Mitsubishi S6S Service Manual

Service Manual

99709-56120

For use with FD40K, FD40KL, FD45K, FD50K,
FD60, FD70, Chassis Service Manual.

S6S Diesel Engine

28620-up

FOREWORD

This service manual covers S6S Diesel Engine of Mitsubishi Forklift Trucks and gives detailed
maintenance and repair information. The instructions are grouped by systems to serve the
convenience of your ready reference.

Long productive life of your forklift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on
before attempting any work.

All descriptions, illustration, specifications, and serial numbers in this manual are effective as
of the printing date of this manual. Mitsubishi reserves the right to change specifications or
design without notice and without incurring obligation.

Pub. No. 99709-56120

How to Use This Manual

This service manual contains the S6S Diesel Engine specifications, maintenance standards and adjustment
procedures as well as service procedures such as disassembly, inspection, repair and reassembly are arranged in
groups for quick reference.

There are separate manuals for the fuel injection pump and governor.

A short summary of each Group is given in the General Contents, and there is also a table of contents at the
beginning of each Group.

Regarding engine operation and periodical maintenance, refer to the Operation & Maintenance Manual. For
component parts and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are
described in various training manuals.

1. Methods of Indication

(1) Parts shown in illustrations and described in text are numbered to correspond with the sequence of disassembly.

(2) Inspections to be conducted during disassembly are indicated in a box in disassembled views.

(3) Maintenance standards for inspection and repair are described in text where they are relevant, are also listed in

Group 2 in the General Contents.

(4) The sequence in which parts are to be assembled is summarized below each assembled view.

Such as:

52431

(5) The following marks are used in this manual to emphasize important safety cautions.

…Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

…Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

…Indicates important information or information which is useful for engine operation or

maintenance.

(6) Tightening torque under wet conditions is indicated by “[Wet].” When so indicated, apply engine oil to the

threaded portion of the fastener. Unless indicated as such, the tightening torque is to be assumed in the dry
condition.

←←←←

WARNING

CAUTION

NOTE

2. Terms Used in This Manual

Nominal value: Indicates the standard dimension of a part to be measured.

Standard: Indicates the dimension of a part, the clearance between parts, or the standard performance. Since the

value is indicated in a range needed for inspection, it is different from the design value.

Limit: A part must be repaired or replaced with a new part when it reaches the limit value.

3. Abbreviations, Standards, Etc.

• BTDC = Before Top Dead Center

• ATDC = After Top Dead Center

• BBDC = Before Bottom Dead Center

• ABDC = After Bottom Dead Center

• TIR = Total Indicated Reading

• API = American Petroleum Institute

• ASTM = American Society for Testing and Materials

• JIS = Japanese Industrial Standards

• LLC = Long Life Coolant

• MIL = Military Specifications and Standards (U.S.)

• MSDS = Material Safety Data Sheet

• SAE = Society of Automotive Engineers (U.S.)

4. Units of Measurement

Measurements are based on the International System of Units (SI), and their converted metric values are indicated in
parentheses ( ). For metric conversion, the following rates are used.

• Pressure: 1 MPa = 10.197 kgf/cm

2

• Torque: 1 N·m = 0.10197 kgf·m

• Force: 1 N = 0.10197 kgf

• Horsepower: 1 kW = 1.341 HP = 1.3596 PS

• Meter of mercury: 1 kPa = 0.7 cmHg

• Meter of water: 1 kPa = 10.197 cmH

2

O (cmAq)

• Rotational speed: 1 min

−

1

= 1 rpm

GROUP INDEX Items

1

2

3

4

5

6

7

8

9

10

11

12

13

GROUP INDEX

GENERAL

Outline, Specifications, Tips on Disassembly and Reassembly

MAINTENANCE STANDARDS

Maintenance Standards Table, Tightening Torques, Sealants and Lubricants,
Regarding Submission of Parts for EPA Exhaust Gas Regulation

SPECIAL TOOLS

Special Tools

OVERHAUL INSTRUCTIONS

Determination of Overhaul Timing, Testing the Compression Pressure

ADJUSTMENTS, BENCH TEST,
PERFORMANCE TESTS

Adjustments, Bench Testing, Performance Tests

ENGINE AUXILIARIES
REMOVAL AND INSTALLATION

Preparation, Engine Auxiliaries Removal, Engine Auxiliaries Installation

ENGINE MAIN PARTS

Cylinder Head and Valve Mechanism, Flywheel, Damper, Timing Gears and
Camshaft, Piston, Connecting Rods, Crankshaft, Crankcase and Tappets

INLET AND EXHAUST SYSTEM

Description, Exhaust Manifold

LUBRICATION SYSTEM

Description, Oil Pump, Oil Filter, Oil Pressure Relief Valve

COOLING SYSTEM

Description, Water Pump and Thermostat

FUEL SYSTEM

Description, Fuel Filter (Paper-Element Cartridge Type), Injection Nozzles

ELECTRICAL SYSTEM

Starter, Alternator, Glow Plug, Stop Solenoid

WORKSHOP TIPS

Basic Recommended Assembly Procedures

1. Outline ................................................................................................. 1 – 1

1.1 External View .................................................................................. 1 – 1

1.2 Engine Serial Number Location ...................................................... 1 – 2

2. Specifications .................................................................................... 1 – 3

3. Tips on Disassembly and Reassembly ....................................... 1 – 5

3.1 Disassembly.................................................................................... 1 – 5

3.2 Reassembly ................................................................................... 1 – 5

1

GENERAL

1-1

GENERAL

1. Outline

1.1 External View

Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.

