j.. maintenance manual - det mitsubishi · 2017. 11. 7. · machine in which the engine is fitted....

~~----

J.. Maintenance Manual Fuse

diesel engine (for industrial use)

6D2

Pub. No. MH998283

Thank you for purchasing a Mitsubishi Fuso industrial engine.

This manual contains operating instructions and simple maintenance procedures to help ensure safe, efficient operation of your engine. Improper use of the engine may lead to a fault or accident, so read this manual carefully before using the engine.

• Use this manual in conjunction with the instruction manual for the machine in which the engine is fitted.

• The information in this manual applies to the standard engine model. • Due to ongoing improvements, the specifications and appearance of

your engine may differ slightly from those shown in this manual.

Applicable engine models:

6024

6D24-T

6D24-TC

6D24-TL

* Particularly important points for the prevention of faults and accidents are given in the "Things You Should Know for Safe Operation" section of this manual and in "DANGER," "WARNING," "CAUTION," and "NOTE" notices on various pages. Be sure to read them before using the engine. The "DANGER," "WARNING," "CAUTION," and "NOTE" notices are classified as follows:

DANGER ~ Particularly important information which, if not heeded, could lead to serious personal injury or death.

WARNING ~ Precautions which, if not observed, could result in personal injury.

CAUTION ~ Precautions which, if not observed, could result in damage to or destruction of components.

NOTE Instructions intended to prevent mechanical damage and to ensure optimum performance.

MITSUBISHI FUSO TRUCK & BUS CORPORATION © 2003 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

Always·.···Ose .. When replacing engine components, lubricants, and other items, be sure to use Mitsubishi genuine products. These are designed specifically for Mitsubishi engines and offer the same high quality as the original items. Mitsubishi genuine parts and consumable products carry the mark shown below.

MITSUBISHI MOTORS

GENUINE PARTS

00008

* To help you find the information you need, the contents of this manual are organized as follows:

Contents Organized Visually According to Engine Parts ............................................. 11 Contents Organized According to Component Names ................................. IV

CONTENTSI I

THINGS YOU SHOULD KNOW FOR SAFE OPERATION ......................... Page 1

DAILY INSPECTIONS (PERFORMED BEFORE OPERATION) ................ Page 13

STARTING AND STOPPING THE ENGINE ............................................. Page 17

DEALING WITH ENGINE PROBLEMS .................................................... Page 25

OPERATION IN COLD WEATHER ........................................................... Page 35

OPERATION IN HOT WEATHER ............................................................. Page 39

LONG-TERM STORAGE ......................................................................... 1

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE ................. Page 45

SIMPLE INSPECTION AND MAINTENANCE. ......................................... Page 53

LUBRICANT REPLACEMENT AND MAINTENANCE ............................. Page 69

MAIN SPECiFiCATIONS .......................................................................... Page 75

-1-

Contents

Contents Organized Visually According to Engine Parts

Replacement of Fuel Filter Element-------...

CDP60

Inspection and Adjustment of V-belt Tension ----......

CD P61

Replenishment and Replacement of Coolant, and Flushing of Cooling System

CDP62

-11-

Lubrication of Fan Drive and ----------" Tension pulley CDP.74

.,--- Cleaning and Replacement of Air Cleaner Element

CD P57

Dust Indicator

CD P.58

"'----- Air-Bleeding of Fuel System

CD P34

"'---- Replacement of Oil Filter Elements CD P.59

Replacement of Engine Oil

CD P.71

E0364

Contents Organized Visually According to Engine Parts

Replacement of coolant and Flushing of Cooling System

mp62

Inspection and Replenishment of Engine Oil m P.71 E0251

Operation in Hot Weather P .39 Long-Term Storage:::: P.41

E0034 E0019 Replacement of Preheating Circuit Draining Water Separator Fuse P.56 P.60

E0036 E0349

Daily Inspections ~i P.13

Dealing with Engine Problems P.25

Inspection of Intercooler '~ P.67

E0032 P.55

E0035

07404

Contents

Starting and Stopping the Engine P.17

E0031 P.35

Lubricant Replacement and P.69

E0038

-111-

Contents

Contents Organized According to Component Names

A L ABNORMAL OIL PRESSURE .................................................................. 32 LONG-TERM STORAGE ......................................................................... .41 AIR CLEANER .......................................................................................... 57 LUBRICATION .......................................................................................... 74

B o BATTERY ..................................................................................... 37, 40, 55 OIL FILTER ............................................................................................... 59 BATTERY SWITCH ............................................................................ 18, 22 OIL LEVEL GAUGE .................................................................................. 71

