110
  - Installation: Main Bearing
    111
  - Installation: Thrust Plate
    111
  - Installation: Main Bearing Cap
    111
  - Installation: Front Oil Seal
    112
  - Installation: Front Cover
    112
  - Lubrication
    113
- Specifications
  114
- Lubrication System
  115
- Oil Pump
  115
- Structure and Operation
  115
- Oil Cooler
  116
  - Bypass Valve
    116
  - Engine Oil Pressure Switch and Regulator Valve
    116
  - Oil Filter
    117
- Lubrication of Engine Components
  118
  - Main Bearing and Connecting Rod Bearing
    118
  - Check Valves and Oil Jets
    119
  - Turbocharger
    120
  - Air Compressor
    120
- Troubleshooting
  121
- Oil Filter Replacement
  122
- Engine Oil Replacement
  124
- Oil Pressure Measurement
  125
- Oil Pan, Oil Jets and Oil Level Sensor
  126
- Oil Pump, Oil Strainer
  128
- Oil Filter
  130
- Oil Cooler
  132
- Regulator Valve
  133
- Fuel and Engine Control
  134
- Specifications
  135
- Fuel System (Flow of Fuel)
  136
- Structure and Operation
  136
- Fuel Filter
  137
- Water Separator
  138
- Troubleshooting
  139
- Air-Bleeding of Fuel System
  141
- Fuel Filter Replacement
  143
- Water Separator Element Replacement
  145
- Fuel Filter
  147
- Water Separator
  149
- Common Rail
  153
- Supply Pump
  155
  - Installation: Supply Pump
    156
  - Installation: Injection Pipe and Fuel Pipe
    156
- Injector
  157
  - Removal: Injector
    158
  - Electronically Controlled Fuel System
    159
- Specifications
  160
- Structure and Operation
  162
- Overview
  162
  - SCV (Suction Control Valve)
    165
  - Flow Damper
    166
- Electronic Control System
  170
  - System Block Diagram
    170
  - Engine Electronic Control Unit
    170
  - Input Signals
    170
  - Fuel Injection Control
    171
  - Pilot Injection
    171
  - Fuel Injection Quantity Control
    172
  - Fuel Injection Quantity During Engine Startup
    172
  - Basic Fuel Injection Quantity
    172
  - Maximum Injection Quantity
    172
  - Fuel Injection Timing Control
    173
  - Main Injection Timing
    173
  - Pre Injection Timing
    173
  - Warm-Up Acceleration Function
    174
  - Starter Continuous Energizing Preventing Function
    174
  - Preheating Function
    174
  - Pre-Glow and After-Glow
    174
  - Operation Mode
    175
  - When the Engine Coolant Temperature
    175
  - Fault Diagnostic Function
    175
- Electronic Control Unit Connection Diagram
  176
- Troubleshooting
  178
- Diagnostic Procedure
  178
- Diagnostic Precautions
  179
- Inspections Based on Diagnostic Codes
  180
- Multi-Use Tester Service Data
  195
- Reading and Erasing Diagnostic Trouble Codes
  197
- Actuator Tests Performed Using Multi-Use Tester
  199
  - After Replacement of Engine Electronic Unit with New One
    201
  - Check after Engine Electronic Control Unit Programming
    201
- Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit
  201
- Inspections Performed at Electronic Control Unit Connectors
  202
  - Electronic Control Unit Connector Terminal Layout
    202
  - Inspection Instructions
    202
- Inspection of Electrical Equipment
  205
- Specifications
  211
- Cooling System (Flow of Coolant)
  212
- Structure and Operation
  212
- Thermostat
  213
- Water Pump
  213
- Troubleshooting
  214
  - Coolant Replacement and Cleaning of Cooling System
    215
  - Draining of Coolant
    215
  - Cleaning Procedure
    215
- Air Bleeding of Cooling System
  217
- Gas Leakage Test
  217
- Inspection of V-Belts
  218
- Disconnection and Connection of Hoses and Pipes
  219
  - Removal Sequence
    219
  - Installation Sequence
    219
- Radiator, Oil Cooler, Intercooler and Fan Shroud
  221
  - Inspection: Air Leaking of Intercooler
    222
  - Inspection: Air Leaking of Oil Cooler
    222
  - Inspection: Pressure Cap
    222
  - Pressure Valve Opening Pressure
    222
  - Inspection of Vent Valve
    223
  - Installation: Fan Shroud
