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Disassembly and inspection of Mitsubishi R16 diesel engine intake and exhaust system


Detailed Description:

Disassembly and Inspection of Mitsubishi R16 Diesel Engine Exhaust System ... 11-3

1.1 Dismantling and Overhaul of Air Pipe ... 11-3

1.2 Removal and maintenance of heat shield ... 11-7

1.3 Disassembly and inspection of exhaust pipe ... 11-9

1.4 Disassembly and Inspection of Exhaust Manifold ... 11-11

2. Mitsubishi R16 Diesel Engine Intake and Exhaust System Disassembly, Maintenance, Assembly ... 11-13

2.1 Mitsubishi S16 Diesel Engine Air Cooler Disassembly, Maintenance and Assembly. 11-13

2.2 Cleaning the air filter .. 11-15

3. Mitsubishi R16 diesel engine inlet and exhaust system installation ... 11-16

3.1 Exhaust pipe installation .. 11-16

3.2 Installation of Mitsubishi S16 Diesel Engine Air Cooler ... 11-17

1. Mitsubishi R16 diesel engine intake and exhaust system disassembly, inspection

1.1 Air pipe disassembly, maintenance

Disassembly and repair of air pipes

Disassembly sequence

1 air pipe

2 pipe joints

3 Air tube

4 Air tube

5 Air tube bracket

Seawater Mitsubishi S16 Diesel Air Cooler Specifications

Disassembly and repair of air pipes

Disassembly sequence

1 air pipe

2 pipe joints

3 Air tube

Disassembly and repair of air pipes

Disassembly sequence

1 air pipe

2 Air pipe

3 pipe joints

4 Rubber hose

5 Air tube (approx. 19 kg)

6 pipe clamp

7 air tube

8 Rape tube

9 pipe clamp

10 Air tube

11 Air tube

12 Air tube bracket

13 Air pipe bracket

14 Air tube bracket

TAA specification (between Mitsubishi S16 diesel engine air cooler, Mitsubishi R16 diesel engine and Mitsubishi R16 diesel engine cylinder block) Disassembly, inspection

Disassembly sequence

1 air pipe

2 rubber hose

3 Air tube

4 Rubber hose

5 Air tube

6 rubber hose

7 air tube

8 rubber hose

9 rubber hose

10 Air box

11 Air box

12 Air tube bracket

13 Air pipe bracket

14 Air tube bracket

15 Air tube bracket

1.3 Disassembly and inspection of exhaust pipe

Disassembly and inspection of exhaust pipe TD15, TF15􃾘􁸐

Disassembly sequence

Disassembly sequence

1 muffler assembly

2 Silencer cover

3 V-shaped fixture

4 Mitsubishi S16 diesel turbocharger

5 Exhaust pipe connector

6 Exhaust pipe (approx. 50 kg)

7 seats

TD13 specification Disassembly and inspection of exhaust pipe

Disassembly sequence

1 muffler assembly

2 Silencer cover

3 V-shaped fixture

4 Mitsubishi S16 diesel turbocharger

5 Exhaust pipe connector

6 Sealing ring

7 Exhaust pipe (approx. 29 kg)

8 seats

Disassembly and inspection of exhaust pipe

Disassembly sequence

1 muffler assembly

2 Silencer cover

3 V-shaped fixture

4 Mitsubishi S16 diesel turbocharger

5 Coupling

6 Coupling

7 Exhaust pipe (approx. 50 kg)

8 Exhaust pipe holder

Disassembly and inspection of Mitsubishi R16 diesel engine exhaust manifold

Mitsubishi R16 diesel engine exhaust manifold removal and inspection

Disassembly sequence

1 Coupling

2 Rape tube

3 exhaust manifold

Mitsubishi R16 diesel engine static pressure exhaust pipe specifications

Disassembly sequence

1 Connection 2 Rao 3 Exhaust manifold

Disassembly and inspection of Mitsubishi R16 diesel engine exhaust manifold

Disassembly sequence

1 Coupling 2 Rape 3 Exhaust manifold

Disassembly and inspection of Mitsubishi R16 diesel engine exhaust manifold

Disassembly sequence

1 V-shaped clamp 2 Rao tube 3 Exhaust manifold

Disassembly and inspection of Mitsubishi R16 diesel engine exhaust manifold

Disassembly sequence

1 V-shaped clamp 2 Rao tube 3 Exhaust manifold

Disassembly, overhaul and assembly of the Mitsubishi R16 diesel engine intake and exhaust system

