Mitsubishi 6M60-TL Service Manual
Service Manual
6M60-TL Diesel Engine
For use with the FD80N-FD160N Service Manuals.
99709-51100
(for industrial use)
GROUP INDEX
FOREWORD
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of the
Mitsubishi 6M60-TL series diesel engine, and includes
procedures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
no wastage.
GENERAL........................................
ENGINE............................................
LUBRICATION.................................
FUEL AND ENGINE CONTROL......
ELECTRONICALLY CONTROLLED
FUEL SYSTEM
COOLING.........................................
INTAKE AND EXHAUST .................
EMISSION CONTROL .....................
ELECTRICAL...................................
..................................
00
11
12
13A
13E
14
14
15
17
54
For more details, please consult your nearest authorized
Mitsubishi forklift truck dealer.
Kindly note that the specifications and maintenance service figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
SEPTEMBER 2006
Applicable models
6M60-TL
SPECIAL EQUIPMENT ...................
61
GROUP 00 GENERAL
HOW TO READ THIS MANUAL ......................................................... 00-2
ENGINE NUMBER ............................................................................ 00-7
PRECAUTIONS FOR MAINTENANCE OPERATION ....................... 00-8
DIAGNOSTIC CODES
1. Using Multi-Use Tester
2. Use of Blinking Warning Lamp for Diagnostic Code ....................
3. Up-Time Service Tool Functions ....................................................
4. Troubleshooting ...............................................................................
TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-31
.............................................................. 00-17
00-19
00-21
00-29
13A
13E
00-1
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HOW TO READ THIS MANUAL
This manual consists of the following parts:
Specifications
Structure and Operation
Troubleshooting
General Inspection and Adjustment
Service procedures
General Inspection and Adjustment
• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the machine are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedure
• Procedures for servicing components and parts off the machine are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
• This service manual contains important cautionary instructions and supplementary information under the follow-
ing four headings which identify the nature of the instructions and information:
DANGER
WARNING
CAUTION
NOTE
Terms and Units
• Front and rear
The forward running direction of the machine is referred to as the front and the reverse running direction is referred to as the rear.
Left and right
Left hand side and right hand side, when facing the forward running direction of the machine, are respectively left
and right.
Precautions that should be taken in handling potentially dangerous substances
such as battery fluid and coolant additives.
Precautionary instructions, which, if not observed, could result in serious injury or
death.
Precautionary instructions, which, if not observed, may result in damage to or destruction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or
better understandings.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
00-2
•
•
Ω
00
Tightening torque
• Values are directly specified for out-of-standard tightening torques for bolts and nuts.
Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. Values in
engine specifications, performance curves, and other items taken from official approval documents are given only
in metric units.
*SI: Le Système International d’Unités
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit
Item SI unit {metric unit} Conversion factor
Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Positive pressure kPa {kgf/cm
Pressure
Vacuum pressure
kPa {mmHg} 0.133322 kPa {1 mmHg}
Pa {mmH
Volume dm
2
} 98.0665 kPa {1 kgf/cm
O} 9.80665 Pa {1 mmH
2
3
{L} 1 dm
3
{1 L}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
Angle ˚ –
Temperature ˚C –
Electric current A –
Voltage V –
Resistance
–
Electric power W –
2
}
O}
2
Unit SI unit Foot-pound unit Conversion rate
Force
Moment of force
Pressure
Volume
Power
Temperature
Mass quantity of
matter
Dimension
Stress
N (Newton)
N·m
kPa (kilopascal)
L
3
cm
3
cm
kW (kilowatt)
˚C
kg
g
m
mm
2
N/cm
lbf 1 N = 0.2248 lbf
lbf.ft 1 N·m = 0.7375 lbf.ft
lbf/in.
gal.
oz
cu.in.
2
1 kPa = 0.145 lbf/in.
1 kPa = 0.2953 in. Hg
1 L = 0.2642 gal. (U.S.)
1 L = 0.220 gal. (Imp.)
3
1 cm
= 0.033814 oz (U.S.)
3
1 cm
= 0.035195 oz (Imp.)
3
1 cm
= 0.061023 cu.in.
HP 1 kW = 1.34 HP
˚F t˚C = (1.8t˚C + 32)˚F
lb
oz
ft.
in.
lbf/in.
2
1 kg = 2.2046 lb
1 g = 0.035274 oz
1 m = 3.2808 ft.
1 mm = 0.03937 in.
2
1 N/cm
= 1.45 lbf/in.
2
2
00-3
HOW TO READ THIS MANUAL
Symbol Denotation Application Remarks
Tightening torque
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or
sealant
Special tool
*a
Associated part
Parts not tightened to standard torques
(standard torques specified where necessary for servicing)
Parts to be coated with lubricant or sealant
for assembly or installation
Parts for which special tools are required for
service operation
Parts associated with those removed/disassembled for servicing
Specified values shown in table
See Table of Standard Tightening Torques for
parts for which no tightening torques are specified.