    223
  - Radiator Assembly
    227
  - Inspection: Air Leaking of Radiator
    228
  - Removal: Upper Tank and Lower Tank
    228
  - Inspection: Core Groove Where Tank Is to be Mounted
    230
  - Repairing Core
    230
  - Installation: Upper Tank, Lower Tank
    231
- Cooling Fan and V-Belt
  233
- Inspection: Tension of V-Belts
  234
- Water Pump
  237
- Thermostat
  241
- Intake and Exhaust
  243
- Specifications
  244
  - Air Cleaner
    245
  - Waste Gate Mechanism
    246
- Structure and Operation
  246
- Air Cleaner
  248
  - Cleaning: Element
    249
  - Inspection: Element
    249
  - Installation: Turbocharger
    251
  - Alignment Mark
    252
- Turbocharger
  252
  - Removal: Turbine Housing
    253
  - Removal: Compressor Cover
    253
  - Inspection: Cartridge Assembly
    253
  - Installation: Snap Ring
    254
  - Inspection: Free Rotation of Cartridge Assembly
    254
- Intake Manifold
  256
- Installation: Intake Manifold
  257
- Exhaust Manifold
  258
- Emission Control
  259
- Exhaust Gas Recirculation System
  260
- Structure and Operation
  260
  - EGR Solenoid Valves
    261
  - EGR Valve
    261
- Blowby Gas Return System
  262
  - PCV: Positive Crankcase Ventilation
    262
  - Replacement of PCV Valve Element
    263
- Egr Valve, Egr Solenoid Valve, Egr Pipe and Egr Cooler
  264
  - Inspection: EGR Cooler
    266
  - Exhaust Gas Passage Side
    266
  - Coolant Passage Side
    266
- Blowby Gas Return System
  267
- Electrical
  270
- Specifications
  271
- Starter
  272
- Structure and Operation
  272
- Alternator
  273
  - Alternator with Neutral Diodes
    274
  - Features
    274
- Circuit Diagram
  276
- Troubleshooting
  277
- To #179 SWITCH
  279
  - Inspection of Starter Relay
    280
  - Inspection of Main Power Relay
    280
  - Inspection of Glow Relay
    280
- To #249 RELAY
  280
- To #349 SENSOR
  281
- To #859 OTHER
  283
- Starter
  285
  - Work before Disassembly
    287
  - Disassembly: Pinion
    287
  - Disassembly: Yoke and Brush Holder
    289
  - Disassembly: Gear Shaft and Internal Gear
    289
  - Disassembly: Front Bearing
    289
  - Inspection: Magnetic Switch
    290
  - Test for Coil Open Circuit
    290
  - Test for Fused-Together Contacts
    290
  - Test for Contact-To-Contact Continuity
    290
  - Inspection: Brush Spring Pressure
    291
  - Inspection: Brush
    291
  - Brush Length
    291
  - Inspection: Yoke
    291
  - Inspection: Brush (+)
    292
  - Inspection: Armature
    292
  - Test for Coil Grounding
    292
  - Commutator Outside Diameter
    292
  - Mold Depth between Segments
    293
  - Inspection: Overrunning Clutch
    293
  - Assembly: Front Bearing
    293
  - Assembly: Yoke and Brush Holder
    294
  - Assembly: Magnetic Switch
    294
  - Assembly: Pinion
    294
  - Inspection: Performance and Pinion Gap
    295
  - Performance Test
    295
- Alternator
  297
  - Inspection: Alternator
    298
  - Adjustment Voltage of Regulator (Bench Test)
    298
  - Disassembly: Rotor and Front Bracket
    300
  - Disassembly: Pulley
    300
  - Disassembly: Field Coil
    301
  - Disassembly: Stator
    301
  - Inspection: Field Coil
    301
  - Inspection: Stator
    302
  - Inspection: Rectiﬁer
    302
- Inspection of Regulator
  304
- Inspection of Preheating System
  305
- Special Equipment
  306
- Specification
  307
- Air Compressor
  307
- Air Dryer
  307
  - During Suction
    310
  - During Compression and Delivery
    310
- Troubleshooting
  314
  - Maintenance and Inspection of Air Dryer
    315
  - Every Three Months or 500 Hours
    315
  - Every Year or 2000 Hours
    315
  - Every Two Years or 4000 Hours
    315
- Inspection and Adjustment of Air Dryer's Air Pressure Governor
  316
- Operating Pressure of Air Pressure Governor
  317
- AIR COMPRESSOR <154 CM 3 {154 Ml
  319
- Air Dryer
  327

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