Service Manual
Contents
1. are indicated in parentheses For metric conversion the following rates are used Pressure 1 MPa 10 197 kgf cm e Torque 1 N m 0 10197 kgf m Force 1 N 0 10197 kgf e Horsepower 1 kW 1 341 HP 1 3596 PS e Meter of mercury 1 kPa 0 7 cmHg e Meter of water 1 kPa 10 197 cmH20 cmAq e Rotational speed 1min 1 rpm INTRODUCTION Safety Cautions Fire and explosion Keep flames away Store fuel and engine oil in a well ventilated designated area Make sure the fuel and engine oil container caps are tightly closed Do not use flames do not smoke and do not work near a heater or other fire hazard where fuel or oil is handled or when cleaning solvent is being used for washing parts Wipe off spilled fuel oil and LLC immediately and thor oughly Spilled fuel oil and LLC may ignite and cause a fire Keep surrounding area tidy and clean Do not leave combustible or explosive materials such as fuel engine oil and LLC near the engine Such sub stances can cause fire or explosion Remove dust dirt and other foreign materials accumu lated on the engine and surrounding parts thoroughly Such materials can cause fire or the engine to over heat In particular clean the top surface of the battery thoroughly Dust can cause a short circuit Always operate the engine at a position at least 1 m 3 28 ft away from buildings and other equipment to prevent possible fire caused by engine heat2. conduct maintenance of the air cleaner pre cleaner while the engine is operating Engine opera tion without the air cleaner precleaner in place allows foreign matters to enter the turbocharger causing it to be seriously damaged Remove the air cleaner pre cleaner slowly to prevent dust accumulated on the element from falling off After removing the air cleaner or pre cleaner imme diately cover the opening inlet port in case of air cleaner port in body in case of pre cleaner with plastic sheet or similar means to prevent dust from entering the engine Air cleaners equipped with a dust indicator will issue an alarm if the element gets clogged Service the cleaner as soon as possible if an alarm is issued Observe safety rules at work site Observe the safety rules established at your workplace when operating and maintaining the engine Do not operate the engine if you are feeling ill Operation of the engine with reduced awareness may cause improper operation that could result in accidents In such a case inform your supervisor of your condi tion When working in a team of two or more people use specified hand signals to communicate among work ers Work clothing and protective gear Wear a hard hat face shield safety shoes dust mask gloves and other protective gear as needed When handling compressed air wear safety goggles hard hat gloves and other necessary protective gear Works without wearing proper protective
3. engine will no longer be guar anteed and the following problems will be expected to occur e Rapid wear of moving and rotating parts e Engine troubles such as damage and seizure of engine parts e Increased consumption of fuel and lubricating oil e Deterioration of engine performance due to poorly balanced fuel injection volume and governor opera tion Break in operation A new engine needs to be broken in for the first 50 hours of operation During this period do not subject the engine to heavy loads Operating a new engine under high loads or severe conditions during the break in period can shorten the service life of the engine VIII Warming up operation After starting the engine run the engine at low idling speeds for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lu bricated before they are subjected to heavy loads This is very important for longer service life high perfor mance and economical operation Do not conduct warm up operation for a longer time than necessary Prolonged warm up operation causes carbon build up in the cylinders that leads to incom plete combustion Avoid engine operations in a overload con dition If the engine is considered to be in an overloaded con dition which is identified by too much black smoke etc immediately reduce the load on the
4. exhaust gas is not discharged toward plants or animals Exhaust gas from the engine contains carbon monox ide and other harmful substances Operating the en gine in an ill ventilated area can produce gas poisoning Protect ears from noises Wear ear plugs Always wear ear plugs when enter ing the machine room engine room Combustion sound and me chanical noise generated by the en gine can cause hearing problems INTRODUCTION Be careful of falling down Lift engine correctly To lift the engine always use a cor rect wire rope capable of withstand O ing the engine weight Attach the wire rope to the lifting hangers provided on the engine us ing a correct sling During lifting process keep the en gine in a well balanced position by taking the center of gravity of the engine into consideration If the wire rope contacts the engine directly place a cloth or other soft padding to avoid damage to the en gine and wire rope Do not climb onto the engine Do not climb onto the engine nor step on any engine parts located on the lateral sides To work on parts located on the upper section of en gine use a ladder stool etc that is firmly secured Climbing on the engine may not only damage engine parts but also cause parts to fall off and result in per sonal injuries Establish firm scaffold during work When working on the upper part of the engine and other hard to reach places use a stabl