Necessary lubricant and/or sealant, quantity required, etc. are specified in table.
Tool name/shape and part number are shown in
table.
00-4
00
00-5
HOW TO READ THIS MANUAL
How to Use Diagnostic Codes <Electronically Controlled Fuel System (Gr13E)>
TROUBLESHOOTING
1. Diagnostic Procedure
This section suggests areas to
inspect for each diagnostic
code.
2. Diagnostic Precautions
3. Inspections Based On Diagnostic Codes
4. Multi-use Tester Service Data
5. Actuator Tests Performed Using Multi-use Tester
6. Inspections Performed At Electronic Control
Unit Connectors
There are the diagnostic code and message displayed on Multi-Use Tester.
Numerical values in parenthesis are added only when a diagnostic code indicated in
the Multi-Use Tester display differs from the code indicated by the number of warning
lamp flashes.
P125A: Common Rail Pressure M/V1 (high) (warning lamp flashes: 63)
Code generation criteria MPROP1 (rail pressure control valve) voltage is above standard valve.
Resetability
Electronic control unit control
Service data 0C: Difference Common Rail Pressure
Inspection
item
Actuator test B9: Fuel Leak Check
Electronic control unit
connector
Electrical part #574: MPROP1 (rail pressure control valve)
System recovers (power is re-supplied to electronic control unit) if signal
becomes normal when starter switch is turned OFF → ON.
• Engine is stopped.
• Exhaust gas recirculation control is stopped.
08
: Resistance of MPROP (rail pressure control valve)
Refer to “Inspection of Electrical
Equipment.”
The contents of this manual include functions and parts that are not used in your truck depending on
the truck specifications. Please refer to the chassis service manual for the details.
00-6
•
ENGINE NUMBER
00
Serial engine numbers are assigned to the engines in manufacturing sequence. Every engine has its own number. These numbers are required for registration and related inspection of the
vehicle.
•
An engine nameplate indicates the following item.
•
Engine model
00-7
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•
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PRECAUTIONS FOR MAINTENANCE OPERATION
Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
about the vehicle. And note the necessary information. This information will help you to service the truck efficiently.
•
Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this manual.
Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could
cause injuries and/or truck damage.
Take extreme care when removing/installing heavy items such
as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
Identify the weight of the item being lifted. Use a cable that is
strong enough to support the weight.
If lifting eyes are not provided on the item being lifted, tie a cable around the item taking into account the item’s center of
gravity.
Never work in shoes that have oily soles.
When working with a partner or in a group, use pre-arranged
signals and pay constant attention to safety. Be careful not to
touch switches and levers unintentionally.
00-8
Inspect for oil leakage etc. before washing the vehicle. If the order is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
•
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•
•
•
•
•
00
Prepare replacement parts ready for installation.
Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine MITSUBISHI replacement parts.
When disassembling parts, visually check them for wear, cracks,
damage, deformation, deterioration, rust, corrosion, defective rotation, fatigue, clogging and any other possible defect.
To facilitate correct reassembly of parts, make alignment marks
on them before disassembly and arrange disassembled parts
neatly. Make punch marks and other alignment marks where
they will not detract from parts’ functionality and appearance.
After removing parts from the vehicle, cover the area to keep it
free of dust.
CAUTION
• Be careful not to mix up identical parts, similar parts and
parts that have left/right alignments.
• Keep new replacement parts and original (removed) parts
separately.
Apply the specified oil or grease to U-seals, oil seals, dust seals
and bearings before reassembly.
Always use the specified oils and greases when performing inspection or replacement. Immediately wipe away any excess oil
or grease with a rag.
00-9
PRECAUTIONS FOR MAINTENANCE OPERATION
Wear safety goggles when using a grinder or welder. Wear
gloves when necessary, and watch out for sharp edges and other items that might wound your hands.
•
Before working on the electrical system, disconnect the (–) battery cable to prevent short circuits.
CAUTION
• Make sure the starter switch and lighting switches are OFF
before disconnecting or connecting battery cable.
Semiconductor components may otherwise be damaged.
•
•
•
•
•
Carefully handle sensors relays, and other items that are sensitive to shock and heat. Do not remove or paint the cover of any
control unit.
When separating connectors, grasp the connectors themselves
rather than the harnesses.
To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them together until they click.
Before washing the vehicle, cover electrical parts to keep them
dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.
00-10
When applying a voltage to a part for inspection purposes,
check that the (+) and (–) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily operate on the battery voltage.
1. Handling Precautions for Electric Circuits
CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Piercing the
wire harness will cause corrosion.