OPERATION IN COLD WEATHER .......................................................... 35 C OPERATION IN HOT WEATHER. ............................................................ 39 COOLANT ................................................................................................. 62 OVERHEATING ........................................................................................ 31

o P DAILY INSPECTIONS (PERFORMED BEFORE OPERATION} .............. 14 PERIODIC INSPECTION AND MAINTENANCE SCHEDULE ................ .45 DEFECTIVE CHARGING OF BATTERy .................................................. 30 DUST INDICATOR ................................................................................... 58 R

REVERSE OPERATION OF ENGINE ...................................................... 30 E RUNNING OUT OF FUEL (AIR BLEEDING} ............................................ 34 EMERGENCY SHUTDOWN ..................................................................... 33 ENGINE NUMBER .................................................................................... 11 S ENGINE OIL ............................................................................................. 71 STARTER SWiTCH .... ........................................................................ 19, 22 EXHAUST COLOR OF ENGINE .............................................................. 55

V F V-BELT ..................................................................................................... 61 FUEL .......................................................................................................... .4 FUEL FILTER ........................................................................................... 60 W FUSE ........................................................................................................ 56 WATER SEPARATOR .............................................................................. 60

INTERCOOLER ........................................................................................ 67

-IV-

~----------~--~--~~----- --- ----

... \ "".. ..'" ....:"

Things You Should Know for Safe Operation

00006

Precautions for Operation Inspection and Maintenance .. ..................................................................... 2 Operation of New Engine ............................................................................ 3 Battery ......................................................................................................... 3 Fuel ........................... : ................................................................................ .4 Engine Oil ................................................................................................... 5 Coolant. ....................................................................................................... 5 Reverse Operation of Engine ...................................................................... 6

Fuel Leakage .............................................................................................. 6 Radiator Cap ............................................................................................... 7 Filter Elements ............................................................................................ 7 Normal Engine Operation ........................................................................... 8 Long-Term Storage ..................................................................................... 9

Inspection and Maintenance Inspection and Adjustment. ....................................................................... 1 0 Daily Inspections ....................................................................................... 10

Engine Number ........................................................................................ 11

) This section contains information, recommendations, and ( ) precautions for safe engine operation. Be sure to read it before ?) ) ( ) using your engine.

~1-


Precautions for . .' . . ..

• Inspection and Maintenance

CAUTION it.

• Inspections should normally be performed when the engine is not running. If you must perform an inspection while the engine is running for unavoidable reasons, be careful not to touch its moving parts.

• The engine is always hot immediately after being stopped. Be careful not to burn yourself. Whenever possible, inspections should be performed when the engine is cold.

• After performing inspections or maintenance, make sure you do not leave rags or tools in the engine compartment. Flammable items could catch fire during engine operation.

-2-

Before inspecting electrical components, turn OFF the battery switch or disconnect the H terminal of the battery.

Always wear appropriate clothing and use tools correctly.

E0250

WARNING it. Always operate the engine in a well ventilated place. Operation of the engine in a poorly ventilated place can result in a poisonous buildup of exhaust gases.

E0326

-------------

In the event of an emergency engine shutdown, identity and rectify the abnormality before restarting the engine.

CAUTION .&.

E0057

The engine is hot immediately after being stopped. Be careful not to burn yourself when performing inspections.

------------------- ----------------

• Operation of New Engine

During your engine's running-in period (the first 60 hours of operation), • Do not rev the engine; • Allow the engine to warm up fully before operation; • Make every effort to avoid overloading the engine.

The engine and transmission oils will deteriorate rapidly during the running-in period. Thus, the oils must be replaced after the following operation hours have reached: Engine oil: first 60 hours Transmission oil: first 250 hours

E0003

• Battery

DANGER .&. The battery emits explosive hydrogen gas. Never use naked flames or perform operations that may create sparks near the battery.

WARNING .&. If battery fluid splashes in your eyes, immediately wash it out with plenty of water and seek medical attention.

CAUTION .&.

Battery fluid contains sulfuric acid, so it can burn the skin and make holes in clothing if spilled. Always handle battery fluid carefully and wash away any spilled fluid with soap and plenty of water.

9I P.55

-3-


• Fuel

Use only diesel fuel, without any compound, for the diesel engine.

WARNING .& Never use gasoline or alcohol. If gasoline or alcohol is put into the ·fuel tank accidentally, it must be completely drained from the fuel system. Operation of the engine with gasoline or alcohol in the fuel system could cause a fire or explosion.