5. gear could re sult in serious injuries Use of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace with new tools Avoidance of prolonged time of starter oper ation Do not operate the starter for more than 10 seconds at a time even if the engine does not start Wait for at least 30 seconds before next engine cranking Continuous operation of the starter will drain the battery power and cause the starter to seize Do not turn off battery switch during opera tion If the battery switch is turned OFF when the engine is running not only various meters will stop working but the alternator may have its diodes and transistors dete riorate Cautionary instructions for transporting en gine When transporting the engine on a truck consider the engine weight width and height to ensure safety Abide by traffic road laws vehicle road acts vehicle restric tion ordinances and other pertinent laws Avoid continuous engine operation in a low load condition Do not operate the engine continuously for more than 10 minutes at a load of less than 30 Engine opera tion in a low load condition increases the emission of unburned fuel Therefore a prolonged time of engine operation in a low load condition increases the quantity of unburned fuel adhering to engine parts provoking the possibility of engine malfunctioning and shorte
6. starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF and attach a Do Not Rur or similar caution tag to the starter switch The starter switch key must be kept by the person who performs inspection and maintenance during the work Keep engine stopped during servicing Be sure to stop the engine before proceeding to inspec tion and service procedure Never attempt to make ad justments on the engine parts while the engine is running Rotating parts such as belt can entangle your body and cause serious injuries Always restore engine turning tools after use Do not forget to remove the tools which have been used for turning the engine during inspection or servic ing after the procedure is finished Remember also that the turning gear must be returned to the operating condition before starting the engine Starting the engine with the turning tools inserted or with the turning gear in engagement can lead to not only engine damage but also personal injuries INTRODUCTION Be careful of burns Do not touch the engine during or immedi ately after operation Do not touch the engine during or immediately after operation to avoid risk of burns To conduct maintenance and in spection work wait until the engine has cooled sufficiently checking t
7. Care about fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found immedi ately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light if accidentally broken may ignite and cause an explo sion Prevent electrical wires from short circuit ing Avoid inspecting or servicing the electrical system with the ground cable connected to the battery Otherwise a fire could result from short circuiting Be sure to dis connect the battery cable from the negative terminal before beginning with the work procedure Short circuits possibly resulting in fire may be caused by a loose terminal or damaged cable wire Inspect the terminals cables and wires and repair or replace the faulty parts before beginning with the service proce dure Keep fire extinguishers and first aid kit handy Keep fire extinguishers handy and become familiar with their usage Keep a first aid kit at the designated place where it is easily accessible by anyone at any time Establish response procedures to follow in the event of fire or accident Provide an emer gency evacuation route contac
8. Y MITSUBISHI FORKLIFT TRUCKS Service Manual S4Q2 Diesel Engine 72645 up FD10N FD15N FD18N FD20CN For use with FD10N FD15N FD18N FD20CN Chassis Service Manual 99719 7Q100 INTRODUCTION This service manual describes the specifications maintenance and service procedures for Mitsubishi diesel engines To maintain the performance of the engine for many years and to ensure safe operation it is important to use the engine correctly and conduct regular inspection and maintenance and it may also be necessary to take measures which involves the disassembly inspection repair and reassembly of the engine and engine parts Read this manual carefully and understand all of the work procedures fully before disassembling inspecting repairing or reassembling the engine The contents of the manual are based on the engine models that are being produced at the time of publication Due to improvements made thereafter the actual engine that you work on may differ partially from the one described in this manual Pub No 99719 7Q100 INTRODUCTION How to use this manual This service manual consists of several Groups which are arranged so as to allow you to make reference quickly to specifications maintenance standards adjustment procedures and service procedures including methods for disassembly inspection repair and reassembly of the Mitsubishi Diesel Engine standard model for land use A short summary describing the co
