PDF Service Manual Mitsubishi FD80 - FD150A Forklift 6D16 Diesel Engine - 6 MB
This service manual is focused on the powerful 6D16 diesel engine used in Mitsubishi FD80 through FD150A series forklifts.
It contains all the procedures necessary for a complete engine overhaul, including specifications, tolerances, and torque settings.
This guide is indispensable for engine mechanics performing in-depth repairs.
Ensure your Mitsubishi forklift's engine runs reliably with this comprehensive manual.
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--- Page 1 ---
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
For use with Chassis Service Manual. 99709-58130
--- Page 3 ---
PRECAUTIONS FOR MAINTENANCE OPERATION
When using testers or the like for continuity tests, be careful not to
allow test probes to touch the wrong terminals.
00027
Measurement Procedures Using Connectors
Test with connectors engaged (continuity through circuit obtained)
<Waterproof connector>
Prepare a test harness and connectors A, then connect if between the
two parts of harness B that is to be tested. Check the circuit by
touching test probe C to the test connector.
Never insert the test probe from the harness side of the waterproof
connection, or waterproof performance might be diminished causing
corrosion of the connector.
02587
<Non-waterproof connector>
Insert test probe C from the harness side of the connector. Where
control units, etc. have connectors that are too small to accept the test
probe, do not force the test probe into them.
02588
Test with connectors disengaged
Using female pins
Insert a test probe into a terminal. However, do not force the probe into
the terminal, or it will cause a poor contact.
02589
00-8
--- Page 4 ---
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Inspecting and Adjusting Valve Clearances
Service standards Unit: mm (in.)
Location Maintenance item Standard value Limit Remedy
– Valve clearance (when cold) 0.4 (0.0158) – Adjust
Tightening torques Unit: N·m (kgf·m) [lbf·ft]
Location Parts to be tightened Tightening torque Remarks
2, 3 Rocker arm adjusting screw lock nut 34 (3.5) [25.1] –
Valve clearances should be checked and adjusted when the engine is cold.
[Inspection]
• Bring piston No. 1 or piston No. 6 to the top-dead-centre (TDC)
position of its compression stroke. To do this, crank the engine until
the “1.6” mark inscribed on the flywheel is aligned with the pointer A
in the flywheel housing inspection window.
NOTE
Pistons whose push rods are not pushing up their rockers are at
top-dead-centre (TDC) of their compression strokes.
01940
• When piston No. 1 or piston No. 6 is at the TDC position of its
compression stroke, measure the clearance B of every valve
marked “ ” in the following table.
Piston No. 1 2 3 4 5 6
Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
No. 1 piston at TDC of compression
stroke
11620
No. 6 piston at TDC of compression
stroke
NOTE
To measure the clearance, insert a feeler gauge 1. The gauge
should be able to move in the gap, albeit not loosely. Accurate
measurements cannot be taken if the gauge moves loosely in the
gap.
11-10
--- Page 5 ---
CYLINDER HEAD AND VALVE MECHANISM
[Removal]
Valve seats 17, 18 are installed by expansion fitting. To remove a valve
seat, grind the inside surface to reduce its thickness, then remove the
valve seat at room temperature.
D: Material to remove
01973
[Installation]
• Check that the valve seat hole diameters E, F in the cylinder head
20 conform with the values shown below.
Unit: mm (in.)
6D16 6D16-TLE
+0.03 +0.0012 +0.025 +0.00098
Inlet valve seat φ51 0 (φ2.01 0 ) φ49 0 (φ1.93 0 )
hole (E)
+0.025 +0.00098 +0.025 +0.00098
01976 Exhaust valve φ44 0 (φ1.73 0 ) φ42 0 (φ1.65 0 )
seat hole (F)
• Cool the valve seats 17, 18 by immersing it in liquid nitrogen.
• Install the valve seats 17, 18 in the cylinder head 20 using the
Caulking Tool Body and Installer Ring.
• After installing the valve seats 17, 18, lap the valve seats and valves
7, 8. P.11-26
01974
20 Inspecting cylinder head
• Measure the extent of distortion in the cylinder head's bottom
surface.
• If the degree of distortion exceeds the specified limit, rectify the
distortion with a surface grinder.
CAUTION
01978
Ensure that grinding does not cause the cylinder head's top
surface-to-bottom surface distance to fall below the specified
limit.
11-28
--- Page 6 ---
FLYWHEEL
16923
● Disassembly sequence
1 Spacer 8 Rear oil seal
2 Bolt 9 Plug
3 Washer plate 10 Flywheel housing
4 Flywheel assembly
5 Pilot bearing
*: Crankcase P.11-66
6 Ring gear A: Locating pin
7 Flywheel : Non-reusable part
● Assembly sequence
Reverse the order of disassembly.
