Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust ...................................................................................................... 13-3

1.1 Valve clearance - Inspect ....................................................................................................... 13-3
1.2 Fuel system - Drain................................................................................................................. 13-3
1.3 Fuel system - Bleed air ........................................................................................................... 13-4
1.4 V-belt tension - Inspect and Adjust ......................................................................................... 13-5
2. Break-in operation ................................................................................................. 13-6
2.1 Starting up .............................................................................................................................. 13-6
2.2 Break-in operation .................................................................................................................. 13-6
3. Performance test ................................................................................................... 13-7
3.1 Engine equipment condition ................................................................................................... 13-7
3.2 Test items and purposes ........................................................................................................ 13-7
3.3 Other inspections.................................................................................................................... 13-7
3.4 Engine output adjustment ....................................................................................................... 13-7

13-1
 Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust
Chapter 13 ADJUSTMENT AND OPERATION

1.1 Valve clearance - Inspect

Inspect the valve clearance.
If the valve clearance is out of standard, adjust it to the stan-
dard value.
For the adjusting procedure, refer to “Valve clearance -
Inspect and Adjust” of “ASSEMBLY OF BASIC
ENGINE”.

1.2 Fuel system - Drain

(a) When draining the fuel filter, fuel flows out

together with the water. Wipe off any spilled fuel.
This can cause fire.
(b) Tighten the drain plug securely after draining the
water. Failure to do so could cause a fire.
If water trapped in the bottom of the fuel filter exceeds the
specified level, the water may enter into the fuel system.
1.2.1 Fuel filter - Drain
(1) Loosen the drain plug on the bottom of the fuel filter.
(2) Water is easily drained by pressing the priming pump
repeatedly (approx. 7 times) to feed the fuel.
(3) Tighten the drain plug securely after draining the water.
(4) Always bleed the air in the fuel system after draining
the water.

Drain plug

Fuel filter - Drain (1)

Priming pump

Fuel filter - Drain (2)

13-3
Chapter 13 ADJUSTMENT AND OPERATION

1.3 Fuel system - Bleed air

Wipe off fuel spilled from the air vent plug thoroughly
with a cloth. Be sure to tighten the air vent plug after
air bleeding. Failure to do so could cause a fire.
1.3.1 Fuel filter - Bleed air
(1) Loosen the air vent plug of the fuel filter with a wrench.
(2) Repeatedly press the priming pump with the cloth
applied to the air vent plug. When fuel with air bubbles
no longer comes out, tighten the air vent plug securely.
(3) Be sure to tighten the air vent plug after air bleeding.

Air vent plug

Fuel filter - Bleed (1)

Priming pump

Air vent plug

Fuel filter - Bleed (2)

13-4
 Chapter 13 ADJUSTMENT AND OPERATION

1.4 V-belt tension - Inspect and Adjust

If the damages such as cuts or surface separations are found during inspection, replace the V-belt with a new one.
Keep oil and grease away from the V-belt. They may cause the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.
Adjust the belt tension accurately by following the procedures.

1.4.1 V-belt - Inspect

(1) Inspect the belt visually for separation or damage. If any abnormality is found, replace the V-belt with a new one.
(2) Inspect the deflection of V-belt.
Inspect the V-belt deflection by pressing it with 98 N {10 kgf} [72 lbf] force at the center of its span. The belt deflection
should be 12 mm [0.47 in.].
If the deflection is out of standard, adjust the belt tension.
1.4.2 V-belt tension - Adjust
98 N
(1) Loosen all retaining bolts of the alternator and adjusting p p rox. f}
A kg Water pump
Adjusting bolt {10 lbf]
plate. [72 pulley
(2) Adjust V-belt tension properly.
(3) Tighten all retaining bolts of the alternator and adjust- mm
Adjusting 12 in.]
ing plate. plate [0. 4 7

Alternator Crankshaft
pulley pulley

Fixing bolt

V-belt tension - Adjust

13-5
Chapter 13 ADJUSTMENT AND OPERATION

2. Break-in operation
2.1 Starting up
(1) Before starting the engine, check the levels of fuel, engine oil, and coolant, and also bleed the fuel system and cooling sys-
tem.
(2) Stop the fuel supply, and crank the engine with the starter for 10 seconds to lubricate the engine.
(3) Move the control lever slightly in the fuel increase direction (but not to the “full injection” position), and then turn the
starter switch key to the [START] position to start the engine.
(4) After the engine has started, adjust the control lever to let the engine operate at a minimum no-load speed (low idle speed).
(5) Turn the starter switch key to the [OFF] position and make sure that the engine is stopped.

2.2 Break-in operation

If an abnormal condition occurs during engine operation, make sure an emergency stop can be activated.

2.2.1 Load in the break-in operation and operation

time
Progressively, increase the load during break-in operation.
The following times indicated in the chart below show the minimum times required for the engine to operate reliably.