9. al of waste oil and coolant LLC Do not discharge waste engine oil or coolant into sew erage river lake or other similar places Such a way of disposal is strictly prohibited by laws and regulations Dispose of waste oil coolant and other environmentally hazardous waste in accordance with the applicable law and regulations or consult a Mitsubishi forklift truck dealer INTRODUCTION Service battery Handle the battery correctly Never use flames or allow sparks to generate near the battery The battery releases hydrogen gas and oxygen gas Any flames or sparks in the vicin ity could cause an explosion Do not use the battery the fluid level of which is low ered below the lower limit line Sustained use of the battery could result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables always remove the cable from the negative terminal first When reconnecting the cables attach the cable to the posi tive terminal first Charge the battery in a well ventilated area with all filling hole plugs removed Make sure the cable clamps are securely installed on flammable the battery terminals A loose cable clamp can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to the Open OFF position or disconnect the cable from the nega tive battery term
10. ature Avoid immediate restart after abnormal stop If the engine stops abnormally do not restart the en gine immediately If the engine stops with an alarm check and remedy the cause of the problem before re starting Sustained use of the engine without any rem edy could result in serious engine problems Avoid continuous engine operation with too low oil pressure If an abnormal engine oil pressure drop is indicated stop the engine immediately and inspect the lubrica tion system to locate the cause Continuous engine op eration with low oil pressure may cause bearings and other parts to seize Stop the engine immediately if the fan belt breaks If the fan belt breaks stop the engine immediately Continuous engine operation with the broken fan belt could cause the engine to overheat and thereby the coolant to boil into steam which may gush out from the reserve tank or radiator and cause personal injuries VII INTRODUCTION Other cautions Modification of engine prohibited Unauthorized modification of the engine will void the manufacturer s warranty Modification of the engine may not only cause engine damage but also produce personal injuries Never break the seals To ensure proper engine operation the fuel control link is provided with seals that protect the fuel injection vol ume and rotation speed settings against tampering If these seals are broken and the settings are changed proper operation of the
11. e work platform Standing on a decrepit stool or parts box may result in personal injury Do not place any unnecessary objects on a work platform Be careful of handling fuel engine oil and LLC Use only specified fuel engine oil and long life coolant LLC Use only the fuel oil and LLC specified in the applica ble operation manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunctions Obtain the Material Safety Data Sheets MSDS issued by the fuel oil and LLC suppliers and follow the direc tions in the MSDSs for proper handling Handle LLC long life coolant carefully When handling LLC always wear rubber gloves and protective face mask If LLC or cooling water containing LLC comes into contact with your skin or eyes or if it is swallowed you would suffer from inflammation irrita tion or poisoning Should LLC be accidentally swallowed induce vomit ing immediately and seek medical attention Should LLC enter your eyes flush them immediately with plen ty of water and seek medical attention If LLC splashes onto your skin or clothing wash it away immediately with plenty of water Keep flames away from LLC The LLC can catch flames causing a fire Coolant containing LLC is a hazardous material Do not dispose of it in unauthorized manner Abide by the ap plicable law and regulations when discarding drained coolant Proper dispos