2.1 Mitsubishi S16 Diesel Engine Air Cooler Disassembly, Maintenance and Assembly

Disassembly, maintenance and assembly of Mitsubishi S16 diesel air cooler

Disintegration order

1 pipe joint

2 Mitsubishi S16 Diesel Engine Air Cooler Tube

3 pipe joints

4 tubes

5 Mitsubishi S16 Diesel Engine Air Cooler Cover

6 Mitsubishi S16 diesel air cooler core (mass: 45 kg) (large Mitsubishi S16 diesel air cooler specifications about 53 kg)

7 Seat

Disassembly, maintenance and assembly of Mitsubishi S16 diesel air cooler

Disintegration order

Disintegration order

1 Mitsubishi S16 diesel engine air cooler cover (approx. 28 kg)

2 Mitsubishi S16 diesel air cooler core (sea water Mitsubishi S16 diesel air cooler specifications about 60 kg) (clear water 2 Mitsubishi S16 diesel air cooler specifications about 51 kg)

3 plates

4 Mitsubishi S16 diesel engine air cooler housing (approx. 23 kg)

5 Mitsubishi S16 diesel air cooler core (sea water Mitsubishi S16 diesel air cooler specification about 60 kg) (clear water 2 section Mitsubishi S16 diesel air cooler specification about 51 kg)

6 plates

7 seat ring (approx. 40 kg)

Inspection of Mitsubishi S16 diesel air cooler

2.1.2 Cleaning method of Mitsubishi S16 diesel air cooler

Blow in compressed air (0.29 to 0.49 MPa {3 to 5 kgf / cm2} or less) in the opposite direction to the normal air flow direction, blow off the adherent, and check for corrosion or cracks.

2.1.3 Leak Detection of Mitsubishi S16 Diesel Engine Air Cooler

Immerse the Mitsubishi S16 diesel air cooler in the water tank, and send compressed air (0.39MPa {4 kgf / cm2}) from the cooling water side to check for air leakage.

2.1.4 Assembly of Mitsubishi S16 Diesel Engine Air Cooler

The order of assembly is the reverse of disassembly.

The gap between the cooler core and the plate is sealed with KE45-W manufactured by Shin-Etsu Chemical Co., Ltd. or an equivalent silicon-based sealant.

2.2 Cleaning the air filter

(1) Remove the air filter from the muffler and clean it with a neutral detergent.

(2) Rinse in clean water.

(3) Install it on the muffler after fully drying.

Note: If the air filter is damaged, please replace it with a new one.

3. Installation of Mitsubishi R16 diesel engine intake and exhaust system

顺序 The order of assembly is the reverse of that of disassembly. (Refer to the disintegration diagram)

􀂌 Thoroughly clean and dry the inlet and exhaust pipes.

3.1 Exhaust pipe installation

3.1.1 How to tighten the exhaust manifold connector

(1) Apply molybdenum disulfide or equivalent lubricant to the bolts.

(2) Tighten the nut with the specified torque.

(3) Apply light vibrations that will not deform the outside of the entire exhaust manifold connector, so that the joint surface of the exhaust manifold and the tapered surface of the exhaust manifold connector are evenly and closely contacted.

(4) Tighten the nut with the specified torque.

(5) Apply a slight vibration again to confirm the tightening torque.

(1) Apply molybdenum disulfide or equivalent lubricant to the bolts.

(2) Tighten the nut with the specified torque.