Fuel injection pump

Fuel filter

Water pump

Front Rear

Fuel feed pump

Relief valve

Stop solenoid

Oil drain plug

Left View

Oil level gauge

Oil pan

Fuel injection nozzle

Inlet manifold

Water drain plug

Flywheel

Oil filter

Exhaust manifold

Alternator

V-belt

Rear Front

Starter

Oil pressure switch

Right View

1-2

GENERAL

1.2 Engine Serial Number Location

The engine serial number is located on the side of the
crankcase.

Engine serial number location

Engine serial
number

2. Specifications

Model designation S6S

Type Water-cooled, 4-stroke cycle

No. of cylinders – arrangement 6 –in line

Combustion chamber type Swirl chamber

Valve mechanism Overhead

Cylinder bore × stroke mm (in.) 94 × 120 (3.70 × 4.72)

Piston displacement liter (cu in.) 4.996 (305)

Compression ratio 22 : 1

Firing order 1 – 5 – 3 – 6 – 2– 4

Direction of rotation Counterclockwise as viewed from flywheel side

Overall length

866 (34.1)

mm (in.)

Dimension

Overall width

622 (24.5)

mm (in.)

Overall height

801 (31.5)

mm (in.)

Weight (dry) kg (lb) Approx. 340 (750)

Type of cylinder sleeve Integral with cylinder block

No. of piston ring

Compression ring 2

Oil ring 1 (w/spring expander)

Inlet valve

Open BTDC 30°

Close ABDC 50°

Valve timing

Exhaust valve

Open BBDC 74°

Close ATDC 30°

Starting system Electric-starter

Starting aid Glow plug

Type Force feed by oil pump

API Service Classification CD or higher

Engine oil Refill capacity

Whole system: Approx. 13.0 (3.4)

liter (U.S. gal.)

Type Trochoid

Speed ratio to crankshaft 0.74

Oil pump

Capacity 38.7 (10.2) at 0.3 MPa (3 kgf/cm

2

) [42.7 psi]

liter (U.S gal.)/min discharge pressure of pump running at 2230 min

-1

Oil pressure

Type Piston valve

relief valve

Opening pressure

0.35±0.05 (3.5±0.5) [50±7]

MPa (kgf/cm

2

) [psi]

Oil filter Type Cartridge of paper element

1-3

GENERAL

General

Engine main
parts

Lubrication
system

1-4

GENERAL

Model designation S6S

Refill capacity (engine water jacket)

9.0 (2.4)

liter (U.S. gal.)

Type Centrifugal

Water pump

Speed ration to crankshaft 1.3

Capacity 160 (42.3) at 0.07 MPa (7.5 kgf/cm

2

) [107 psi]

liter (U.S gal.)/min/min

-1

discharge pressure of pump running at 3600 min

-1

Belt Type mm (in.) Low-edge B type V-belt × 1 1190 (46.9)

Type Wax pellet

Thermostat

Valve opening temperature

76.5±1.5 (170±2.7)

°C (°F)

Type Bosch A

Diameter of plunger

7 (0.276)

Injection pump mm (in.)

Cam lobe lift

8 (0.315)

mm (in.)

Governor Type Bosch RSV, centrifugal

Type of nozzle Bosch hole

No. of discharge orifice 1

Diameter of discharge

1.0 (0.039)

Injection nozzle

orifice mm (in.)

Spray cone angle 0°

Valve opening pressure

11.77 (120) [1707]

MPa (kgf/cm

2

) [psi]

Fuel filter Type Cartridge of paper element

Voltage – polarity 24 V – (−) ground

Model M008T60372

Type Pinion shift

Starter Output V – kW 24 – 5

No. of pinion teeth/

10/122

flywheel ring gear teeth

Type 3-phase, with rectifier

Output V – A 24 – 35

Working speed min

-1

8000

Alternator

Rated output generating

5000

speed min

-1

Maximum permissible

10,000

speed min

-1

Speed ratio to crankshaft 2.0

Type Electric

Glow plug

Rated voltage – current

22 – 4.4 (1.5 sec rating)

V– A

Stop solenoid Rated voltage V 24

Electrical
system

Cooling system

Fuel system

1-5

GENERAL

This service manual covers recommended procedures to
be followed when servicing diesel engines. It also
contains information on special tools required and basic
safety precautions.

It is the responsibility of service personnel to be
familiar with these requirements, precautions and
potential hazards and to discuss these points with their
foreman or supervisor.

Study this manual carefully and observe the following
general precautions to prevent serious personal injury
and to avoid damage to the engine, equipment and
parts.

3.1 Disassembly

(1) Use the correct tools and instruments. Serious

injury or damage to the engine can result from
using the wrong tools and instruments.

(2) Use an overhaul stand or work bench if necessary.

Also, use assembly bins to keep the engine parts in
order of removal.

(3) Lay down disassembled or cleaned parts in the

order in which they were removed. This will save
you time at reassembly.

(4) Pay attention to the marks on assemblies,

components and parts for positions or directions.
Put on your own marks, if necessary, to aid
reassembly.

(5) Carefully check each part for faults during removal

or cleaning. Signs of abnormal wear will tell if
parts or assemblies are functioning improperly.

(6) When lifting or carrying heavy parts, get someone

to help you if the part is too awkward for one
person to handle. Use jacks and chain blocks when
necessary.

3.2 Reassembly

(1) Wash all engine parts, except oil seals, O-rings,

rubber seals, etc. in cleaning solvent and dry them
with compressed air.

(2) Use only the correct tools and instruments.

(3) Use only good quality lubricating oils and greases.

Be sure to apply a coat of oil, grease, or sealant to
parts as specified. (Refer to section 3 of Group 2.)

(4) Use a torque wrench to tighten parts when specified

tightening torques are required. (Refer to section 2
of Group 2.)

(5) Replace all gaskets and packing. Apply appropriate

amount of adhesive or liquid gasket when required.