12. engine so that the correct output and load conditions may be achieved Overloading the engine causes not only high fuel con sumption but also excessive carbon deposits inside the engine Excessive carbon deposits can cause various engine problems and shorten the service life of the en gine remarkably Cooling operation before stopping engine Always conduct the cooling operation low speed idling for 5 to 6 minutes before stopping the engine Abruptly stopping the engine immediately after high load operation can cause partial overheating and short en the service life of the engine During cooling operation check the engine for abnor malities Protection of engine against water entry Do not allow rainwater etc to enter the engine through the air inlet or exhaust openings Do not wash the engine while it is operating Cleaning fluid water can be sucked into the engine Starting the engine with water inside the combustion chambers can cause the water hammer action which may result in internal engine damage and serious acci dents INTRODUCTION Maintenance of air cleaner or pre cleaner The major cause of abnormal wear on engine parts is dust entering with intake air Worn parts produce many problems such as an increase of oil consumption de crease of output and starting difficulties For effective removal of dust from intake air conduct maintenance of the air cleaner according to the following instruc tions e Do not
13. es 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 a potentially hazardous situation which if not avoided can result in property damage Note Emphasizes important matter or indicates information useful for operation or maintenance of the engine INTRODUCTION Terms used in this manual Nominal means the rated design size or magnitude of a part to be measured Standard means the quantitative requirement for dimension of a part clearance between parts and performance This is given in a form of tolerance Therefore the values shown are not in agreement with the design values Limit means that if this value is reached the part must be repaired or replaced with a new part Abbreviations BTDC Before Top Dead Center e ATDC After Top Dead Center BBDC Before Bottom Dead Center ABDC After Bottom Dead Center e TIR Total Indicated Runout API American Petroleum Institute e ASTM American Society for Testing and Materials e JIS Japanese Industrial Standards e LLC Long Life Coolant e MIL Military Specifications and Standards U S A e MSDS Material Safety Data Sheet e SAE Society of Automotive Engineers U S A Units of measurement Measurements are based on the International System of Units SI and their converted metric values
14. he temperature gauge Slowly and carefully open radiator cap Never attempt to open the radiator cap while the engine is running or immediately after the engine stops Give a sufficient cooling time to the engine coolant before opening the cap When opening the radiator cap slowly turn the cap to release internal pressure To prevent scalds with steam gushing out wear thick rubber gloves or cover the cap with a cloth Close the radiator cap tightly without fail The coolant is very hot and under pressure during en gine running or just after the engine stops If the radia tor cap is not closed tightly steam and hot coolant may gush out and can cause scalds Add coolant only after the coolant tempera ture dropped Do not add coolant immediately after the engine stops Wait until the coolant temperature lowers sufficiently to avoid a risk of burns Never remove heat shields The exhaust system which becomes extremely hot while the engine is operating is provided with various heat shields Do not remove these heat shields If any of these heat shields have been removed owing to un avoidable circumstances during the work be sure to re store them after the work is completed Be careful of exhaust fume poi soning Operate engine in well ventilated area 9 If the engine is installed in an en closed area and the exhaust gas is ducted outside ensure that there is no exhaust gas leak from duct joints Take care that the
15. inal to cut off the electrical cur rent Electrolyte battery fluid contains dilute sulfuric acid Careless handling of the battery can lead to the loss of sight and or skin burns Also keep the battery fluid off the mouth Wear protective goggles and rubber gloves when working with the battery when adding water charg ing etc If electrolyte is spilled onto the skin or clothing immediately wash it away with lots of water Use soap to thoroughly clean The battery fluid can cause blindness if splashing into eyes If it gets into eyes immediately flush it away with plenty of clean fresh water and seek immediate medical attention If the battery fluid is accidentally swallowed gargle with plenty of water then drink lots of water and seek immediate medical attention When abnormality occurs Stop overheated engine after cooling run Even if the engine is about to overheat do not stop the engine immediately Abrupt stopping of an overheated engine can cause the coolant temperature to rise re sulting in seized engine parts If the engine is about to overheat run the engine at low idling speed cooling operation and stop the engine after the coolant tem perature lowers sufficiently Do not add coolant immediately after stopping the en gine Adding coolant to a hot engine can cause the cyl inder heads to crack due to sudden change in temperature Add coolant little by little after the engine cools down to room temper