11-46
--- Page 7 ---
CAMSHAFT
• Install the bushings 12 to 15 by using all components of the
Camshaft Bushing Installer and Extractor (rod A, camshaft bushing
adapter B, guide piece C and nut D).
• Install the camshaft bushings 12 to 15 in the following order: No. 3,
No. 4, No. 2 and No. 1.
NOTE
Install the No. 3 and No. 4 camshaft bushings 12, 13 from the rear
of the engine. Install the No. 1 and No. 2 camshaft bushings 14,
06225
15 from the front of the engine.
• Ensure that the oil holes F in the No. 1 and No. 4 camshaft bushings
15, 12 are aligned with the oil holes G in the crankcase. With the
No. 4 camshaft bushing, ensure also that the longer oil hole H is
toward the rear of the engine.
J: Bushing clinch joint
: Camshaft Bushing Installer and Extractor
04109
11-64
--- Page 8 ---
12
● Turbocharger <6D16-TLE>
1 Bearing housing
2 Snap ring
3 Piston ring
4 Bearing
A: From main oil gallery
B: To oil pan
Via an oil pipe, engine oil is delivered from the main oil gallery to the
bearing housing 1 to lubricate the inside of the bearing housing. At
each end of the turbine wheel shaft, piston ring 3 acts as an oil seal.
01488
● Injection pump
1 Injection pump
2 Governor
3 Air compressor (or injection pump drive)
A: From main oil gallery
B: To oil pan
Engine oil that has lubricated injection pump 1 and governor 2 returns
to the oil pan via the timer case, air compressor 3 (or injection pump
01489
drive), and timing gear train.
● Air compressor
1 Piston
2 Connecting rod
3 Crankshaft
4 Connecting rod bushing
5 Crankcase
A: From main oil gallery
B: To oil pan
Engine oil from the main oil gallery splashes onto connecting rod 2 and
lubricates connecting rod bushing 4. Piston 1 and the connecting rod's
small end are lubricated by oil that is splashed onto them by the
rotation of the crankshaft 3.
11107
12-9
--- Page 9 ---
12
Lubricant and/or sealant
Location Points of application Specified lubricant Quantity
and/or sealant
2, 4, 11 Apply to O-rings Engine oil As required
13, 14 Wrap around thread of engine oil pressure gauge unit and Teflon tape 3 1/2 turns
engine oil pressure switch
◆ Service procedure
● Cleaning
• Check whether carbon deposits or sludge have accumulated in the
oil passages of oil cooler element 6 and oil cooler cover 8 or in the
oil cooler's bypass arrangement. Remove any deposits with
cleaning sealant.
• Clean out any water scale or fur that has accumulated in the oil
cooler element 6 or oil cooler cover 8. Gr 14
6 Inspection of oil cooler element
Plug outlet A of oil cooler element 6 and connect a hose to the oil inlet.
Then, immerse the oil cooler element in a tank of water.
Apply the specified air pressure via the hose and check that no air
leaks from the oil cooler element.
If any air leaks, replace the oil cooler element.
01505
13 Engine oil pressure gauge unit
If the engine oil pressure gauge unit 13 is installed horizontally, it must
be fitted with its arrow pointing upward.
16886
12-27
--- Page 11 ---
13
• Ensure that the key way A on the injection pump drive or air
compressor (*a) crankshaft is facing upwards.
• If key way A is not facing upwards, rotate the engine crankshaft by
one turn.
13222
• Align line B inscribed on the injection pump and line C inscribed on
the automatic timer.
P 46823
• Fit driving coupling 22 to the injection pump drive or air compressor
*a crankshaft D. Push the driving coupling against the injection
pump drive or air compressor crankshaft D.
• Fit injection pump assembly 23 to injection pump bracket 25.
13223
• Set driving coupling 22 apart from coupling plate E by 0.5 mm
(0.020 in.) as shown in the illustration. Tighten cotter bolt 21 to the
specified torque.
13185
• Using bolts 20, fit driving coupling 22 and coupling plate E.
13186
13-31
--- Page 12 ---
STRUCTURE AND OPERATION
3. Thermostat
1 Thermostat cover
2 Thermostat
3 Thermostat case
A: To radiator
B: With low coolant temperature
C: With high coolant temperature
D: From cylinder head
E: To water pump
Thermostat 2 is a bottom bypass type that uses wax-
charged pellets as its regulating element. As the wax
changes from solid to liquid in line with temperature
increases, the total wax volume changes. As a result, the
06361 position of the valve, changed by the coolant temperature,
regulates the flow of coolant to the radiator and water pump
(bypass side) and controls the coolant temperature.