3. Tips on Disassembly and Reassembly

1. Maintenance Standards Table ...................................................... 2 – 1

2. Tightening Torques ........................................................................... 2 – 6

2.1 Important Bolts and Nuts ................................................................ 2 – 6

2.2 Standard Bolts ................................................................................ 2 – 7

2.3 Standard Studs ............................................................................... 2 – 7

2.4 Standard Plugs ............................................................................... 2 – 7

3. Sealants and Lubricants Table ...................................................... 2 – 8

4. Regarding Submission of Parts for EPA Exhaust Gas
Regulation

........................................................................................... 2 – 8

2

MAINTENANCE STANDARDS

2-1

MAINTENANCE STANDARDS

1. Maintenance Standards Table

Unit: mm (in.)

Nominal Assembly Standard

Repair Service

Inspection Point Limit Limit Remark

Value [Standard Clearance]

[Clearance] [Clearance]

Maximum min

−

1

, (no-load)

According to engine

Adjust governor setting.

Minimum min

−

1

, (no-load)

specification

Compression pressure 3.2 (33) [469] 2.8 (29) Oil and water temp.:

MPa (kgf/cm

2

) [psi] at 300 min

−

1

[413] 20 to 30°C (68 to 86°F)

0.3 to 0.5 (3 to 5) [43 to 71] 0.15 (1.5)

Engine oil pressure at 1500 min

−

1

[21.3]

Oil temperature:

MPa (kgf/cm

2

) [psi] 0.1 (1) [14.2] or more 0.05 (0.5)

70 to 90°C (158 to 194°F)

at idling [7]

Inlet valve open BTDC 30°
Inlet valve close ABDC 50°

Valve timing Exhaust valve open BBDC 74°

Exhaust valve close ATDC 30°

±3° (crank angle)

Valve clearance (cold) [0.25 (0.0098)] Both inlet and exhaust valves

The timing for each model of
engine varies according to its

Fuel injection timing — specification. Be sure to

verify the timing by referring
to the specifications of each
model.

10 to 12

Push belt inward with thumb

V-belt deflection pressure and measure

(0.394 to 0.472)

deflection.

Crankcase

Warpage of gasket contact 0.05 (0.0020) 0.20

Regrind if warpage is minor.

surface or less (0.0079)

Inside diameter 94 (3.70)

94.000 to 94.035 94.200 94.700
Refinish cylinder to 0.25

(3.7008 to 3.7022) (3.7087) (3.7283)

(0.0098) or 0.50 (0.0197)

Cylinder Circularity

0.01 (0.0004) oversize of normal value by
or less honing and use the same

Taper

0.015 (0.0006)

oversize pistons and piston

or less

rings.

If repair limit is reached,

–0.9 replace bearings. If is

(–0.035) exceeded, regrind journals
Main Clearance between bearing [0.050 to 0.110 [0.200 as journal and use undersize bearings.
bearing and journal (0.0020 to 0.0043)] (0.0079)] diameter Bearing undersizes:

which is 0.25 (0.0098)

78 (3.07) 0.50 (0.0197)

0.75 (0.0295)

Inside diameter

14.000 to 14.018 14.100

Tappet bore

(0.5512 to 0.5519) (0.5551)

Clearance between tappet [0.016 to 0.052 [0.08 If it exceeds the repair limit,
and bore (0.0006 to 0.0020)] (0.0031)] replace tappets.

Camshaft Clearance between camshaft [0.040 to 0.119 [0.15 If it exceeds the repair limit,
bushing journal and bushing (0.0016 to 0.0047)] (0.0059)] replace the bushings.

GeneralCrankcase Group

2-2

MAINTENANCE STANDARDS

Nominal Assembly Standard

Repair Service

Inspection Point Limit Limit Remark

Value [Standard Clearance]

[Clearance] [Clearance]

Warpage of gasket contact 0.05 (0.0020) 0.20

Regrind if warpage is minor.

Cylinder

surface or less (0.0079)

head

Compressed thickness of

1.2 (0.05) ±0.05 (±0.002)

gasket

Inlet valve

7.940 to 7.955 7.900

Diameter of valve

8 (0.31)

(0.3126 to 0.3132) (0.3110)

stem

Exhaust 7.920 to 7.940 7.850
valve (0.3118 to 0.3126) (0.3091)

Valve and

Inlet valve

[0.065 to 0.095 [0.150

valve guide

Clearance between

(0.0026 to 0.0037)] (0.0059)]

guide and stem

Exhaust [0.080 to 0.115 [0.200
valve (0.0032 to 0.0045)] (0.0079)]

Height to top of valve guide 14 (0.55) ±0.1 (±0.004)

Angle 30˚

Inlet valve

0.4

Valve sinkage

(0.016)

±0.1 (±0.004)

1.0

Exhaust 0.5

(0.039)

Valve seat

valve (0.020)

Width

1.4
±0.14 (±0.0055)

1.8

(0.055) (0.071)

Up to 1.83

Valve margin 2.13 (0.0839) (0.0720) by

refacing

Free length

48.85 47.60

(1.92) (1.87)

Valve spring

Perpendicularity 1.5° or less

Set length 43 (1.69)

Set force N (kgf) [lbf]

176 to 196 (18 to 20) 147 (15)

[40 to 44] [33]

Inside diameter of rocker 19.010 to 19.030
bushing

19 (0.75)

(0.7484 to 0.7492)

Rocker arm Diameter of rocker shaft

18.980 to 19.000

(0.7472 to 0.7480)

Clearance between bushing [0.010 to 0.050 [0.070
and shaft (0.0004 to 0.0020)] (0.0028)]

Valve

Deflection

0.3 (0.012)
1/2 of dial indicator reading

pushrod or less

Deflection

0.02 (0.0008) 0.05
or less (0.0020)

Journal diameter 78 (3.07)

77.955 to 77.970 77.850 77.100

(3.0691 to 3.0697) (3.0650) (3.0354)

Crankpin diameter 58 (2.28)

57.955 to 57.970 57.800

(2.2817 to 2.2823) (2.2756)

Crankshaft

Center to center distance

60 (2.36) ±0.04 (±0.0016)

between journal and crankpin

Parallelism between journal

Runout:

0.01 (0.004) or less

and crankpin

(over crankpin length)

Circularity of journal and
crankpin

0.01 (0.0004) 0.03

Taper of journal and crankpin

or less (0.0012)

Cylinder headMain moving parts Group

Unit: mm (in.)