CAUTION .& Always stop the engine before refueling it. Never smoke or use a lighter or other naked flame while filling the fuel tank.

-4-

Diesel Fuel Properties

Engine operating conditions

Normal operation at temperatures of -12°C {10°F} or higher

Operation at temperatures below -12 °C {10 OF} or prolonged idling

Recommended fuel

*ASTM 0-975 Grade 2-D

ASTM 0-975 Grade 1-0

* ASTM: American Society for Testing Materials. The ASTM recommends the use of fuel with a sulfur content of 0.5% or less. The use of fuel with a sulfur content exceeding 0.5% shortens the engine oil replacement interval by 50%.

CAUTION .& The lower the fuel's cetane number, the greater is the likelihood of internal engine damage.

Fuel-Related Precautions

• After filling a fuel storage tank, allow 24 hours for dirt and water to sink to the bottom.

• Always refill the engine's fuel tank completely after engine operation. By minimizing the amount of air in the fuel tank, this reduces the likelihood of moisture (the air's water content) freezing and causing corrosion and starting difficulties.

• When refueling the engine from a storage tank, be careful not to draw up sediment from the bottom of the tank.

• To prevent dirt and water from entering the fuel storage tank and the engine's fuel tank, fit the caps securely when refueling is complete. Periodically allow dirt and water to escape via the drain plug at the bottom of each tank.

r--------------------~-~----

• Engine Oil

'e

Use oil with a viscosity appropriate for the ambient temperature.

40 30 2.0 10

(r) 40c ~o (lo4"F) ~

[00 I Soc ~ <.f')

-go • (Sq"F) ~ '30·c. 60 0 C UJ °

o -10 -20 -30

l3tF) Or." a:: (86 F) 32 ex: ~ c.r> 20 0 lfJ~ "'. 0 ...... " -:>C -20 ~ 8 _,~oc (Z3°F)

Q ...... (S·F) U,J 0-a:: «X V) ......

Engine starting temperature

<}C:Q P.71

Lubrication point

All models

E023?

Classification Remarks

API CD MIL-L-2104C

-- --- --~--------- ---------


• Coolant

<}CJ] P.62

Use anti-rust additive in hot weather. Use anti-freeze additive in cold weather.

EOOO?

When tap water is used, it should have the following properties:

Total hardness 300 ppm or less

Sulfate SO; 100 ppm or less

Chloride cr 100 ppm or less

Total dissolved solids 500 ppm or less

pH 6 to 8

-5-


• Reverse Operation of Engine

CAUTION & If the engine operates in reverse, immediately operate the shutdown mechanism to stop the engine. If the engine is not stopped, it may seize or suffer a severe fault within a few minutes. Also, exhaust gases may emerge from the air cleaner, leading to a fire.

-6-

)j

if you hear a knocking sound

or see black smoke emerging

from the air cleaner.

E0008

<>[0 P.30

• Fuel Leakage

CAUTION & Fuel leakage can cause a fire. If you discover a leak, rectify it immediately.

Wipe up any spilled fuel.

E0009

.--------------~----------------- --- ---------------------

• Radiator Cap

WARNING .& Do not open the radiator cap until the coolant temperature has dropped. When removing the radiator cap, cover the cap with a cloth and turn it slowly. Unless the cap is opened carefully, boiling coolant and steam could spray out and scald you.

o

E0010

~o P.65


• Filter Elements

E0011

To maximize the engine's service life and keep the engine running well, it is essential to inspect and replace its filter elements periodically.

~cr P.57-P.60

-7-


• Normal Engine Operation

Ammeter

Z06944

If the needle points to the "-" side of the scale or the charge lamp illuminates, the battery is not charging properly. The engine must be stopped.

For instructions on dealing with battery charging problems, see:: P.30

-8-

Coolant Temperature Gauge

If the coolant temperature exceeds 95°e {203°F} (when the engine is cooled with water from a tank) or 1000 e {212°F}

(when the engine is cooled using a radiator) and/or the

E0015 coolant temperature warning lamp illuminates, the engine is close to overheating. Immediately stop the machine and let the engine idle until the coolant temperature has decreased.

For instructions on dealing with an overheated engine, see CO P.31.

Oil Pressure Gauge

Z06945

If the needle enters the red zone (below 0.2 MPa {28 psi; 2 kgf/cm'}) or the oil pressure warning lamp illuminates, the oil pressure is abnormal. The engine must be stopped.