(3) On the outside of the V-shaped pipe clamp, apply mild vibration without deformation, so that the mating surface of the exhaust manifold and the tapered surface of the V-shaped pipe clamp are evenly and closely contacted.

(4) Tighten the nut with the specified torque.

(5) Apply slight vibration again to confirm that there is no looseness.

3.2 Mitsubishi S16 Diesel Engine Air Cooler Installation

(1) The following shows the application of a silicone sealant to the air cooler core.

之间 Between the gap between the plate and the core (gray part)

之间 Between the gaps of the joint between the plate and the core (4 places)

(2) Tighten the mounting bolts to the specified torque.

Mitsubishi R16 diesel engine air starting system

1. Remove Mitsubishi R16 diesel engine air starting system ..... 12-3

1.1 Disassembling the solenoid valve ... 12-3

1.2 Removal of Air Pipe, Starter Valve and Distribution Valve. 12-4

1.3 Removing Mitsubishi R16 Diesel Engine Air Starter Motor ........ 12-5

2. Mitsubishi R16 diesel engine air starter system dismantling, maintenance, assembly ......... 12-6

2.1 Disassembly and Overhaul of Solenoid Valve ... 12-6

2.2 Installing the Solenoid Valve ... 12-7

2.3 Disassembly of starter motor, detection ......... 12-8

2.4 Detecting the starting valve ... 12-9

2.5 Assembly of starter valve .. 12-10

2.6 Disassembly of distribution valve, detection ...

2.7 Detection of distribution valve ... 12-12

2.8 Assembly of the starter valve. 12-13

3. Installing Mitsubishi R16 Diesel Engine Air Starting System ... 12-13

1. Remove Mitsubishi R16 diesel engine air start system

1.1 Remove the solenoid valve

Remove the solenoid valve

Disassembly sequence

1 air pipe

2 Air pipe

3 check valve

4 pipe connection

5 Air tube

6 Rape tube

7 Elbow

8 Activate the air filter

9 air tube

10 Solenoid valve

1.2 Disassembly of air pipe, starter valve and distribution valve

Disassembly of air pipe, starter valve and distribution valve

Disassembly sequence

1 No. 1 to 6 control air pipe

2 Main air pipe

3 Distribution valve

4 Start valve

1.3 Removing the Mitsubishi R16 Diesel Engine Air Starter Motor

Remove the Mitsubishi R16 diesel engine air starter motor

Disassembly sequence

1 pipe clamp

2 Automatic silencer

3 Elbow

4 pipe clamp

5 Mitsubishi R16 diesel engine air starter motor (approx. 60 kg)

2. Mitsubishi R16 diesel engine air starter system dismantling, maintenance and assembly

2.1 Disassembly and overhaul of solenoid valve

Direct air start, Mitsubishi R16 diesel engine air starter specifications

Disassembly and repair of solenoid valve

Disassembly sequence

1 Solenoid valve

2 winding

3 plunger spring

4 Mitsubishi R16 diesel engine piston spring

5 Mitsubishi R16 diesel engine piston assembly

6 valve

7 return spring

8 valve spring

2.2 Installing the solenoid valve

Direct air start, Mitsubishi R16 diesel engine air starter specifications

Install the solenoid valve

Mitsubishi R16 diesel engine adjustment and operation

1. Adjustment of Mitsubishi R16 diesel engine ... 13-3

1.1 How to use the crank gear ... 13-3

1.2 Confirmation of bridge and adjustment screw ... 13-4

1.3 Checking the valve clearance ... 13-4

1.4 Confirmation of Mitsubishi R16 Diesel Engine Fuel Injection Timing ... 13-4

1.5 Excluding Air from Fuel System of Mitsubishi R16 Diesel Engine ... 13-4

1.6 Detection of belt and adjustment of tension ... 13-6

2. Running in ............. 13-8

2.1 Preparation before starting ... 13-8

2.2 Starting Mitsubishi R16 Diesel Engine ... 13-8

2.3 Run-in operation ............ 13-8

3. Test and adjustment of Mitsubishi R16 diesel engine. 13-10

3.1 General Performance Test of Mitsubishi R16 Diesel Engine ... 13-10