Break-in operation
Time
Engine speed (min-1) Load (PS)
(min)
1 Low rotation speed 600 to 900 No-load 20
Medium rotation
2 1000 to 1200 No-load 10
speed
3 High rotation speed 1400 to rated speed No-load 10
4 25% 20
5 50% 20
Rated speed
6 75% 30
7 100% 20

2.2.2 Inspecting engine condition after starting up

During the break-in operation, take care the followings and make sure no abnormalities are found.
Oil pressure, oil temperature Exhaust temperature
Coolant level, water level Blow-by gas (level and color)
Any leakage of oil, coolant fuel, and gas (air) Rotational fluctuation
Noise, vibration Face and radial runouts of rotating parts
Intake air pressure, intake air temperature Indication and operation of meter and alarm
Exhaust color, odor
2.2.3 Inspection and adjustment after break-in opera-
tion
Valve clearance Belt tension
Fuel injection timing Inspect and repair for defects such as oil leakage
Additional tightening of exterior bolt and nut

13-6
 Chapter 13 ADJUSTMENT AND OPERATION

3. Performance test
The following describes the procedures specified in “Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)” and “Earth moving machinery -
Engines - Part 2: Standard format of specifications and test-
ing methods of diesel engines (JIS D0006-2).” Other test
items may be required in some applications. All test results
should be evaluated comprehensively in order to determine
the engine performance.

3.1 Engine equipment condition

The engine must be equipped with standard auxiliary
devices such as cooling fan, air cleaner and alternator.

3.2 Test items and purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions corre-
sponding to the nominal brake power. In this test, evaluate
the fuel consumption rate and operating condition, and con-
firm that the engine is capable of continuous operation.
3.2.3 No-load minimum engine speed test
Conduct this test to confirm that the engine can operate sta-
bly at the specified No-load minimum engine speed.

3.3 Other inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustment as needed.

3.4 Engine output adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity. Therefore, correction calcula-
tions must be performed to obtain the value of engine output
under the standard atmospheric conditions.
3.4.1 Standard atmospheric conditions
Base temperature: 298 K (25°C) [77°F]
Total pressure: 100 kPa (750 mmHg)
Dry pressure: 99 kPa (743 mmHg)

13-7
Chapter 13 ADJUSTMENT AND OPERATION

3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the calcu-
lated diesel engine correction factor to obtain a corrected
value. If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.

Calculation output = Correction factor ( ) × Measured brake power

Atmospheric conditions during test
Temperature( ):283 K(10 °C)[50 °F] T 313 K(40 °C )[104 °F]
Dry atmospheric pressure( ):80 kPa(600 mmHg) 110 kPa(825 mmHg)

=( ) :Atmospheric factor :Engine factor

Range of correction equation use

The range of correction factor ( ) is as follows:
0.9 1.1.
Calculation of engine factor ( )
Calculation of correction factor ( ) =0.036 -1.14
Natural aspiration engine and engine with :Corrected fuel supply volume
mechanically driven air charger =
99 0.7
=( )·( ) ( ) × (Fuel flow rate g/s)
298 =
(Stroke volume ) × (Engine speed min-1)
Turbocharged engine without air cooler = 120000 (4-cycle engine)
or with air-to-air cooler :Ratio between pressure at turbocharger or
99 0.7 1.2 air cooler outlet and atmospheric pressure
=( ) ·( )
298 ( =1 for natural aspiration engine)
Turbocharged engine with air-to-liquid · Applicable range of engine factor ( )
cooler 37.2 65mg/( -cycle)
99 0.7 0.7 · 37.2mg/(l -cycle): =0.2 (constant)
=( ) ·( )
298 · 65mg/( -cycle) : =1.2 (constant)

13-8
 TECHNICAL PUBLICATIONS FEEDBACK

(Please print)

Dealer name: __________________________ Submitted by: _________________________

Address: _____________________________ P. O. Box: ____________________________
City: ________________________________ State: ________________________________
Zip code: _____________________________ Country: _____________________________

The following discrepancy or omission has been discovered in:

Operation & Maintenance Manual Option Bulletin

Part List/Manual Special Instruction

Service Manual Service Data Manual

Electronic Manual Other: ___________________________

Publication # ________________________ Engine model # ________________________
Truck model # _______________________ Issue date # ___________________________
Truck serial # _______________________ Page # _______________________________

(Please print)

Explanation of discrepancy or omission:

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Please fax or mail completed form to:

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Product Support
2121 W. Sam Houston Parkway N. Hefbrugweg 77
Houston, Texas 77043-2305 1332 AM, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. MCF Forklift (Shanghai) Co., Ltd.
Attn: Warranty & Service Engineering A/23F, Meixin Mansions
No.1 Tuas West Street 728 Xizang Rd (M.)
Singapore 637444 Shanghai, 200001 China
Republic of Singapore Fax: +86-21-6360-7107
Fax: 65-6897-7562
RCB No.: 199203169H
Cat Lift Trucks Service Manual S6S Diesel Engine 99739-32110
 Mitsubishi Caterpillar Forklift Asia Pte. Ltd.
RCB No.: 199203169H
No.1, Tuas West Street
Singapore 637444

Copyright © 2013. All rights reserved. CAT, CATERPILLAR, their

respective logos, "Caterpillar Yellow," the "Power Edge" trade dress as well
as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. All registered trademarks are the
property of their respective owners. Some products may be shown with
optional equipment.
Printed in China
99739-32110 03/13