OVERHAUL INSTRUCTIONS

1. Determination of Overhaul Timing ............................................... 4 – 1

2. Testing the Compression Pressure .............................................. 4 – 2

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 OVERHAUL INSTRUCTIONS

1. Determination of Overhaul Timing

In most cases the engine should be overhauled when the

CAUTION
engine’s compression pressure is low. Other factors
that indicate the necessity of engine overhaul are as When replacing parts, make sure to use OEM
follows: designated parts. If OEM parts are not used,
the exhaust emission’s warranty will be
(a) Decreased power
voided. New parts may be updated due to
(b) Increased fuel consumption improvement. Fuel and Exhaust system
(c) Increased engine oil consumption repairs should only be conducted by an
(d) Increased blow-by gas volume through the breather authorized Mitsubishi forklift dealer.
due to abrasion at the cylinder liner and the piston Tampering or adjusting the fuel system
ring components will void the warranty and could
be in violation of the EPA regulations. The
(e) Gas leakage due to poor seating of the inlet and the
fuel injection pump must be replaced as an
exhaust valves
assembly.
(f) Starting problems
(g) Increased noise from engine parts
(h) Abnormal color of exhaust gas from engine after
warm-up
Any one or a combination of these symptoms may
indicate that engine overhaul is required. Of the items
listed above some are not directly related to the
necessity of engine overhaul. Items (b) and (f) are more
likely to be affected substantially by
• Injection volume of the fuel injection pump
• Fuel injection timing
• Wear of injection-pump plunger
• Fitting of the injection nozzle
• Condition of electrical equipment: battery, starter, or
alternator
Item (d) above, however, requires special consideration
because decreased pressure due to wear at the cylinder
liner and the piston ring is one of the most obvious
signs that the engine requires overhauling.
The most effective way to make a decision is by testing
the compression pressure; other factors are to be
considered secondarily.

4-1
OVERHAUL INSTRUCTIONS

2. Testing the Compression Pressure

(1) Remove the injection nozzle from the cylinder head

where the compression pressure is to be measured.
(2) On the direction injection type engine, attach gauge
adapter (30691 - 21100) to the cylinder, and connect Gauge adapter
the compression gauge (32A91 - 03100) to the adapter.
(3) Crank the engine by means of the starter, with the
governor stop lever pulled (the fuel supply shut off), Compression
and read the compression gauge indication when the gauge
engine running at the specified speed.
(4) If the compression pressure is lower than the repair
limit, overhaul the engine.
Measuring compression pressure

CAUTION
(1) Measure the compression pressure on all
cylinders. It is not a good practice to
measure the compression pressure on only CAUTION
few cylinders, and presume the compression
on the remaining cylinders. When replacing parts, make sure to use
OEM designated parts. If OEM parts are
(2) Compression pressure varies with engine
not used, the exhaust emission's warranty
speed. Check engine speed when measuring
will be voided. New parts may be updated
the compression pressure.
due to improvement. Fuel and Exhaust
system repairs should only be conducted
by an authorized Mitsubishi forklift dealer.
Unit: MPa (kgf/cm2) [psi] Tampering or adjusting the fuel system
components will void the warranty and
Assembly Repair could be in violation of the EPA regulations.
Item
Standard Limit
The fuel injection pump must be replaced
Compression pressure 3.2 (33) [469] 2.8 (29) [413] as an assembly.

NOTE
Measure the compression pressure with the engine
running at 300 min-1.

CAUTION
(1) Measure the compression pressure at
regular intervals to obtain correct data.
(2) The compression pressure will be slightly
higher in a new or overhauled engine due to
new piston rings, valve seats, etc. Pressure
will drop gradually by the wear of parts.

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