14-4
--- Page 15 ---
STRUCTURE AND OPERATION
4. Starter
<24V–5kW (6.7 HP)>
10739
1 Rear bracket 10 Pinion stopper 19 Yoke assembly
2 Brush 11 Pinion 20 Armature assembly
3 Brush spring 12 Front bearing 21 Packing
4 Brush holder assembly 13 Overrunning clutch 22 Rear bearing
5 Magnet switch 14 Washer
6 Ball 15 Gear shaft assembly B: Terminal B
7 Lever 16 Internal gear assembly M: Terminal M
8 Front bracket 17 Planetary gear S: Terminal S
9 Spring 18 Packing
This starter uses planetary gear 17 in the reduction gear mechanism.
13501
54-12
--- Page 16 ---
ALTERNATOR <24V–40A (with vacuum pump)>
Vacuum Pump Assembly
● Disassembly sequence
1 Vacuum housing
2 O-ring
3 Vane
4 Rotor
5 Plate
6 O-ring
*: Alternator P.54-26
: Non-reusable part
● Reassembly sequence
Reverse the order of removal.
00359
Service standards
Location Maintenance item Standard value Limit Remedy
– Attainable vacuum pressure 93 kPa – –
(when alternator speed is 1500 rpm) (0.95 kgf/cm2)
[13 psi]
54-30
--- Page 17 ---
STARTER <24V–5kW>
(2) Pinion gap
[Inspection]
• Wire the starter as shown.
C: Switch
D: Switch
E: Cable
10768
M: Starter terminal M
S: Starter terminal S
• The following operations are performed by supplying current to the
starter. It is therefore necessary that the series of operations up to
completion of measurement of the pinion gap is completed in less
than 30 seconds.
• Set the switch C and switch D to ON to supply current to the
starter. At the time, the pinion 3 will spring out and rotate.
P 14259
• Immediately (in less than 5 seconds) after the pinion has started
rotation, set the switch D to OFF stop rotation of the pinion.
CAUTION
When the switch C and switch D are set to ON, current is
supplied to both the pull-in coil P and holding coil H. Since
wiring is such that no voltage is applied to terminal B of the
starter, current flows to the pull-in coil during rotation of the
P 14260
pinion 3.
To prevent baking the pull-in coil, therefore, it is necessary that
the switch E is set to OFF immediately (in less than 5 seconds)
after the pinion has started rotating.
• Pull out the overrunning clutch 32 by hand, then push back its
end lightly and measure the amount F the clutch moves in the
axial direction (pinion gap).
• Set the switch C to OFF to stop supplying current to the starter.
P 10769 • If the reading is out of the standard value, replace the lever
assembly 33.
54-48
--- Page 77 ---
COOLING SYSTEM
Specifications .......................................................................................... 2 – 1
Description ............................................................................................... 2 – 2 2
Removal and Installation ...................................................................... 2 – 3
Radiator and Intercooler ........................................................................... 2 – 3
Troubleshooting ...................................................................................... 2 – 6
--- Page 78 ---
ELECTRICAL SYSTEM
1. To harness A
2. To harness C
3. Glow plug
4. Electronic horn
5. Lining wear detection switch
6. Fuel tank unit
7. Battery relay
8. M5 terminal
9. Battery side terminal
10. Frame side terminal
11. Battery
12. Starter relay
13. Alternator
14. Engine coolant temperature gauge unit
15. Ground point
16. Earphone switch (option)
3-9
--- Page 79 ---
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Dead or weak battery Recharge or replace.
Starter circuit defective Repair or replace.
Starter will not crank
engine Poor continuity in starter switch Replace.
Starter or starter relay defective Replace.
Transmission shift lever not in neutral Move the lever to
Starter switch position neutral position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine Control timer defective Replace.
Gauges
Open or short circuit Repair or replace.
Will not indicate at all Gauge internally defective Replace.
Gauge unit defective Replace.
Temperature Will not indicate Wrong type of gauge or gauge unit Replace.
gauges accurately Loose terminal connection Repair.
Will indicate higher than Circuit between gauge and gauge unit Repair.
grounded
actual temperature
Gauge internally defective Replace.
Open or short circuit Repair or replace.
Will not indicate at all Gauge internally defective Replace.
Gauge unit defective Replace.
Will not indicate Gauge or gauge unit not of the type Replace.
called for
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.
Will indicate “Full” grounded
regardless of fuel level
in tank Gauge internally defective Replace.
Gauge unit defective Replace.
Circuit between gauge and gauge unit Repair.
Will indicate “Empty” open or short
regardless of fuel level
in tank Gauge unit defective Replace.
Gauge internally defective Replace.
Will not indicate Open or short circuit Repair or replace.
(even if air pressure is Gauge defective Replace.
acting on gauge unit) Gauge unit defective Replace.
Air pressure
gauge
Indication will not Circuit between gauge and gauge unit Repair.
return to 0 (when air grounded
pressure is 0 kPa Gauge defective Replace.
(0 kgf/cm2) [0 psi]) Gauge unit defective Replace.