Seat width

Valve
margin

Valve sinkage

Valve seat
angle

2-3

MAINTENANCE STANDARDS

Nominal Assembly Standard

Repair Service

Inspection Point Limit Limit Remark

Value [Standard Clearance]

[Clearance] [Clearance]

Fillet radius of journal and

3 (0.12) ±0.2 (±0.008)

crankpin

If thrust plate clearance
exceeds the repair limit,

Crankshaft replace thrust plates.

End play 31 (1.22)

[0.100 to 0.264 [0.300 If it is exceeded, use oversize

(0.0039 to 0.0104)] (0.0118)] thrust plates.

Thrust plate oversizes:

0.15 (0.0059)

0.30 (0.0118)

Standard

93.955 to 93.985 93.770

(3.6990 to 3.7002) (3.6917)

Outside

0.25 (0.0098)
94 (3.70)

94.205 to 94.235 94.020

diameter

oversize (3.7089 to 3.7100) (3.7016)

(at skirt)

0.50 (0.0197) 94.455 to 94.485 94.270

Piston

oversize (3.7187 to 3.7199) (3.7114)

Protrusion

−0.25 to 0.15
Checking bearing clearance.

(−0.0098 to 0.0059)

Clearance between piston pin [0.000 to 0.016 [0.050
and bore (0.0000 to 0.0006)] (0.0020)]

Piston weight difference per 5 g (0.18 oz)
engine or less

No.1 ring

2.5 [0.135 to 0.157 [0.200

Clearance

(0.098) (0.0053 to 0.0062)] (0.0079)]

between

No.2 ring

2.0 [0.045 to 0.085 [0.150

groove and (0.079) (0.0018 to 0.0034)] (0.0059)]

Piston ring

ring

Oil ring

4.5 [0.025 to 0.065 [0.150

(0.177) (0.0010 to 0.0026)] (0.0059)]

No. 1 ring,

0.30 to 0.50 1.50

Ring gap No. 2 ring,

Oil ring

(0.0118 to 0.0197) (0.0591)

Diameter 30 (1.18)

29.994 to 30.000

Piston pin

(1.1809 to 1.1811)

Clearance between pin and [0.020 to 0.051 [0.080
bushing (0.0008 to 0.0020)] (0.0031)]

Inside diameter of bushing 30 (1.18)

30.020 to 30.045

(1.1819 to 1.1829)

Bend and twist

0.05/100 0.15

(0.0020/3.94) or less (0.0059)

Connecting Clearance between crankpin [0.030 to 0.090 [0.200
rod and connecting rod bearing (0.0012 to 0.0035)] (0.0079)]

Big end width 33 (1.30)

[0.15 to 0.35 [0.50

Replace connecting rod.

(0.0059 to 0.0138)] (0.020)]

Rod weight difference per 10 g (0.35 oz)
engine or less

Flywheel

Flatness

0.15 (0.0059) 0.50

Face runout

or less (0.020)

Circular runout

0.5 (0.020) 1.5

Damper

or less (0.0591)

Replace after 8000 service

Face runout

0.5 (0.020) 1.5

hours.

or less (0.0591)

Main moving parts Group

Unit: mm (in.)

2-4

MAINTENANCE STANDARDS

Nominal Assembly Standard

Repair Service

Inspection Point Limit Limit Remark

Value [Standard Clearance]

[Clearance] [Clearance]

Deflection

0.02 (0.0008) 0.05 Straighten by cold working
or less (0.0020) or replace.

A=

6.184

Inlet valve 46.916 6.684 (0.2631)

Cam lift C

(1.8471 )

(0.2434)

Exhaust

A=

6.220

46.880 6.720 (0.2646)

Camshaft

valve

(1.8457 )

(0.2450)

No.1, 2, 3 54 (2.13)

53.94 to 53.96 53.90

Journal diameter

(2.1236 to 2.1244) (2.1220)

No.4 53 (2.09)

52.94 to 52.96 52.90

(2.0843 to 2.0850) (2.0827)

End play 5 (0.20)

[0.10 to 0.25 [0.30

Replace thrust plate.

(0.0039 to 0.0098)] (0.0118)]

Clearance between shaft and [0.009 to 0.050 [0.100

Replace bushing.

bushing (0.0004 to 0.0020)] (0.0040)]

Idler gear End play 30 (1.18)

[0.05 to 0.20 [0.35

Replace thrust plates.

(0.0020 to 0.0079)] (0.0138)]

Fit (interference) of bushing

35 (1.38)

[0.035T to 0.076T

in crankcase bore (0.0014T to 0.0030T)]

Backlash

[0.03 to 0.18 [0.25

Replace gears.

