Mitsubishi Forklift Trucks FD80, FD90, FD100, FD115, FD135, FD150A Service Repair Manual

Service Manual 99709-58130 For use with Chassis Service Manual. 6D16 Diesel Engine FD80 F32B-00011-up FD90 F32B-50001-up FD100 F15C-50001-up FD115 F15C-50001-up FD135 F15C-50001-up FD150A F24A-50011-up

diesel engine Shop Manual (for industrial use) FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of 6D16 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 service with no wastage. For more details, please consult your nearest authorized Mitsubishi dealer or distributor. 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. Applicable models 6D16 6D16-TLE GROUP INDEX HOW TO READ THIS MANUAL GENERAL ........................................... ENGINE ............................................... LUBRICATION .................................... FUEL AND ENGINE CONTROL .......... COOLING ............................................ INTAKE AND EXHAUST ...................... ELECTRICAL SYSTEM ....................... SPECIAL EQUIPMENT ....................... 00 11 12 13 14 15 54 61 Pub. No. 99709-58130

HOW TO READ THIS MANUAL HOW THIS MANUAL IS COMPILED ii GENERAL EXPLANATION OF THIS MANUAL iii TERMS AND UNITS vii i

How This Manual Is Compiled • This manual is compiled by classifying various systems into certain groups. • Each group contains specifications; troubleshooting; maintenance service standards; tightening torque; lubricant, fluid and sealant; special tools; and service procedure. • Page enumeration is independent by every group where first page is always 1. ii HOW TO READ THIS MANUAL Group No. Group denomination Contents 00 General General specifications, engine No. and name plate, precautions for maintenance operations, table of standard tightening torques 11 Engine Engine body 12 Lubrication Lubrication system 13 Fuel and engine control Fuel system 14 Cooling Cooling system 15 Intake and exhaust Intake and exhaust system, intercooler 54 Electrical system Alternator, starter, preheating system, engine start system, automatic stop system 61 Special equipment Air compressor

General Explanation of This Manual ● Specifications Particulars relative to maintenance service are made. ● Structure and operation (1) Regarding conventional equipment, descriptions are made in brief. (2) Regarding new equipment, descriptions of system and operating condition are made in detail. ● Troubleshooting Symptoms of troubles and possible causes are described comparatively. ● Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle. ● Service procedure In principle, an explanation is given at the spread title page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation. Regarding the design of this manual 1. ............... Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. 1a. ........ Names of parts show an example of the disassembly (removal) sequence. 1b. ........ When the assembly (installation) sequence differs from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown. 2. ............... Service standards are shown collectively, classified by location. 3. ............... Tightening torques are shown collectively, classified by location. 4. ............... Points of lubricant, fluid and sealant application are shown collectively, classified by location. 5. ............... Special tools to be used are shown collectively, classified by location. 6. ............... When it is considered hard to understand the service procedure, just by the foregoing description, a supplementary description of the service procedure is given. iii 1a 1 1b 2 3 4 5 6

1. Illustration for disassembly and assembly or removal and installation iv HOW TO READ THIS MANUAL This shows that the appropriate service procedure is described in the text. This shows the key No. of the part. In the text, this No. is referred to uniformly throughout. This shows an example of the disassembly (removal) sequence. No service procedure is referred to in this section, but the item can be an objective of various procedures. This is shown when the assembly (installation) sequence is not the reverse of the disassembly (removal) sequence. Meaning of symbols : shows that the tightening torque is specified. : shows that application of lubricant, fluid or sealant is required. : shows that the part should not be reused. This shows that a repair kit is available. This shows that the service procedure is described in another section. P. - : shows reference page within the same group. Gr : shows reference group within the same book.

2. Service standards table Service standards Unit: mm (in.) 3. Tightening torque table Tightening torques Unit: N·m (kgf·m) [lbf·ft] 4. Lubricants and sealant table Lubricants and sealant Location Maintenance item Standard value Limit Remedy 1, 11 Clearance between strap bolt and strap 0.01 to 0.16 0.3 (0.0118) Replace plate (0.0039 to 0.0629) 7 Pressure spring Installed load 835 N 710 N Replace (Installed length 49.1) (85 kgf) (72.3 kgf) [187.7 lbf] [159.6 lbf] Tilt 2.9 (1.1417) or less 5.0 (0.197) Replace v Only the relevant service standards are shown. This shows the key No. of the relevant part. This shows specified tightening torque. This shows the key No. of the relevant part. This shows that the item is to be tightened wet. Only the relevant lubricants and sealant are shown. This shows the application point. This shows the key No. of the relevant part. This shows the specified brand. Location Parts to be tightened Tightening torque Remarks 1 Strap bolts (Strap bolt mounting) 39 to 59 (4 to 6) [28.8 to 43.5] – 4 Bolt (Lock plate mounting) 5.9 to 7.8 (0.6 to 0.8) [4.3 to 10.5] Wet Location Points of application Kinds Quantity 1 Thread area of bolt LOCTITE 272 As required 10, 16 Friction surfaces of release lever plate and release Molybdenum disulfide grease As required lever [NLGI No. 2 (Li soap)]

5. Special tools table Special tools Unit: mm (in.) 6. Service procedure Removal and installation of clutch cover • Depress pressure spring 7 using clutch installer, then remove the following parts: Strap bolt 1, washer 2, washer 3, bolt 4, lock plate 5, support nut 6 • Loosen the clutch installer gradually, then remove clutch cover 11 when the pressure spring is fully released. • For installation, follow the removal sequence in reverse. 11 vi HOW TO READ THIS MANUAL Only the relevant special tools are shown. Purpose of special tools is shown. This shows the key No. of the relevant part. Quote this number when placing an order for the part. This shows the key No. of the relevant part. Servicing procedures of disassembly (removal), assembly (installation), inspection, adjustment, etc. are shown collectively. The key No. referred to in the text is always the same as the key No. shown in the illustration. This indicates a special service tool. Location Tool name and shape Part No. Application 11 Clutch installer MH061051 Removal and installation of clutch cover 16 Master plate MH062291 Adjust release lever heights 01277 01278 01281

Terms and Units The terms and units in this manual are defined as follows. ● This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: DANGER WARNING CAUTION NOTE ● Front and rear The terms “front” is the fan side and “rear” the flywheels side of the engine. ● Left and right The terms “right” and “left” shall be used to indicate the side as viewed from the flywheel side of the engine. ● Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [ ] is the basic diameter. (2) 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. ● Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. 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, and tighten at specified torque. ● Unit Length, weight, surface area and capacity are in SI units with foot-pound units are given in brackets. Tightening torques and other parameters are given in SI units with metric and foot-pound units added in brackets ( ) and [ ]. Example: 390 N·m (40 kgf·m) [289 lbf·ft] Temperatures are given in degrees Celsius with degrees Fahrenheit given brackets. For the conversion into the foot-pound system, refer to the following conversion table. vii 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, could result in damage to or destruction of equipment or parts. Suggestions or supplementary information for more efficient use of equipment or a better understanding. SI unit Metric unit Foot-pound unit

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Mitsubishi Forklift Trucks FD80, FD90, FD100, FD115, FD135, FD150A Service Repair Manual

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