3.2 Exhaust performance test ... 13-10

3.3 Speed governor performance test ............ 13-10

3.4 Alarm action, emergency stop test ... 13-10

3.5 Setting the Maximum Fuel Injection Amount ... 13-10

3.6 Seal 13-10

1. Adjustment of Mitsubishi R16 diesel engine

1.2 Confirmation of bridge and adjustment screw

Check the adjustment of the bridge and adjustment screw. If no adjustment is made, adjust it to the standard value range. For the adjustment procedure, please refer to the "Adjustment of Bridge and Adjustment Screws" item of "Assembly of Mitsubishi R16 Diesel Engine Body".

1.3 Check the valve clearance

Check the air valve clearance.

If no adjustment is made, adjust it to the standard value range. For the adjustment procedure, refer to the "Mitsubishi R16 Diesel Engine Intake and Exhaust Valve Gap Detection and Adjustment" item in "Mitsubishi R16 Diesel Engine Assembly".

1.4 Confirmation of Mitsubishi R16 Diesel Engine Fuel Injection Timing

Check the fuel injection timing of Mitsubishi R16 diesel engine.

When no adjustment is made, adjust to the prescribed timing. For the adjustment method, refer to the "Mitsubishi R16 Diesel Engine Fuel Injection Timing Confirmation and Adjustment" item in "Assembly of Mitsubishi R16 Diesel Engine Body".

1.5 Excluding Air from Fuel System of Mitsubishi R16 Diesel Engine

(a) Clean the fuel spilled from the exhaust plug with a cloth.

(b) After removing the air, securely lock the end cap of the pre-supply pump. Loose end caps may cause damage to the pre-supply pump or a fire due to fuel leakage.

The air removal of the fuel system of Mitsubishi R16 diesel engine must start with the fuel filter and the fuel injection pump of Mitsubishi R16 diesel engine in the order of fuel filter, starting from the position closer to the fuel tank.

1.5.1 Air removal from fuel filter (paper filter element)

(1) Loosen the bleed plug of the fuel filter for approximately 1.5 weeks.

(2) Move the pre-supply pump up and down to pressurize the fuel.

(3) When the fuel discharged from the vent plug does not contain air bubbles, tighten the vent plug according to the specified torque.

1.5.2 Excluding Air from Fuel Injection Pump of Mitsubishi R16 Diesel Engine

(1) Loosen the bleed plug of the fuel injection pump of the Mitsubishi R16 diesel engine for about 1.5 weeks.

(2) Move the pre-supply pump up and down to pressurize the fuel.

(3) Tighten the plug when the fuel discharged from the bleed plug does not contain air bubbles, but before tightening the last bleed plug, press down the end cap of the pre-supply oil pump to turn it right and return to the original state. locking.

Note: (a) When confirming the operation of the check valve, lock the pre-supply oil pump after all bleed plugs are tightened. It feels heavy during the pre-supply operation under the pressure of the oil pump, and the opening pressure of the check valve is stabilized, so that the operation condition of the check valve can also be confirmed. (b) Clean up any fuel spilled from the bleeder.

1.5.3 Locking method of pre-supply pump end cover

If the end cap of the pre-supply pump is not tightened enough, the internal threads will be worn by the vibration of the Mitsubishi R16 diesel engine, causing the end cap of the pre-supply pump to fly out or the fuel to overflow. Conversely, if the end cap of the pre-supply pump is over-tightened, the head of the pre-supply pump may be damaged. Therefore, it must be tightened at an appropriate angle.

Confirm that the gasket of the pre-supply pump head is not deformed or damaged. When deformed or damaged, replace the pre-supply pump.

(1) Tighten the pre-supply pump by hand and mark it at this position.