00
•
1.1 Inspection of harnesses
(1) Inspections with connectors fitted together
(1.1) Waterproof connectors
• Connect an inspection harness and connector A between the
connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry
sides of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
(1.2) Non-waterproof connectors
• Perform the inspection by inserting a test probe C into the wire-
entry sides of the connectors. An extra-narrow probe is required
for control unit connectors, which are smaller than other types of
connector. Do not force a regular-size probe into control unit
connectors since this would cause damage.
(2) Inspections with connectors separated
(2.1) Inspections on female terminals
• Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
00-11
PRECAUTIONS FOR MAINTENANCE OPERATION
(2.2) Inspections on male terminals
• Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuitry.
• When using a multimeter to check continuity, do not allow the
test probes to touch the wrong terminals.
1.2 Inspection of connectors
(1) Visual inspection
• Check that the connectors are fitted together securely.
• Check whether wires have been separated from their terminals
due to pulling of the harness.
00-12
• Check that male and female terminals fit together tightly.
00
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals
• If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
1.3 Inspections when a fuse blows
• Remove the fuse, then measure the resistance between ground
and the fuse’s load side.
Next, close the switch of each circuit connected to the fuse. If the
resistance measurement between any switch and ground is zero, there is a short circuit between the switch and the load. If the
resistance measurement is not zero, the circuit is not currently
short-circuited; the fuse probably blew due to a momentary short
circuit.
• The main causes of short circuits are as follows:
• Harnesses trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)
2. Service Precautions for Alternators
• When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
If the polarity of the battery connections were to be reversed,
a large current would flow from the battery to the alternator,
damaging the diodes and regulator.
00-13
PRECAUTIONS FOR MAINTENANCE OPERATION
• Never disconnect the battery cables with the engine running.
Disconnection of the battery cables during engine operation
would cause a surge voltage, leading to deterioration of the diodes and regulator.
• Never perform inspections using a high-voltage multimeter.
The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.
Water on alternators can cause internal short circuits and damage.
• Never operate an alternator with the B and L terminals short-circuited. Operation with the B and L terminals connected together
would damage the diode trio.
• Disconnect the battery cables before quick-charging the battery
with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
00-14
3. Intermittent Faults
00
• An intermittent fault typically occurs only under certain operating
conditions. Once these conditions have been identified, the
cause of the intermittent fault can be ascertained easily. First,
ask the customer about the vehicle operating conditions and
weather conditions under which the fault occurs. Also ask about
the frequency with which the fault occurs and about the fault
symptoms. Then, reproduce the fault based on this information.
In accordance with the conditions under which the fault occurs,
determine whether the fault is caused by vibration, heat or other
factors. if vibration is a possible factor, see if the fault can be reproduced by performing the following checks on individual connectors and other parts:
• Gently move connectors up and down and to left and right.
• Gently move wiring harnesses up and down and to left and
right.
• Gently wiggle sensors and other devices by hand.
• Gently wiggle wiring harnesses on suspension systems and
other moving parts.
• Connectors and other parts to be checked are those included or
given as likely fault locations in inspection procedures corresponding to diagnostic codes and/or fault symptoms.
00-15
PRECAUTIONS FOR MAINTENANCE OPERATION
4. Precautions for Arc Welding
• When arc welding is performed, current from the welder flows to ground via the machine metal parts. Unless ap-
propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses.
And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be
largely damaged.
• The current of the welder will flow backward through the battery’s (–) cable and damage the battery and electrical systems
directly connected to the battery. Be sure to disconnect the battery’s (–) cable in the following procedure.
• Turn the battery switch to the LOCK position.
• Turn the starter switch to the LOCK position.
• Disconnect the battery’s (–) cable.
• Cover all parts of the machine that may be damaged by welding
sparks.
• Connect the welder’s (–) cable to the machine as close as possible to the area being welded.
• Set the welding current in accordance with the part being welded.
00-16
DIAGNOSTIC CODES
00
NOTE:
The Multi-Use tester tool will not be used to service the 6M60-TL diesel engine at this time. Please disregard
the Multi-Use Tester information. The Up-Time 2.41 or later software must be used to service the 6M60-TL
diesel engine.
1. Using Multi-Use Tester
1.1 Connecting Multi-Use Tester
Special tools
Mark Tool name and shape Part No. Application
FMSi-E06-1
PC
(Multi-Use
Tester-III version)
Data transmission to/from V.C.I.
V.C.I. N/A
Multi-Use Tester harness A
Multi-Use Tester test
harness D
(used for extension)
USB cable MB991827
MH062928
MH062931
(1 m)
MH062951
(2 m)
Data transmission between electronic
control unit and PC
Power supply to V.C.I. and communication with electronic control unit
Multi-Use Tester test harness A
extension
Communication between V.C.I. and
PC
• Move the starter switch to the LOCK position.