For instructions on dealing with oil pressure abnormalities, see P.32

Battery Switch

Never turn OFF the battery switch while the engine is running. All gauges and switches would stop functioning, and the electrical system could suffer a fault.

AJFF

g 1>1 i ;\-

11 E0142

Starter Switch

Always keep the starter switch in the "ON" ("0") position while the engine is running.

E0018

• Long-Term Storage

If you do not plan to use the engine

for a while, take the steps described on this page.

o o

If you want to keep the engine ready for

immediate use, just turn it over and let it

warm up once a week. It is not necessary to take any other steps.

E0019

¢c P.41

If the storage period exceeds a year, repeat the same steps.

(Planned strage)

Qj t:: o r. en (; r. C o E Q) c o

en r. C o E

.9 Q) Q) Q) C L-

o~

en r.

.9 C Q) 0

~ E r. x I- ·00

en ~ r. C Q)

>-0 Q) E c x 0

U5 .9


( Preparations for Storage)

• Clean the air cleaner, then spray antirust oil (MIL-L-644B) and seal off all openings with waterproof tape.

• Clean the starter, alternator, and relays with dry compressed air, and cover them with polyethylene sheets or polyethylene-coated paper.

• Loosen the V-belts. • Make sure the battery fluid is full and the

battery is fully charged and store the battery in a cool and dry place. Recharge the battery once a month.

• Touch up painted surfaces and apply a thin coat of antirust oil (MIL-L-21260) to other metal surfaces.

• Spray antirust oil (MIL-L-644B) into the intake system.

• Sprinkle vaporizing-type antirust powder (MIL-P-3420) into the cooling system.

• Fill the lubrication system with antirust oil (MIL-L-21260), run the engine at idle, then drain out the antirust oil.

• Replace the fuel with an antirust fuel, run the engine at idle, then drain out the antirust fuel.

-9-

• Inspection and Adjustment

To be sure of optimum engine operation, it is essential to perform inspections and maintenance on a regular basis.

-10-

This manual contains simple maintenance operations that you can perform yourself. Any operations not shown in this manual must be performed by your dealer.

E0020

• Your engine was adjusted for optimal operation before leaving the factory. Under no circumstances should you make adjustments yourself.

• Unnecessary adjustment or removal of engine components can detract from performance and lead to excessive exhaust emissions and noise.

• Faults resulting from improper adjustment are not covered by your warranty.

• Daily Inspections

To help prevent faults, the user should inspect the engine before starting it each day.

<>[CP.14

E0327

-----~----

I· §ngl,.Nurnber • Engine Number

Make a note of the engine number.

It is stamped on the crankcase in the position illustrated. When you order parts or require repairs, quote the engine number to be sure of optimum service.

-- -- ------------------------


I

6024-012345 E0143

-11-

MEMO----------------------------------------------

-12 -

.", ,' ••... ,'. . ...• , ",> . , .. ' . •.• ...... ..•.. ,'., ••• ' < , .. ,' ---------1 Daitylnspections (Performed Before Operation)

V-belt Tension ........................................................................................... 14

Coolant Level and Coolant Leakage ......................................................... 14

Engine Oil Level .. ...................................................................................... 15

Previously Identified Abnormalities ........................................................... 15

Fuel Level .......... ....................................................................................... 15

-13 -

Daily Inspections (Performed Before Operation)

The user should inspect the engine before starting it each day.

-14 -

• Coolant Level and Coolant Leakage

• Check the coolant level in the radiator or coolant tank. • Check that the radiator, radiator hoses, and related

components are free of coolant leakage. Check also that there is no sign of coolant leakage under the engine. For instructions on coolant replenishment, see CD P.65

E0327

Check that the V-belts are free of damage and that they are correctly tensioned.

For instructions on adjustment of V-belt tension, see P.61

deflect by the following amount

when pressed with a force of approxlffia1ely 98 N {22Ibf, 10 kgf}'

<Models with fan drive>

10 1015 mm (039 10 0.59 ,nJ

<Models without fan drive> 17 10 22 mm (0 67 10 0.87 ,nl

E0146

.~~~~--------~-.

Oil level gauge

-------------~~~--~~~~~~-

Daily Inspections (Performed Before Operation)

NOTE Check the engine oil level on a level surface with the engine turned off. The engine oil level cannot be checked accurately with the engine tilted, when the engine is running, or immediately after engine operation

E0328

• Fuel Level

Check that the fuel tank contains sufficient fuel. Check also that the engine is free of fuel leakage.