(2) Tighten 90 ± 10 ° from the marked position with a wrench or the like.

(3) Check the installation state of the head gasket, and replace the pre-supply pump if it is deformed or damaged.

1.6 Belt inspection and tension adjustment

During the inspection, if a part of the belt is peeled off or damaged, the belt should be replaced with a new one.

Do not allow oil on the belt. Belt slippage can reduce service life.

If the belt tension is too large, it will affect the life of the bearing or belt of the Mitsubishi S16 diesel charger. It should be adjusted appropriately according to the following methods.

1.6.1 Testing of belts

(1) Check the appearance of the belt for peeling or damage. When abnormality is found, replace with new gear.

(2) Check the belt tension (sag amount).

V-belt

When the central part of the belt is strongly pressed (approximately 98 to 147 N {10 to 15 kgf}), the depression amount of 10 to 15 mm is normal. When the amount of sag of the belt exceeds the standard value range, adjust it.

Multi-V-belt

Referring to the table below, press the middle of the Mitsubishi S16 diesel engine pulley to make the sag amount reach 15mm, and adjust when the pressure measured by the dynamometer does not meet the standard value.

1.6.2 Adjustment of belt tension (Mitsubishi S16 diesel charger)

(1) Remove the protective cover of the belt.

(2) Loosen the fixing bolts of all Mitsubishi S16 diesel chargers.

(3) Turn the adjusting lever to adjust the tension of the belt.

(4) Tighten the fixing bolts of the Mitsubishi S16 diesel charger.

(5) Install the belt cover.

Multi-V-belt tensioner

2. Run-in operation

2.1 Preparation before starting

Check the capacity of the fuel oil, Mitsubishi R16 diesel engine lubricating oil, and cooling water, and exclude the fuel and air from the Mitsubishi R16 diesel engine cooling system.

Check the connection of the governor output handle to the Mitsubishi R16 diesel engine fuel injection pump rack. Make sure that the control rack is in the non-injection position when stopped. Operate the stop lever to confirm that the control rack returns to "0" position.

Check the wiring of Mitsubishi R16 diesel engine electrical system (sensor, instrument alarm panel, starter motor, Mitsubishi S16 diesel charger, Mitsubishi S16 diesel engine stop solenoid, battery), and confirm that the system is normal when the controller main switch is ON.

Set the speed lever position of the governor to idling after starting.

Activate the Mitsubishi S16 diesel engine to stop the solenoid, and confirm that the rack of the fuel injection pump of the Mitsubishi R16 diesel engine is in the set non-injection position.

Install pressure gauges, temperature gauges, or flow meters as necessary.

2.2 Start Mitsubishi R16 diesel engine

(1) Turn the stop lever to the non-injection position, and use the starter motor to turn the crankshaft of the Mitsubishi R16 diesel engine 2 to 3 times (within 10 seconds, stop for more than 1 minute in the middle), so that all parts of the Mitsubishi R16 diesel engine are Lube oil circulation. At the same time, confirm that there are no abnormalities such as abnormal noises or rotation speed changes.

(2) Start the Mitsubishi R16 diesel engine in the normal starting operation. Confirm that idle operation is possible after starting.

(3) Confirm that the oil pressure rises immediately and the cooling water circulates.

(4) Confirm that there are no oil leaks, water leaks, fuel leaks, and air leaks, and there are no abnormal sounds or abnormal vibrations.

(5) After confirming that the idling operation can be performed smoothly, turn the key switch to OFF to confirm that the Mitsubishi R16 diesel engine can stop normally.

2.3 Run-in operation

2.3.1 Load and time of running-in

The running-in operation must increase the load in the following sections. In addition, the indicated time is the minimum time for which stable operation can be confirmed.

2.3.2 Mitsubishi R16 diesel engine running test

Pay attention to the following items during running-in operation to confirm that there is no abnormal phenomenon.