16. ing and repairing cylinder head and valve mechanism Inspecting and repairing flywheel Inspecting and repairing timing gear camshaft and oil pan Inspecting and repairing piston connecting rod crankshaft and crankcase Reassembly of basic engine Reassembling piston connecting rod crankshaft and crankcase Reassembling timing gear camshaft and oil pan Reassembling flywheel Reassembling cylinder head and valve mechanism Fuel system Removing fuel system Disassembling inspecting and reassembling fuel system Replacing fuel injection pump Installing fuel system Lubrication system Removing lubrication system Disassembling inspecting and reassembling lubrication system Installing lubrication system Cooling system Removing and inspecting cooling system Disassembling inspecting and reassembling cooling system Installing cooling system 10 Inlet and exhaust systems Removing and inspecting inlet and exhaust systems Inspecting inlet and exhaust systems Installing inlet and exhaust systems 11 Electrical system Removing electrical system Disassembling inspecting and reassembling electrical system Installing electrical system 12 Adjustment and operation Adjusting engine Break in operation Performance test JIS standard 13
17. ning the service life of the engine Ventilation of engine room Always keep the engine room well ventilated Insuffi cient amount of intake air causes the operating temper ature to rise resulting in poor output and lowered performance It is highly recommended to calculate the required amount of air supply to the engine and install an ade quate ventilation system before installing the engine Avoid contact with high pressured fuel Should fuel leak from a fuel injection pipe do not touch the spouting fuel directly Fuel in the fuel injection pipes are under high pressure If high pressured fuel comes into contacts with your skin it could penetrate through the skin and may result in gangrene GENERAL CONTENTS Group Name Contents Group No General External view System flow diagrams Engine serial number location Main specifications Tips on disassembling and reassembling Service data Maintenance service data Tightening torque table Service tools General tools Special tool Determination of overhaul Determining overhaul timing Testing compression pressure Disassembly of basic engine Disassembling and inspecting cylinder head and valve mechanism Disassembling and inspecting flywheel Disassembling and inspecting timing gear camshaft and oil pan Disassembling and inspecting piston connecting rod crankshaft and crankcase Inspection and repair of basic engine Inspect
18. ntent of each Group is given in the General Contents page and there is also a detailed table of contents at the beginning of each Group Regarding the procedures for operation and periodical maintenance of the engine refer to the Operation and Maintenance Manual For information on the engine components and ordering of service parts refer to the Parts Catalogue Structure and function of the engine are described in the relevant training manuals Methods of presentation 1 Index numbers allotted to parts in exploded views are not only a call out of part names listed in the text but also an indi cation of the sequence of disassembly 2 Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views 3 Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text They are also collectively indicated in Group 2 the General Contents group 4 Fasteners to be tightened in wet condition or with engine oil applied are identified by Wet placed after tightening torque values If no such indication is suffixed the fastener should be tightened in dry condition or without lubricating with engine oil 5 In this manual important safety or other cautionary instructions are emphasized with the following marks headed Indicates an immediately hazardous situation which if not avoided will result in death or serious injury Indicat
19. t points and means of communication in case of emergency INTRODUCTION Stay clear of all rotating and moving parts Install protective covers on rotating parts Make sure the protective covers for engine rotating parts are properly An installed as intended Repair loose AT eZ SU or damaged protective covers as ES 3 necessary AA Never remove the covers guarding personnel from rotating parts when the engine is oper ating When combining the engine with the engine driven ma chine or radiator always provide a cover on every ex posed moving part such as driving belt and coupling Never remove protective covers Ensure safety of neighboring people before starting engine Before starting the engine ensure that there is nobody in the neighborhood and that no tools are left on or near the engine Verbally notify people around the engine or in the work area when starting the engine When the starter device is posted with a sign that pro hibits startup operation do not operate the engine Stay clear of moving parts during engine running Do not approach rotating or sliding parts of the engine when the engine is in operation Keep objects likely to be caught by rotating parts away from such parts If any part of the clothing or outfit ting is caught by a rotating part se rious bodily injuries could result y IF Lockout and tagout Be sure to lockout and tagout before
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