• Previously Identified Abnormalities

To check the engine oil level, withdraw the oil level gauge, wipe it clean, then insert and remove it again. Check also the viscosity of the oil and the extent to which the oil is soiled.

If any abnormality was identified when the engine was last operated, determine whether it will interfere with continued operation. If you cannot rectify the problem yourself, have the engine inspected by your dealer.

For instructions on oil replenishment, see

- 15-

MEMO----------------------------------------------

-16-

,----------------------------

-------------~I starting and StOpping the Engine I

Starting the Engine ................................................................................... 18

Warming Up the Engine ............................................................................ 20

Stopping the Engine ..... ............................................................................. 22

Inspections after Engine Operation ........................................................... 23

-17-

The engine starting and stopping methods depend upon the machine in which the engine is fitted. Read this section in conjunction with the instruction manual supplied with the machine .

• Starting the Engine

- 18-

E0023

1. Perform your daily inspections before starting the engine.

2. Disconnect all loading from the engine. If a clutch is fitted, disengage it.

3. Check that the area surrounding the engine is safe, and warn people nearby that you are about to start the engine.

Turn ON the battery switch.

CAUTION & Never turn OFF the battery switch Q~ while the engine is running. All gauges and switches would stop functioning. and the electrical system could suffer a fault.

E0148

(Crank the engine after it has been stored for a long period.)

1. Operate the shutdown

mechanism to terminate

fuel injection and thereby

stop the engine.

NOTE

"8" poSition, then crank the

engine for approximately

15 seconds.

E0042

To ensure that oil is distributed to all parts of the engine, be sure to crank the engine before starting it. This is particularly important with a turbocharged engine since the turbocharger's rotating parts will seize if the engine is started before they are lubricated.

c)

----_ .. _--- -- -------------------------------------

( Starting the engine in cold weather)

1. Turn the starter switch to

the "H" position.

E0043

2. Check that the indicator

glows red. (It should glow

within 40 to 60 seconds.)

E0044

• If the indicator does not glow red, the fuse that serves the air

heater relay may have blown. ~I P.56

• In extremely cold conditions, the engine oil's fluidity decreases

significantly. To facilitate starting of the engine, warm the oil pan

with an electric heater.

NOTE Do not preheat the engine continuously for longer than 60 seconds since this can drain the battery.

Starting and Stopping the Engine

~\ ---I Lv '----_____ M_o_v_e_t_h_e_c_o_n_tr_o_"_e_vec='r~t~o,t-he-s-ta-rt_in_g POSiti_o_n_. _____ J ~~~

~~========================~--------~ ON Turn the starter switch to the "S" position to

start the engine. When the engine starts,

immediately release the key. It will

automatically return to the "ON" ("0")

E0045 • If the starter operates for 10 seconds but the engine does not start,

return the key to the "OFF" position, check that the engine has stopped

completely, then wait a while before trying to start the engine again.

• Avoid rewing the engine immediately after starting it. If a turbocharged

is fitted, the engine must not be rewed for any reason when the engine

has just been started.

NOTE • Never operate the starter for more than 15 seconds since the starter

may malfunction and the battery may be drained. • Never turn the starter switch to the "S" position while the engine is

running since the starter may suffer damage .

When the engine starts, immediately move the control lever to the

idling position. Allow the engine to warm up until the needle in the

coolant temperature gauge starts to move.

- 19-


• Warming Up the Engine

Let the engine warm up until the needle in the coolant temperature gauge starts

E0046

Do not rev the engine since it can lead to poor operation and/or faults.

-20-

WARNING .&. Always operate the engine in a well ventilated place. Operation of the engine in a poorly ventilated place can result in a poisonous buildup of exhaust gases.

CAUTION .&.

The exhaust pipe and related components become extremely hot during engine operation. To prevent a fire, check that the area is free of grass, waste paper, and other flammable materials.

~. '! P.55

E0035

Check that the exhaust color is normal.

CLUNK SQUEAK

E0047

Check that the engine operates without abnormal noise, vibration, and smells.

Check that no oil, water, or fuel is leaking from the engine.

Ammeter or Charge Lamp

Z06946

After starting the engine, check that the needle points toward the "+" side of the scale or that the charge lamp is not illuminated.

Oil Pressure Gauge

Z06947

Check that the needle indicates a pressure of at least 0.1 MPa {14 psi; 1.0 kgf/cm2} or is in the green zone.

Warning Lamp

E0106

Check that no warning lamps are illuminated.