Oil 圧, oil temperature

Cooling water temperature and water capacity

Oil leak, water leak, fuel leak, air leak (air)

Sound and vibration

Intake pressure, inlet temperature

Exhaust color, odor

Exhaust gas temperature

Left and right cylinders are not consistent

Oil mist gas (amount, color)

Speed variation

End face runout and radial runout of the rotating part

Instrument and alarm display and action

2.3.3 Detection and adjustment after running-in

Air valve clearance

Fuel injection timing of Mitsubishi R16 diesel engine

Tighten bolts and nuts on the periphery

Tension of belt

Investigation and repair of oil leakage and other abnormalities

3. Test and adjustment of Mitsubishi R16 diesel engine

(a) Testing, adjustment and sealing of Mitsubishi R16 diesel engines are only allowed to be carried out in our designated maintenance plant.

When the seal is implemented outside the maintenance factory designated by our company, an application for a contract for testing, adjustment and seal operation of the seal operation shall be submitted to the maintenance factory designated by our company.

(b) The performance testing and adjustment of Mitsubishi R16 diesel engines should be performed after the Mitsubishi R16 diesel engines have been fully warmed up, and implemented after the water and oil temperatures have stabilized.

After the break-in operation is completed and normal operation can be performed, the performance and function of the Mitsubishi R16 diesel engine are tested and adjusted.

Be sure to record the test results and compare them with the factory data.

3.1 General Performance Test of Mitsubishi R16 Diesel Engine

Fuel consumption rate, temperature of each part, pressure of each part, exhaust concentration

3.2 Exhaust performance test

Exhaust analysis

3.3 Speed governor performance test

Setting of no load minimum speed (low idling)

Confirmation of load setting, no-load shutdown test, governor change rate, chatter, and speed variation of the highest speed (high idling) without load Confirmation of governor controller setting conditions

3.4 Alarm action and emergency stop test

Oil pressure decreases, water temperature rises, overspeed

3.5 Setting the Maximum Fuel Injection Amount

(1) The rack at the front (front) side of the rack of the fuel injection pump of the Mitsubishi R16 diesel engine is set with the end cap removed, and the rated (maximum) load is applied.

(2) Tighten the nut at the position where the double nut on the front end of the rack comes into contact with the end face of the spring case.

Mitsubishi R16 Diesel Engine Inspection Record Sheet (SR Series)

No.1 inspection cylinder inner diameter of Mitsubishi R16 diesel engine

No.2 Detecting the amount of protrusion of the cylinder sleeve shoulder of the gas Mitsubishi R16 diesel

No.3 detecting the inner diameter of the valve duct and the outer diameter of the valve stem

No.4 Detects the amount of valve sinking, seat width and valve machining allowance of the cylinder head of Mitsubishi R16 diesel

No.5 Detects the amount of deformation of the lower surface of the cylinder head of Mitsubishi R16 diesel engine

No.6 Detecting the inner diameter of the connecting rod bushing of the Mitsubishi R16 diesel engine and the inner diameter of the large end bearing hole of the connecting rod

No.7 Detects the inner diameter of the Mitsubishi R16 diesel engine rocker bushing and the outer diameter of the Mitsubishi R16 diesel engine rocker shaft

No.8 Detecting the inner diameter of the piston pin hole of Mitsubishi R16 diesel engine and the outer diameter of the piston pin of Mitsubishi R16 diesel engine

No.9 Detecting the clearance of the air valve

No.10 detects the fuel injection pressure of the fuel injector of the Mitsubishi R16 diesel engine

No.11 Detecting the inner diameter of the bushing of the camshaft of the Mitsubishi R16 diesel engine and the outer diameter of the journal of the camshaft of the Mitsubishi R16 diesel engine (right side)

No.12 Inspection of the inner diameter of the bushing of the camshaft of the Mitsubishi R16 diesel engine and the outer diameter of the journal of the camshaft of the Mitsubishi R16 diesel engine (left side)

No.13 Inspection of axial clearance of crankshaft of Mitsubishi R16 diesel engine

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