(0.0012 to 0.0071)] (0.0098)]

Clearance between outer [0.20 to 0.30 [0.50

Replace pump assembly.

rotor and case (0.0079 to 0.0118)] (0.0197)]

Diameter of main shaft

16 (0.63)

15.985 to 16.000

(case side) (0.6293 to 0.6299)

Diameter of main shaft

14 (0.55)

13.957 to 13.975

(oil pump bushing side) (0.5495 to 0.5502)

Oil pump

Clearance between main shaft [0.032 to 0.074 [0.15

Replace pump assembly.

and case (0.0013 to 0.0029)] (0.0059)]

Clearance between main shaft [0.025 to 0.111 [0.200 Replace bushing or pump
and oil pump bushing (0.0010 to 0.0044)] (0.0079)] assembly.

Clearance between outer and [0.13 to 0.15 [0.20 Replace outer rotor and shaft
inner rotors (0.0051 to 0.0059)] (0.0079)] assembly.

End play between rotors and [0.04 to 0.09 [0.15

Replace pump assembly.

cover (0.0016 to 0.0035)] (0.0059)]

Relief valve

Valve opening pressure 0.35±0.05 (3.5±0.5)

MPa (kgf/cm

2

) [psi] [50±7]

Temp. at which valve starts 76.5±1.5°C

Thermostat

opening (170±2.7°F)

Temp. at which valve lift is

90°C (194°F)

more than 9 (0.35)

+ 0.004

− 0.012

+ 0.1

− 0.3

+ 0.004

− 0.012

+ 0.1

− 0.3

Timing gearLubrication system

Cooling

system

Group

Unit: mm (in.)

A

C

B

2-5

MAINTENANCE STANDARDS

Nominal Assembly Standard

Repair Service

Inspection Point Limit Limit Remark

Value [Standard Clearance]

[Clearance] [Clearance]

Make shim adjustment.

Valve opening pressure

11.77 11.77 to 12.75
Pressure varies by 1 (10)

MPa (kgf/cm

2

) [psi]

(120) (120 to 130)

[142] per 0.1 mm (0.004 in.)

[1707] [1707 to 1849]

thickness of shim.

Test with hand tester, using
diesel fuel, at 20°C (68°F).

Injection

Spray cone angle 0°

If discharge pattern is bad

nozzle even after nozzle is washed

in clean diesel fuel, replace
the nozzle tip.

Seat shall hold a test pressure

Oil tightness of needle 2 MPa (20 kgf/cm

2

) [285 psi]

Wash or replace nozzle tip.

valve seat lower than valve opening

pressure for 10 seconds.

Diameter of commutator 32 (1.26) 31.4 (1.24)

Length 18 (0.71) 11 (0.43)

Brush Spring force 34.3 (3.5) 29.4 to 39.2 (3 to 4) 13.7 (1.4)

N (kgf) [lbf] [7.7] [6.6 to 8.8] [3.1]

0.5 to 2.0

Pinion clearance (0.020 to

Starter 0.079)

Output

Rotating

1500 min

-1

20 A or higher When cold

current

speed

2500 min

-1

29 A or higher When cold

(27 V)

5000 min

-1

33 A or higher When cold

Regulator adjusting voltage
(alternator at 5000 min

−

1

, 28.5±0.5 V

Alternator

load at 5 A or lower)

Brush spring tension

5.8 to 7.0 3.2

(590 to 710) (330)

N (kgf) [lbf]

[1.30 to 1.57] [0.73]

Brush length 21.5 (0.85) 8 (0.3)

Resistance between slip rings

9.0 to 10.4 ohm

[at 20°C (68°F)]

Glow plug

Rated voltage 24 VDC

Current 4.4 A (15 sec rating)

Working voltage 16 to 27 V

Stop

Working temp.

−30 to 90°C

solenoid

(−22 to 194°F)

Rated time 10 sec or lower

Rated Current 11.7 A or less

Fuel systemElectrical system Group

Unit: mm (in.)

No-load characteristics Locked characteristics Magnetic switch

Voltage Current Speed Voltage Current Torque Switch-in voltage

23 V

85 A 3300 min

−

1

9 V

1400 A 88.26 N·m (9.0 kgf·m)

16 V or less

or less or more or less [65.1 lbf·ft]

2. Tightening Torques

2.1 Important Bolts and Nuts

Thread Width

Tightening Torque

Description Dia. × Pitch across flats, Remark

(M-thread) mm

N·m kgf·m lbf·ft

Cylinder head M12 × 1.75 19 113 to 123 11.5 to 12.5 83 to 90

Rocker cover M8 × 1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Rocker shaft brackets M8 × 1.25 12 10.0 to 20.0 1.0 to 2.0 7.23 to 14.5

Main bearing caps M14 × 2 22 98 to 108 10.0 to 11.0 72 to 80

Connecting rod cap nuts M10 × 1.25 14 49.0 to 59.0 5.0 to 6.0 36.2 to 43.4

Flywheel M12 × 1.25 17 78.5 to 88.3 8.0 to 9.0 57.9 to 65.1

Camshaft thrust plate M8 × 1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Front plate M8 × 1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Timing gear case M8 × 1.25 12 17.0 to 20.0 1.7 to 2.0 12.3 to 14.5

Crankshaft pulley M30 × 1.5 46 480 to 500 49 to 51 354 to 369

Idler gear thrust plate M10 × 1.25 14 29.0 to 39.0 3.0 to 4.0 21.7 to 28.9

Oil pan M8 × 1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Oil pan drain plug M20 × 1.5 24 73.0 to 83.0 7.5 to 8.5 54.2 to 61.5

Rear plate M10 × 1.25 14 5.40 to 65.7 5.5 to 6.7 39.8 to 48.5

Fuel injection nozzle

M16 × 0.75 — 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9

retaining nut

Fuel injection nozzle

M20 × 1.5 21 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6

(install to engine)

