Mitsubishi S6S User 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/cm2
• 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 cmH2O (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 feed pump
Water pump
Fuel filter
Stop solenoid
Relief valve
Fuel injection pump Oil level gauge
Fuel injection nozzle
Inlet manifold
Water drain plug
Flywheel
Oil filter
Oil pan
Oil drain plug
Front Rear
Left View
V-belt
Alternator
Exhaust manifold
Starter
Oil pressure switch
Rear Front
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
Engine serial number location

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/cm2) [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/cm2) [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/cm2) [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/cm2) [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/cm2) [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/cm2) [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/cm2) [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/cm2) [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/cm2) [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.