-21-


• Stopping the Engine

CAUTION &.

• The engine and exhaust pipe become extremely hot during engine operation. To prevent a fire, check that the area is free of grass and other flammable materials.

• If the engine operates in reverse, immediately operate the shutdown mechanism to stop the engine. If the engine is not stopped, it may seize or suffer a severe fault within a few minutes. Also, exhaust gases may emerge from the air cleaner, leading to a fire.

E0042

NOTE

Let the engine warm up for at least three minutes.

Always let the engine idle for a while before stopping it. This idling period allows the engine to cool down. It is particularly with a turbocharged engine and/or after high-load operation, when the engine's components are extremely hot.

-22-

Operate the shutdown mechanism to stop the engine. (For details, refer to the instruction manual supplied with the machine.)

Turn the starter switch to the "OFF" position, then remove the key.

E0149

Turn OFF the battery switch.

NOTE If the battery switch is left in the "ON" position for a long period, the battery may be drained.

------- ------ -----

If the engine does not stop <6D24-TL>

Z06949

If the engine does not stop when the starter switch is turned to the OFF position, stop it by pulling the engine stop button. Return the button to its original position when the engine has stopped.

NOTE • Use the engine stop button only in an

emergency. After using the engine stop button, turn the starter switch to OFF position to reset the computer before next starting the engine .

• After using the engine stop button, have the vehicle inspected by your dealer.

-------------

• Inspections after Engine Operation

After shutting down the engine, clean it and perform the following inspections:

• Inspect and rectify any abnormalities that were identified during engine operation.

• Check for loose components, damaged components, oil leakage, water leakage, and other abnormalities.

• During the winter months, completely drain the coolant if antifreeze has not been used. If the coolant is not drained, it may freeze and cause cracks and other problems in the crankcase and cooling system.

For instructions on draining the coolant, see P.66


-23-

MEMO----------------------------------------------

-~-

.-------~---------~-------- ---- ------------------

-----------------11 Dealing with Engine Problems 1

Causes and Remedies of Faults ............................................................... 26

Reverse Operation of Engine .................................................................... 30

Defective Charging of Battery ................................................................... 30

Overheating .............................................................................................. 31

Abnormal Oil Pressure .............................................................................. 32

Emergency Shutdown <Engines with Emergency Shutdown Mechanism> ................................ 33

Running Out of Fuel (Air Bleeding) ........................................................... 34

~25~

Dealing with Engine Problems

• Causes and Remedies of Faults

(~ __ S_ym_pt_om __ )

The starter does not turn, or the starter turns slowly and the engine does not start.

E0068

The starter turns but the engine does not start.

/

I E0069

-26-

( Possible cause) (~ __ R_em_e_d--,--y_~)

o The battery switch is turned OFF ............................. .Turn ON the battery switch. o The battery is flat... .................................................... Charge or replace the battery. o The battery terminals are disconnected, loose, ....... File off any corrosion, then make sure the

or corroded. terminals are fitted securely. 9I P.56 o The earth cable is disconnected ............................... Fit the earth cable securely. o The engine oil is too viscous ..................................... Replace the oil with a type of suitable viscosity.

9~' P.71

o The fuel tank is empty ............................................... Fill the fuel tank and air-bleed the fuel system. 92] P.34

o The starting procedure is incorrect... ......................... 9[J P.18 o Air has entered the fuel system ................................. Air-bleed the fuel system. 9C P.34 o The fuel filter element is clogged .............................. Replace the fuel filter element. 9iT P.60 o The air cleaner element is clogged ........................... Clean or replace the air cleaner element.

9CJ P.57 o The preheating circuit is faulty ................................... .If the preheating indicator lamp fails to illuminate,

check whether the preheating circuit's fuse has blown, whether the heater relay is faulty, and whether any wires are disconnected. Rectify any abnormality.

~-----.~----------------- -

( __ S_ym_pt_om __ )

The engine tends to stall at low speeds.

qJJ o

Abnormally low power

The engine overheats.

E0070

E0071

- ------------- ------------~------


( Possible cause) ( Remedy ~

o The idling speed is too low ........................................ Have the idling speed adjusted by your dealer. o The fuel filter element is clogged .............................. Replace the fuel filter element. ~ ~ .• P.60 o The air cleaner element is clogged ........................... Clean or replace the air cleaner element.

~J.J P.57

o The fuel filter element is clogged .............................. Replace the fuel filter element. ~~~: P.60 o The air cleaner element is clogged ........................... Clean or replace the air cleaner element.