Fuel injection pump

— 22 34.5 to 39.2 3.5 to 4.0 25.3 to 28.9

delivery valve holders

Fuel injection pump gear M12 × 1.75 19 58.8 to 68.6 6.0 to 7.0 43.4 to 50.6

Exhaust manifold M8 × 1.25 12 15.0 to 22.0 1.5 to 2.2 10.8 to 15.9

Oil pressure relief valve M22 × 1.5 27 44.1 to 53.9 4.5 to 5.5 32.5 to 39.8

Coolant drain plug 1/4 – 18NPSF 14 35.3 to 43.1 3.6 to 4.4 26.0 to 31.8

Fuel injection pipe nuts M12 × 1.5 17 26.5 to 32.4 2.7 to 3.3 19.5 to 23.9

Fuel return pipe nut M10 × 1.25 14 17.7 to 21.6 1.8 to 2.2 13.0 to 15.9

Oil pump gear M10 × 1.25 14 28.0 to 38.0 2.9 to 3.9 21.0 to 28.2

Starter terminal B M8 × 1.25 12 9.81 to 11.8 1.0 to 1.2 7.23 to 8.68

Plug M16 × 1.5 24 39.2 to 49.0 4.0 to 5.0 28.9 to 36.2

Cylinder head

Fuel injection pump eye bolt M14 × 1.5 22 15.0 to 20.0 1.5 to 2.0 10.8 to 14.5

Fuel injection pump

M10 × 1.0 — 7.9 to 12.7 0.8 to 1.3 5.8 to 9.4

oil inlet eye bolt

Thermostat case M8 × 1.25 12 16.0 to 20.0 1.8 to 2.0 11.8 to 14.5

Alternator pulley M20 × 1.5 27 132 to 162 12.9 to 15.9 93.3 to 115

Glow plug (Body) M10 × 1.25 12 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5

Glow plug (Connection plate) M4 × 0.7 7 0.98 to 1.47 1.0 to 1.5 0.72 to 1.08

2-6

MAINTENANCE STANDARDS

2-7

MAINTENANCE STANDARDS

2.2 Standard Bolts

2.3 Standard Studs

2.4 Standard Plugs

Remarks: 1. The torque values shown above are for the bolts with spring washers.

2. Do not apply any oil to the bolt threads.

Thread Diameter

Torque

(mm)

4T 7T

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 2.94 to 4.90 0.3 to 0.5 2.17 to 3.62 7.89 to 9.80 0.8 to 1.0 5.79 to 7.23

M8 9.80 to 12.7 1.0 to 1.3 7.23 to 9.40 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

M10 17.7 to 24.5 1.8 to 2.5 13.0 to 18.1 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

M12 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

Thread Diameter

Torque (tap end)

(mm)

For driving in aluminum materials For driving in ferrous materials

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M8 4.90 to 5.90 0.50 to 0.60 3.62 to 4.34 11.8 to 13.7 1.2 to 1.4 8.68 to 10.1

M10 12.7 to 14.7 1.3 to 1.5 9.40 to 10.8 21.6 to 25.5 2.2 to 2.6 15.9 to 18.8

Torque

Thread Diameter For aluminum materials For ferrous materials

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

NPTF 1/16 4.90 to 7.85 0.5 to 0.8 3.62 to 5.79 7.85 to 11.8 0.8 to 1.2 5.79 to 8.68

PT 1/8 7.85 to 11.8 0.8 to 1.2 5.79 to 8.68 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

PT 1/4, NPTF 1/4 19.6 to 29.4 2.0 to 3.0 14.5 to 21.7 34.3 to 44.1 3.5 to 4.5 25.3 to 32.5

PT 3/8 –– –– –– 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

2-8

MAINTENANCE STANDARDS

3. Sealants and Lubricants Table

ThreeBond 1207C/1212/1211; Silicon liquid gasket Oil resistant/Formed-in-place/Low viscosity

ThreeBond 13860D; Anaerobic adhesive

4. Regarding Submission of Parts for EPA Exhaust Gas Regulation

The following parts have been submitted in accordance with EPA emission regulation.

(1) Fuel injection assembly

(2) Fuel injection nozzle

(3) Turbocharger assembly

(4) Other related parts (including designated fuel and lubricant)

Apply to Mating part Sealant or Lubricant How to Use

Oil pan Crankcase ThreeBond 1207C Apply to seal.

Rear bearing cap seat on crankcase Rear bearing cap ThreeBond 1212

Apply to corners before
installing cap.

Side seals

Crankcase rear

ThreeBond 1211 Apply to side seals.

bearing cap

Cylinder head coolant hole plug Cylinder head ThreeBond 1386D Apply to plug hole.

Crankcase coolant hole plug Crankcase ThreeBond 1386D Apply to plug hole.

Crankcase oil hole plug Crankcase ThreeBond 1386D Apply to plug hole.

Return oil hole blind plug or pipe

Crankcase ThreeBond 1386D Apply to blind plug or pipe.

of crankcase

Crankshaft threads

Crankshaft pulley

ThreeBond 1212

Apply to crankshaft thread

nut before tightening nut.

CAUTION

When replacing parts, make sure to use OEM designated parts. If OEM parts are not used, the
exhaust emission’s warranty will be voided. New parts may be updated due to improvement. Fuel
and Exhaust system repairs should only be conducted by an authorized Mitsubishi forklift dealer.
Tampering or adjusting the fuel system components will void the warranty and could be in
violation of the EPA regulations. The fuel injection pump must be replaced as an assembly.

