This is the factory service manual for the Mitsubishi S6E and S6E2 diesel engines, the units fitted to Mitsubishi FD35, FD38, FD40, FD45, FD50C and FD50 forklift trucks. Across 167 pages it walks the engine end to end: cylinder head and valve mechanism, timing gear and camshaft, pistons, connecting rods, crankshaft and crankcase, the injection pump, governor, feed pump and nozzles, cooling, inlet and exhaust, and the starter and alternator.
An engine apart on a stand earns nothing, and every hour spent hunting for a bearing clearance or a torque figure is an hour it stays that way. The Service Standards section collects the tightening torques, wear limits and sealant list in one place, and each teardown chapter pairs inspection values with the procedure.
It is a printable PDF, so the same pages work on a shop laptop or as grease stained printouts beside the block, wherever the engine happens to be.
What's Inside This Mitsubishi S6E, S6E2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-5 | Foreword, Range of Coverage and How to Use This Manual, General Contents |
| General | 6-14 | Oil Seals, O-Rings, Bearing, Lock Plates, Split Pins and Spring Pins |
| Service Standards | 15-27 | Table of Service Standards, List of Tightening Torques, List of Sealants to Be Applied |
| List of Special Tools | 28-32 | Valve Guide Installer, Valve Guide Mover, Valve Spring Pusher, Insert Caulking Tool, Sleeve Installer, Piston Ring Plier |
| Disassembly Determination | 33-36 | Determining When to Overhaul, Measuring Compression Pressure |
| Adjusting, Running in and Performance-Testing the Engine | 37-44 | Adjusting the Engine, Run-In, Performance Test |
| Removing and Mounting Auxiliary Equipment | 45-50 | Removing Auxiliaries, Mounting the Auxiliaries |
| Engine Body | 51-94 | Cylinder Head and Valve Mechanism, Flywheel, Timing Gear and Camshaft, Piston, Connecting Rod, Crankshaft and Crankcase |
| Inlet and Exhaust System | 95-98 | Air Cleaner, Inlet Manifold, Exhaust Manifold, Muffler |
| Cooling | 99-104 | Water Pump, Thermostat |
| Fuel | 105-148 | Injection Nozzle, Feed Pump, Injection Pump, Governor |
| Electrical | 149-163 | Starter, Alternator |
| Miscellaneous | 164-167 | Oil Seals, O-Rings, Bearing, Lock Plates, Split Pins, Spring Pins |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| S6E | ||
| Cylinder sleeve inside diameter S6E | 94.000-94.035 mm (3.7008-3.7022 in) | p. 17 |
| Piston outside diameter (Skirt) S6E S.T.D. | 93.875-93.845 mm (3.6959-3.6947 in) | p. 19 |
| S6E2 | ||
| Cylinder sleeve inside diameter S6E2 | 98.000-98.035 mm (3.8583-3.8596 in) | p. 17 |
| Piston outside diameter (Skirt) S6E2 S.T.D. | 97.875-97.845 mm (3.8533-3.8522 in) | p. 81 |
| All Models | ||
| Piston ring No. 1 ring clearance | 0.030-0.070 mm (0.00118-0.00276 in) | p. 20 |
| Piston ring No. 2 ring clearance | 0.025-0.060 mm (0.00098-0.00236 in) | p. 20 |
| Main bearing clearance between crankshaft and journal | 0.050-0.115 mm (0.00197-0.00453 in) | p. 17 |
| Clearance between crank pin and rod bearing | 0.035-0.100 mm (0.00138-0.00394 in) | p. 20 |
| Thrust bearing width (thrust clearance) | 0.100-0.264 mm (0.00394-0.01039 in) | p. 17 |
| Valve clearance (cold) | 0.25 mm (0.01 in) | p. 17 |
| Intake valve stem outside diameter | 7.955-7.940 mm (0.3132-0.3126 in) | p. 18 |
| Clearance between main bearing and crank journal | 0.050-0.115 mm | p. 89 |
Mitsubishi S6E, S6E2 Common Problems This Manual Covers
Hard starting and low compression
Worn rings, valves or sleeves let compression bleed off until the engine cranks but will not light. The manual explains how to measure compression pressure and judge when a full overhaul is actually warranted, so you tear down on evidence rather than guesswork.
Manual Section: Disassembly Determination p. 33Oil consumption and blue exhaust smoke
High hour engines pull oil past worn valve guides and tired piston rings. The Engine Body chapters cover the cylinder head, valve mechanism, pistons and connecting rods with the inspection procedures needed to find which parts are past their limits.
Manual Section: Engine Body p. 51Black smoke and rough combustion
A nozzle with poor spray pattern or low opening pressure smokes, knocks and washes down a cylinder. The Fuel section covers the injection nozzles, feed pump and injection pump, including pressure testing and adjustment.
Manual Section: Fuel p. 105Surging or hunting engine speed
When idle wanders or the engine hunts under light load, the governor is the usual suspect. Governor service is covered in the Fuel section alongside the injection pump it works with.
Manual Section: Fuel p. 105Overheating under load
A lazy thermostat or a water pump with a worn seal will cook an otherwise healthy engine. The Cooling section covers inspection and rebuild of both the water pump and thermostat.
Manual Section: Cooling p. 99Slow cranking or charging trouble
Dragging starters and weak alternators get blamed on batteries long after the battery is ruled out. The Electrical section covers disassembly, testing and reassembly of the starter and alternator.
Manual Section: Electrical p. 149Frequently Asked Questions
Which engines does this manual cover?
The Mitsubishi S6E and S6E2 diesel engines, as fitted to Mitsubishi FD35, FD38, FD40, FD45, FD50C and FD50 forklift trucks. The procedures apply to the engine itself, so it is just as useful with the engine out of the machine and on a stand. p. 3
Does it include torque values and clearances?
Yes. The Service Standards section holds the table of service standards, the list of tightening torques and the sealant list. Verified examples include valve clearance of 0.25 mm cold and main bearing clearance of 0.050 to 0.115 mm. p. 15
Is the injection pump and governor covered?
Yes. The Fuel section covers the injection nozzle, feed pump, injection pump and governor. It also carries the nozzle valve opening pressures, which differ by part number: 175 kgf/cm2 (2490 psi) for nozzle 093400-0540 and 120 kgf/cm2 (1710 psi) for 093400-0050, so you pop test against the figure for the nozzle actually fitted (page 129). p. 105
How do I know if the engine needs an overhaul?
The Disassembly Determination section explains how to decide when to overhaul and how to measure compression pressure. The standard compression figure is 27 kgf/cm2, giving you a hard number to test against before committing to a teardown. p. 33
What format is this Mitsubishi S6E manual in?
One searchable PDF covering 167 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Can I print a copy of this Mitsubishi S6E Service Manual for the shop?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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