• Connect , , and as illustrated.
• Connect the Multi-Use Tester connector on the vehicle with the
connector of .
00-17
DIAGNOSTIC CODES
• Use to extend the cable if is not long enough such as
when using Multi-Use Tester outside the vehicle.
1.2 Access and Clearing of Stored Diagnostic Code
(1) Difference of diagnostic code
• There are two types of diagnostic codes – present code and past code.
(1.1)
(1.2) Present diagnostic code
• Fault developed in the machine after the starter switch is set to ON is indicated by corresponding diagnostic code.
• The fault warning lamp is lit at the same time.
(1.3) Past diagnostic code
• Past fault developed in the machine is indicated by corresponding diagnostic code stored in the memory of the
electronic control unit.
• With the machine restored to its normal condition or the starter switch turned from OFF to ON after inspection or
repair against present diagnostic codes, the present diagnostic code is stored as past diagnostic codes in the
memory of the electronic control unit.
• The warning lamp is not lit because the indicated fault is not present one.
(2) Access of diagnostic code
• Set the starter switch to ON.
• Operate the Multi-Use Tester for a display of necessary diagnostic codes stored in the memory of the electronic
control unit and identify the location of the fault.
(3) Clearing of diagnostic code
• Set the starter switch to ON (the engine not to be started).
• Operate the Multi-Use Tester to delete all the diagnostic codes stored in the memory of the electronic control unit.
00-18
00
2. Use of Blinking Warning Lamp for Diagnostic Code
• Using the diagnostic and memory clear switches, display diagnostic codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnostic codes
from the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure described below before handling diagnostic codes.
2.1 Reading diagnostic codes
• To read a diagnostic code, observe how may times the warning
lamp flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.2 sec.
• First digit: 0.4 sec.
• A diagnostic code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnostic code has “0” in
the second digit, only the first digit will be displayed.
• The same diagnostic code will be displayed 3 times in a row before moving to the display of the next code.
• After the last diagnostic code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
2.2 Present diagnostic codes
• Turn the starter switch ON.
• Remove the diagnostic switch.
• Diagnostic codes will be displayed (flashing of the warning
lamp).
• When the diagnostic switch is connected, electronic control unit
will immediately stop (terminate) displaying diagnostic codes.
2.3 Present and past diagnostic codes
• Turn the starter switch to the ON position.
• Open the diagnostic switch.
• Open the memory clear switch.
• The corresponding warning lamp will display diagnostic codes
by flashing.
• Turn the starter switch to the OFF position, connect the memory
clear switch and then connect the diagnostic switch. The electronic control unit terminates (exits) the diagnostic code displaying mode.
00-19
DIAGNOSTIC CODES
2.4 Erasing diagnostic codes
• Turn the starter switch to the ON position (do not start the en-
gine).
• Open the memory clear switch and reconnect it; all diagnostic
codes stored in electronic control unit memory will be erased. To
erase diagnostic code after opening the memory clear switch,
turn the starter switch to the OFF position and then reconnect
the memory clear switch.
00-20
TABLE OF STANDARD TIGHTENING TORQUES
3. Up-Time Service Tool Functions
3.1 Menu
Monitor menu
• Input Monitor
Indicates the input values of the controllers.
• Output Monitor
Indicates the output values of the controllers.
• Custom Monitor
Indicates the input/output values of the item selected.
• Fault Status
Indicates all error codes occurring.
• Fault History
Indicates the fault data, such as the error codes and
hour meter data, stored in the controller.
Tool menu
• Set-up Option
Indicates or sets the Setup Option data.
• Oscilloscope
Graphs the input/output values. The oscillograph
can be stored as data.
• Active Test
Outputs the signal forcibly to check the operation of
the equipment selected.
• Connection Change
Designates the controller operated by the service
tool and the controller connected to it.
• Firmware Update
Updates the firmware of the controller connected.
00
212338
00-21
TABLE OF STANDARD TIGHTENING TORQUES
3.2 Input Monitor and Output Monitor
These screens indicate the input and output values of each controller.
3.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)
00-22
(InputUnit)
212339
00
(
OutputUnit
(
OutputUnit
(
OutputUnit
[]
)
V
)
)
212340
00-23
3.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP)
00-24
212341
3.2.3 MP input monitor (VCM-3→ MP)
00
212342
00-25
3.2.4 ECU input monitor and output monitor (VCM-3 → ECU)
Accel pedal position (unfiltered)
Accel pedal position (filtered)
Reference injection quantity
212343
00-26
3.3 Fault Status
This screen indicates all error codes occurring.
OutputUnit Communication error
InputUnit Communication error
00
212344
00-27
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