Special Tool List ...................................................................................... 3 – 1

3

SPECIAL TOOLS

3-1

SPECIAL TOOLS

Special Tool List

Tool name Part No. Shape Use

Valve spring pusher 30691 - 04500 Valve spring removal/

installation

Valve guide remove 32A91 - 00300 Valve guide removal

Stem seal installer 32A91 - 10200 Valve stem installation

Valve seat insert Inlet valve: Valve seat installation
caulking tool 36791 - 00200

Exhaust valve:

34491 - 03020

Piston ring pliers 31391 - 12900 Piston ring removal/installation

Piston installer 34491 - 00200 Piston installation

Idler shaft puller MH061077 Idler gear shaft removal

3-2

SPECIAL TOOLS

Tool name Part No. Shape Use

Valve guide installer 32A91 - 00100 Valve guide installation

Idler bushing installer 30091 - 07300 Idler gear bushing removal

Oil seal sleeve 30691 - 13010 Crankshaft rear oil seal sleeve
installer set installation

Gauge adapter 30691 - 21100 Compression pressure

measurement

Compression gauge 32A91 - 03100 Compression pressure

measurement:

0 to 7 MPa (0 to 71.4 kgf/cm

2

)

[0 to 1015 psi]

Turning socket 58309 - 73100 Engine turning

Socket 34491 - 00300 Camshaft thrust plate and

rocker bracket installation

3-3

SPECIAL TOOLS

Tool name Part No. Shape Use

Connecting rod 32A91 - 00500 Connecting rod bushing
bushing puller removal/installation

Camshaft bushing 30691 - 00010 Camshaft bushing removal/
installer set installation

Oil pump bushing 32A91 - 00400 Oil pump bushing installation
installer

1. Determination of Overhaul Timing ............................................... 4 – 1

2. Testing the Compression Pressure .............................................. 4 – 2

4

OVERHAUL INSTRUCTIONS

4-1

OVERHAUL INSTRUCTIONS

In most cases the engine should be overhauled when the
engine’s compression pressure is low. Other factors
that indicate the necessity of engine overhaul are as
follows:

(a) Decreased power

(b) Increased fuel consumption

(c) Increased engine oil consumption

(d) Increased blow-by gas volume through the breather

due to abrasion at the cylinder liner and the piston
ring

(e) Gas leakage due to poor seating of the inlet and the

exhaust valves

(f) Starting problems

(g) Increased noise from engine parts

(h) Abnormal color of exhaust gas from engine after

warm-up

Any one or a combination of these symptoms may
indicate that engine overhaul is required. Of the items
listed above some are not directly related to the
necessity of engine overhaul. Items (b) and (f) are more
likely to be affected substantially by

• Injection volume of the fuel injection pump

• Fuel injection timing

• Wear of injection-pump plunger

• Fitting of the injection nozzle

• Condition of electrical equipment: battery, starter, or
alternator

Item (d) above, however, requires special consideration
because decreased pressure due to wear at the cylinder
liner and the piston ring is one of the most obvious
signs that the engine requires overhauling.

The most effective way to make a decision is by testing
the compression pressure; other factors are to be
considered secondarily.

1. Determination of Overhaul Timing

CAUTION

When replacing parts, make sure to use OEM
designated parts. If OEM parts are not used,
the exhaust emission’s warranty will be
voided. New parts may be updated due to
improvement. Fuel and Exhaust system
repairs should only be conducted by an
authorized Mitsubishi forklift dealer.
Tampering or adjusting the fuel system
components will void the warranty and could
be in violation of the EPA regulations. The
fuel injection pump must be replaced as an
assembly.

4-2

OVERHAUL INSTRUCTIONS

2. Testing the Compression Pressure

(1) Remove the injection nozzle from the cylinder head

where the compression pressure is to be measured.

(2) On the direction injection type engine, attach gauge

adapter (30691 - 21100) to the cylinder, and connect
the compression gauge (32A91 - 03100) to the adapter.

(3) Crank the engine by means of the starter, with the

governor stop lever pulled (the fuel supply shut off),
and read the compression gauge indication when the
engine running at the specified speed.

(4) If the compression pressure is lower than the repair

limit, overhaul the engine.

Unit: MPa (kgf/cm

2

) [psi]

CAUTION

(1) Measure the compression pressure on all

cylinders. It is not a good practice to
measure the compression pressure on only
few cylinders, and presume the compression
on the remaining cylinders.

(2) Compression pressure varies with engine

speed. Check engine speed when measuring
the compression pressure.

Item

Assembly Repair

Standard Limit

Compression pressure 3.2 (33) [469] 2.8 (29) [413]

NOTE

Measure the compression pressure with the engine
running at 300 min

-1

.

CAUTION

(1) Measure the compression pressure at

regular intervals to obtain correct data.

(2) The compression pressure will be slightly

higher in a new or overhauled engine due to
new piston rings, valve seats, etc. Pressure
will drop gradually by the wear of parts.

Measuring compression pressure

CAUTION

When replacing parts, make sure to use
OEM designated parts. If OEM parts are
not used, the exhaust emission's warranty
will be voided. New parts may be updated
due to improvement. Fuel and Exhaust
system repairs should only be conducted
by an authorized Mitsubishi forklift dealer.
Tampering or adjusting the fuel system
components will void the warranty and
could be in violation of the EPA regulations.
The fuel injection pump must be replaced
as an assembly.

Gauge adapter

Compression
gauge

5

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. Adjustments ....................................................................................... 5 – 1

1.1 Valve Clearance .............................................................................. 5 – 1

1.2 Fuel System Bleeding ..................................................................... 5 – 2

1.3 Fuel Injection Timing ...................................................................... 5 – 3

1.4 No-load Minimum (Idle) Speed and Maximum Speed Setting.......... 5 – 4

1.5 V-belt Inspection and Adjustment .................................................... 5 – 8

2. Bench Testing .................................................................................... 5 – 9

2.1 Starting Up ...................................................................................... 5 – 9

2.2 Inspection After Starting Up ............................................................ 5 – 9

2.3 Bench Testing (Dynamometer) Conditions ..................................... 5 – 9

2.4 Inspection and Adjustment After Bench Testing............................... 5 – 9

3. Performance Tests ........................................................................... 5 – 10

3.1 Engine Equipment Condition ........................................................... 5 – 10

3.2 Tests and Their Purposes................................................................ 5 – 10

3.3 Other Inspections ............................................................................ 5 – 10

3.4 Adjustment Engine Output............................................................... 5 – 10

5-1

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. Adjustments

1.1 Valve Clearance

Valve clearance should be inspected and adjusted when the
engine is cold.