~.L P.57 o The clutch is slipping ................................................. Have the clutch inspected by your dealer. o Clamps are loose on rubber hoses in the intake ....... Tighten the clamps.

system <applies to turbocharged engine only>. o Rubber hoses in the intake system are split ............. Have any split rubber hoses replaced by your

<applies to turbocharged engine only>. dealer.

o The coolant level is too low ........................................ Top up the coolant. Make sure that the cooling system does not leak and that the radiator cap is fitted securely. ~:l: P.65

o The front of the radiator is clogged .......................... Clean the radiator. with mud or dirt.

o The V-belts are loose or damaged ............................. Adjust the V-belts' tension or replace the V-belts with new ones. ~Q= P.61

o The coolant contains accumulated rust or scale ....... Flush out the radiator or replace the coolant.

E0034 ~]J P.66

-27-


( __ S~ym~p~t~om __ )

Black exhaust emissions

Excessive fuel consumption

Excessive engine oil consumption

( Possible cause) ( __ ~Re~m~e~d~y_~)

o The air cleaner element is clogged ........................... Clean or replace the air cleaner element. <>(: P.57

o Fuel is leaking ........................................................... Have any leaks repaired by your dealer. o The air cleaner element is clogged ........................... Clean or replace the air cleaner element.

<>JJ P.57 o The clutch is slipping ................................................. Have the clutch inspected by your dealer. o Clamps are loose on rubber hoses in the intake ....... Tighten the clamps.

system <applies to turbocharged engine only>. o Rubber hoses in the intake system are split ............. Have any split rubber hoses replaced by your

<applies to turbocharged engine only>. dealer.

o An incorrect type of oil is being used ........................ Replace the oil with the correct type.

<>CD P.71 o The oil level is too high .............................................. Make sure the engine contains the correct

amount of oil. <>C' P.71 o Oil is leaking .............................................................. Have any leaks repaired by your dealer. o The oil is overdue for replacement. ........................... Replace the oil at the correct intervals.

<>[IJ P.72 E0073 0 The engine is not being allowed to warm up ............. Warm up the engine in the proper manner.

-28-

.--------------~--------------

(~ __ S_ym_p_t_om __ )

The oil pressure does not increase.

The battery goes flat repeatedly.

,~/ -~-

, , , \

E0074

E0075

----------------------------~


( Possible cause) (~ __ R_e_m_ed_y __ )

o The oil level is too low ............................................... Make sure the engine contains the correct amount of oil. ¢:~ P.71

o Oil is leaking .............................................................. Have any leaks repaired by your dealer. o The oil's viscosity is not suitable ............................... Replace the oil with a type of suitable viscosity.

¢~= P.71 o The oil filter(s) is clogged (indicated by ..................... Replace the engine oil filter elements.

illumination of the oil filter warning lamp). ¢::::: P.59

o The battery terminals are disconnected, loose, ....... File off any corrosion, then make sure the or corroded. terminals are fitted securely. ¢C~ P.56

o The battery fluid level is too low ............................... .Top up the battery fluid. ¢[C P.55 o The V-belts are loose or damaged ............................. Adjust the V-belts' tension or replace the V-belts

with new ones. ¢rr; P.61 o The battery has reached the end of its ..................... Replace the battery.

service life.

~29~


• Reverse Operation of Engine

CAUTION .6. If the engine operates in reverse, immediately operate the shutdown mechanism to stop the engine. If the engine is not stopped, it may seize or suffer a severe fault within a few minutes. Also, exhaust gases may emerge from the air cleaner, leading to a fire.

After stopping the engine, inspect the air cleaner and the rubber hoses of the intake system. Replace any item that appears abnormal.

-30-

• Defective Charging of Battery

06987

Check that the V-belts are free of damage and that they are correctly tensioned. ~Il P.61

deflect by the following amount when pressed with a force of approXimately 98 N {22Ib!; 10 kg!}: <Models with fan drive> 10 to 15 mm (0.39 to 0.59 In) <Models without fan dnve> 17 to 22 mm (0 67 to 0.87 In)

A6253

Check for looseness in the alternator, relays and wiring. If the engine has a charge lamp, check that it illuminates when the starter switch is turned to the "ON" position and goes out when the engine is stopped.

If all connections and terminals are normal, the charging circuit is probably faulty. Have the electrical system inspected by your dealer.

• Overheating

WARNING 6 Do not open the radiator cap until the coolant temperature has dropped. When removing the radiator cap, cover the cap with a cloth and turn it slowly. Unless the cap is opened carefully, boiling coolant and steam could spray out and scald you.