3-27
--- Page 80 ---
POWER TRAIN
4. Electrical Parts Removal
Suggestions for Removal
(1) Harness B disconnecting points (see page 3-8.)
1. Glow plug terminal
2. Joint with harness C
3. Lining wear detection switch connector
4. Alternator connector
5. Engine coolant temperature gauge unit terminal
Note: Disconnect the harness B from the right-hand side
of the truck. Then, unclip the harness at two mid-
points and put it aside to the left-hand side of the
truck.
(2) Harness C disconnecting points (see page 3-10.)
1. Engine stop solenoid connector
2. Oil bypass alarm switch terminal
3. Engine oil pressure switch terminal
(3) Starter cable
Disconnect the cable at the starter relay side connector.
(4) Engine grounding cable
Remove the bolt securing the cable to the frame.
210338
4-11
--- Page 81 ---
2-SPEED POWERSHIFT TRANSMISSION
Control Valve
2 5
A A
Section A – A
4
3
Section B – B
B B
C C
1
Section C – C
205461
1. Accumulator valve 3. Inching valve plunger 5. Travel speed (1st/2nd)
2. Direction valve 4. Inching valve valve
Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
200554A
1. Bolts 5. Spool 9. Main pressure port
2. Cover 6. Body 10. Torque converter inlet
3. O-ring 7. Spring pressure port
4. Slug 8. Drain port
5-5
--- Page 82 ---
2-SPEED POWERSHIFT TRANSMISSION
5. Stator shaft 31 removal
Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25
holes in one end of the shaft evenly or hit the other end by
using a protective plate.
Special tool needed
Bolt 67284 - 15400
6. Roller bearing outer race removal
Do not remove the outer race of roller bearing 33 for idler
gear 32 unless it has a defect.
5-23
--- Page 83 ---
2-SPEED POWERSHIFT TRANSMISSION
Reassembly
1 15
2
14
13 A A
Section A – A
13
12
11
10
3
8
7
Section B – B 9 B
B
16
C C
6 4
Section C – C 5
210192
Sequence
1. Valve body 9. Spring, Inching valve plunger
2. Oil filter 10. Stopper pin, O-ring
3. Oil seal 11. Oil filter, O-ring
4. Plate, O-ring 12. Spring, Direction valve
5. Accumulator piston, Springs (inner and outer), 13. Solenoid valves
Spring seat 14. Plug, O-ring, Roller bearing
6. Plate, O-ring 15. Spring, Travel speed valve, Solenoid valve
7. Plug, O-ring, Roller bearing 16. Plug, O-ring
8. Inching valve, Spring, Slug
Start by:
Clean the oil passages in the control valve thoroughly and
make sure they are not restricted.
Suggestions for Reassembly
(1) Replace oil seal 3 with a new one.
(2) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
5-41
--- Page 84 ---
2-SPEED POWERSHIFT TRANSMISSION
A: Standard value
Unit: mm (in.)
Truck Model
FD100 FD115 FD135 FD150A
Item
Input gear and counter gear 1 A 0.12 to 0.28 (0.0047 to 0.0110)
Forward 1st speed gear and reverse 1st
A
speed gear 2
0.13 to 0.32 (0.0051 to 0.0126)
Forward 2nd speed gear and reverse 2nd
A
speed gear 3
Pump drive gear and idler gear 4 A
0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 5 A
4 5
3 2
Backlash of
gears R2 R1
1
3
F2 F1
2
210217
5-59
--- Page 85 ---
3-SPEED POWERSHIFT TRANSMISSION
Suggestion for Disassembly
To remove the stator assembly, slightly force the stator just
like turning it counterclockwise to prevent the rollers from
falling and pull the stator together with the hub by sliding
the splines.
204530
Inspection
1. Pump (impeller)
(1) Check for cracks.
(2) Check for oil leaks due to looseness of the bolts holding
the boss to the pump, or defective O-ring.
(3) Check the face of the pump boss in contact with the oil
seal for wear.
(4) Check the face of the pump boss in contact with the
seal ring.
Oil seal O-ring
Seal ring
200561
6-13
--- Page 86 ---
3-SPEED POWERSHIFT TRANSMISSION
Reassembly
1. Forward clutch shaft subassembly
(1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)
16 5 10 9 78 4 7 8 4 9 10 5 11
6
6
14 15
21
1
20 13
19 18 17 2 3 2 12
207515
Sequence
1. Forward clutch shaft (1st-speed/3rd-speed 11. Thrust washer, Snap ring
clutch shaft or reverse clutch shaft) 12. Needle roller bearings
2. Sealing rings, Piston seals 13. Gear (forward drive)
3. Pistons 14. Thrust washer
4. Springs 15. Roller bearing
5. Retainers 16. Thrust washer
6. Snap rings 17. Needle roller bearings