Mitsubishi 6M60-TL User manual

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

14
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 ser-
vice 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 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:
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 re-
ferred 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 neces-
sary for servicing)
Specified values shown in table
See Table of Standard Tightening Torques for
parts for which no tightening torques are speci-
fied.
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 re-
quired, 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 num-
bers are required for registration and related inspection of the
vehicle.
• An engine nameplate indicates the following item.
• Engine model
ENGINE NUMBER

00-8
• 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 re-
moved 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 man-
ual. 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 ca-
ble 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.
• Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-9
• 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 ro-
tation, 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 in-
spection or replacement. Immediately wipe away any excess oil
or grease with a rag.

00-10
• Wear safety goggles when using a grinder or welder. Wear
gloves when necessary, and watch out for sharp edges and oth-
er items that might wound your hands.
• Before working on the electrical system, disconnect the (–) bat-
tery 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 sensi-
tive 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 to-
gether until they click.
• Before washing the vehicle, cover electrical parts to keep them
dry. (Use plastic sheets or the like.) Keep water away from har-
ness connectors and sensors and immediately wipe off any wa-
ter that gets on them.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-11
• 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 op-
erate 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.
1.1 Inspection of harnesses
(1) Inspections with connectors fitted together
(1.1) Waterproof connectors
•Connect an inspection harness and connector Abetween the
connectors Bof the circuit to be inspected. Perform the inspec-
tion by applying a test probe Cto the connectors of the inspec-
tion harness. Do not insert the test probe Cinto 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 Cinto 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.

00-12
(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 circuit-
ry.
•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.
•Check that male and female terminals fit together tightly.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-13
•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 connec-
tor 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 ze-
ro, 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.

00-14
•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 di-
odes 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 dam-
age.
•Never operate an alternator with the B and L terminals short-cir-
cuited. 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.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-15
3. Intermittent Faults
•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 re-
produced by performing the following checks on individual con-
nectors 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 corre-
sponding to diagnostic codes and/or fault symptoms.

00-16
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 bat-
tery’s (–) cable and damage the battery and electrical systems
directly connected to the battery. Be sure to disconnect the bat-
tery’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 possi-
ble to the area being welded.
•Set the welding current in accordance with the part being weld-
ed.
PRECAUTIONS FOR MAINTENANCE OPERATION

00
00-17
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
•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 .
Mark Tool name and shape Part No. Application
PC
FMSi-E06-1
(Multi-Use
Tester-III ver-
sion)
Data transmission to/from V.C.I.
V.C.I. N/A Data transmission between electronic
control unit and PC
MH062928 Power supply to V.C.I. and communi-
cation with electronic control unit
Multi-Use Tester har-
ness A
Multi-Use Tester test
harness D
(used for extension)
MH062931
(1 m)
MH062951
(2 m)
Multi-Use Tester test harness A
extension
USB cable MB991827 Communication between V.C.I. and
PC
DIAGNOSTIC CODES