(1) Inspection

(a) Inspect the valve clearance in the injection

sequence. To check, turn the crankshaft by the
specified crank angle in the normal direction to
bring the piston to the top dead center of the
compression stroke.

(b) Put socket (58309 - 73100) and ratchet handle on the

crankshaft pulley nut and turn the crankshaft in the
normal direction (clockwise as seen from the front
end).

(c) The top dead center on compression stroke of No.1

piston is identified by the timing mark “0” on the
crankshaft pulley and aligned with the pointer on the
gear case. With the piston so positioned, both the
inlet and exhaust valve rocker arms are not being
pushed up by their pushrods.

(d) Insert a feeler gauge in between the rocker arm and

valve cap, and check the clearance.

(2) Adjusting

(a) Loosen the lock nut of the adjusting screw. Adjust

the clearance by turning the screw in either direction
to the extent that the gauge is slightly gripped
between the rocker arm and valve cap.

(b) After adjusting the clearance, tighten the lock nut.

Inspect the clearance again and make sure that it is
correct.

Injection sequence Crank angle

1 – 5 – 3 – 6 – 2 – 4 120°

Checking valve clearance (turning)

Item Assembly Standard

Valve clearance

Inlet

0.25 mm (0.0098 in.)

(cold setting)

Exhaust

Width across flats of crankshaft

46 mm (1.81 in.)

pulley nut

Adjusting valve clearance

Crankshaft pulley

5-2

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.2 Fuel System Bleeding

(1) Fuel filter

(a) Loosen the air vent plug of the fuel filter by 1.5 full

turns.

(b) Turn the cap of the priming pump counterclockwise

to unlatch. Move the priming pump cap up and
down.

(c) When fuel flowing from the plug hole contains no

air bubbles, close the plug.

(2) Fuel injection pump

(a) Loosen the air vent plug of the fuel injection pump

by 1.5 full turns.

(b) Move the priming pump cap up and down.

(c) When fuel flowing from the plug hole contains no

air bubbles, depress the priming pump cap and turn
clockwise to lock in place.

(d) Close the plug.

NOTE

Cover the plug with a cloth to prevent fuel from
splashing.

NOTE

Cover the plug with a cloth to prevent fuel from
splashing.

NOTE

Do not close the air vent plug before locking the
priming pump cap in place, otherwise internal pressure
prevents the priming pump cap from returning to the
original position.

Bleeding fuel system

Air vent plug

Air vent plug

Priming pump

5-3

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.3 Fuel Injection Timing

The injection timing varies according to the output, speed
and specifications of the engine. Be sure to verify the
timing by referring to the specifications.

(1) Bringing the No.1 cylinder piston to the top dead

center on compression stroke

(a) Put socket (58309-73100) on the crankshaft pulley

nut and turn the crankshaft in the normal direction
(clockwise as seen from the front end).

(b) Stop turning the crankshaft when the timing the

mark “0” on the crankshaft pulley is aligned with the
pointer.

(c) Push down on the inlet and exhaust valve rocker

arms for the No.1 cylinder to make sure they are not
being pushed up by the pushrods (the inlet and
exhaust valves have some clearance).

(2) Checking injection timing

(a) Remove delivery valve holder from the No.1

plunger of the injection pump. Remove delivery
valve and spring from the holder. Restore the holder
to the pump.

(b) Connect a spare injection pipe to the No.1 plunger,

with its free end held downward so that you can
observe the fuel flow from that end.

(c) Turn the crankshaft to bring the No.1 piston to 60°

position before top dead center on compression
stroke.

(d) While operating the priming pump to allow the fuel

to flow from the injection pipe, slowly turn the
crankshaft in the normal direction. Stop turning the
crankshaft when the fuel flow stops.

(e) Make sure the timing mark on the crankshaft pulley

is aligned with the pointer.

Finding top dead center on compression stroke

Checking injection timing

(Removing delivery valve)

Checking injection timing

Crankshaft pulley

Delivery valve holder

Spring

Delivery valve

5-4

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(3) Adjusting the injection timing

(a) If the injection timing is retarded move the injection

pump toward the crankcase. If the timing is
advanced, move the pump away from the crankcase.

(b) One graduation of the scale on the injection pump

coupling changes the timing by 6° in terms of crank
angle.

1.4 No-load Minimum (Idle) Speed and
Maximum Speed Setting

For inspection and adjustment, warm up the engine
thoroughly until the coolant and oil temperatures are above
70°C (158°F).

Adjusting injection timing

Adjusting injection timing (scale)

CAUTION

(1) The no-load minimum (idle) speed and maxi-

mum speed are set for each engine on the test
bench at the factory. The set bolts are sealed.
These settings are to be inspected and
adjusted by a Mitsubishi forklift dealer only.

(2) After adjusting the governor by breaking the

seals, be sure to re-seal all visible stoppers,
making them appear as if they were sealed at
the factory.

(3) Whether the stopper seals are intact or not

has important bearing on the validity of claims
under warranty.

(4) When inspecting and adjusting these settings,

be on standby to operate the engine stop
lever manually in the event of engine overrun.

To advance
injection timing

To retard
injection timing

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