Mitsubishi 6M60 Diesel Engine Service Repair Manual

Service Manual 99709-51100 For use with the FD80N-FD160N Service Manuals. 6M60-TL Diesel Engine

GROUP INDEX 00 11 12 13A 13E 14 15 17 54 61 GENERAL ........................................ ENGINE............................................ LUBRICATION ................................. FUEL AND ENGINE CONTROL...... ELECTRONICALLY CONTROLLED FUEL SYSTEM .................................. COOLING......................................... INTAKE AND EXHAUST ................. EMISSION CONTROL ..................... ELECTRICAL................................... SPECIAL EQUIPMENT ................... 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. 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 (for industrial use)

00-1 13E 13A 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 .............................................................. 00-17 2. Use of Blinking Warning Lamp for Diagnostic Code .................... 00-19 3. Up-Time Service Tool Functions .................................................... 00-21 4. Troubleshooting ............................................................................... 00-29 TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-31

00-2 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 described 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 following four headings which identify the nature of the instructions and information: 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. 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. DANGER Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, may result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or better understandings. HOW TO READ THIS MANUAL

00 00-3 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 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} Pressure Positive pressure kPa {kgf/cm 2 } 98.0665 kPa {1 kgf/cm 2 } Vacuum pressure kPa {mmHg} 0.133322 kPa {1 mmHg} Pa {mmH 2 O} 9.80665 Pa {1 mmH 2 O} Volume dm 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 Ω – Electric power W – Unit SI unit Foot-pound unit Conversion rate Force N (Newton) lbf 1 N = 0.2248 lbf Moment of force N·m lbf.ft 1 N·m = 0.7375 lbf.ft Pressure kPa (kilopascal) lbf/in. 2 1 kPa = 0.145 lbf/in. 2 1 kPa = 0.2953 in. Hg Volume L cm 3 cm 3 gal. oz cu.in. 1 L = 0.2642 gal. (U.S.) 1 L = 0.220 gal. (Imp.) 1 cm 3 = 0.033814 oz (U.S.) 1 cm 3 = 0.035195 oz (Imp.) 1 cm 3 = 0.061023 cu.in. Power kW (kilowatt) HP 1 kW = 1.34 HP Temperature ˚C ˚F t˚C = (1.8t˚C + 32)˚F Mass quantity of matter kg g lb oz 1 kg = 2.2046 lb 1 g = 0.035274 oz Dimension m mm ft. in. 1 m = 3.2808 ft. 1 mm = 0.03937 in. Stress N/cm 2 lbf/in. 2 1 N/cm 2 = 1.45 lbf/in. 2 Example: 390 N·m {40 kgf·m} Metric unit SI unit

00-4 Symbol Denotation Application Remarks Tightening torque Parts not tightened to standard torques (standard torques specified where necessary for servicing) Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are specified. Locating pin Parts to be positioned for installation Non-reusable parts Parts not to be reused Lubricant and/or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and/or sealant, quantity required, etc. are specified in table. Special tool Parts for which special tools are required for service operation Tool name/shape and part number are shown in table. *a Associated part Parts associated with those removed/disas- sembled for servicing HOW TO READ THIS MANUAL

00 00-5

00-6 How to Use Diagnostic Codes <Electronically Controlled Fuel System (Gr13E)> 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 System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON. Electronic control unit control • Engine is stopped. • Exhaust gas recirculation control is stopped. In- spec- tion item Service data 0C: Difference Common Rail Pressure Actuator test B9: Fuel Leak Check Electronic control unit connector : Resistance of MPROP (rail pressure control valve) Electrical part #574: MPROP1 (rail pressure control valve) 08 This section suggests areas to inspect for each diagnostic code. TROUBLESHOOTING 1. Diagnostic Procedure 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. 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. HOW TO READ THIS MANUAL

00 00-7 • Serial engine numbers are assigned to the engines in manufac- turing 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 ENGINE NUMBER

Mitsubishi 6M60 Diesel Engine Service Repair Manual

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