E0010

If the coolant temperature exceeds 100 °C {212 OF} (when the engine is cooled using a radiator) or 95°C {203 OF} (when the engine is cooled with water from a tank) and/or the coolant temperature warning lamp illuminates, the engine is close to overheating.

E0052

If the engine overheats, stop the machine immediately and let the engine idle until the coolant temperature has decreased.

NOTE Do not stop the engine if it starts to overheat; the coolant temperature could increase rapidly, causing the engine to seize. Let the engine idle until the coolant temperature has decreased.


---- . \ Stop the engine when the needle in the coolant I

temperature gauge reaches the middle of the I

scale. Then, wait a while for the engine to cool, I

remove the radiator cap, and pour coolant into! the radiator until it reaches the bottom of the opening. If a reservoir tank is fitted, pour coolant into the reservoir tank until it reaches the "FULL" mark. I}:-'::: P.65

NOTE Pour coolant into the radiator a little at a time. If cold coolant enters an overheated engine suddenly, it can cause the engine to crack.

Check for water leakage, for V-belt looseness and/or damage, and for clogging of the radiator. If no coolant- or V-belt-related abnormalities are apparent, have the engine inspected by your dealer.

If the radiator cap has a pressure relief lever, raise the lever and allow the pressure to escape before slowly removing the cap.

Pressure relief lever

E0053

-31 -


• Abnormal Oil Pressure

During Idling, the oil pressure should not drop below 0.1 MPa {14 psi; 1.0 kgf/em'l During normal operation, the oil pressure should not drop below 0.2 MPa {28 psi; 2.0 kgffem 2

}

If the oil pressure drops abnormally, the oil pressure warning lamp and/or oil filter warning lamp illuminates.

E0054

Immediately after the engine is started, the oil pressure gauge may show a high reading since the engine is still cold. Check the oil pressure after allowing the engine to warm up.

-32-

If the oil pressure drops abnormally, immediately operate the shutdown mechanism to stop the engine.

NOTE If the engine is not stopped, its bearings and other components may seize.

Check the engine oil level and add oil if the level is too low. ¢LJ P.71

• Check whether the oil filter elements are clogged.

• Replace the oil filter elements if the oil filter warning lamp illuminates. ¢tll P.59

E0151

~~ / I \

E0014

Check for oil leakage and rectify any leaks.

Z06948 E0106

If the oil pressure is normal and there is no oil leakage, check whether the oil pressure gauge and warning lamps are faulty. Measure the oil pressure using a gauge that you know to be working normally.

If these steps fail to rectify the abnormality, have the engine inspected by your dealer.

• Emergency Shutdown <Engines with Emergency Shutdown Mechanism>

CAUTION &

The engine is hot immedeately after being stopped. Be careful not to burn yourself when performing inspections.

NOTE The emergency shutdown mechanism is designed to minimize engine damage. In the event of an emergency engine shutdown, identify and rectify the abnormality before restarting the engine.

After rectifying the abnormality, wait for the coolant temperature to drop before attempting to restart the engine, The engine will not start while it is extremely hot.

deflect by the follOWing amount when pressed with a force of

approxHnalely 98 N {22Ibf. 10 kgf} <Models wrth fan dnve>

10 to 15 mm {O.39to 0.59 In}

<Models without fan drive> t 7 to 22 mm (0.67 to 0.87 In)

A6253

E0041

Check that the V-velts are free of damage and that they are correctly tensioned. <}CJ P.61

Check the engine oil level and add oil if the level is too low. <}r~i P.71


Check the coolant level and add coolant if the level is too low. <}il: P.62

Check for oil leakage, for water leakage, and for clogging of the radiator.

If these steps fail to rectify the abnormality, have the vehicle inspected by your dealer.

-33-


• Running Out of Fuel (Air Bleeding)

CAUTION ~

Wipe up any spilled fuel after refueling and air-bleeding the fuel system. Also, check carefully for fuel leakage since leaking fuel could cause a fire.

If air enters the fuel system, it must be expelled in accordance with the following procedure before the engine can be started. It is not sufficient only to fill the fuel tank.

<6024, 6024-T, 6024-TC>

E0152 <6024-Tl>

Air bleeding plug

07182

-34-

Loosen the knob on the priming pump.

E0216

• Loosen the air bleeding plug on the fuel filter.

• Cover the air bleeding plug with a cloth.

Moving the knob up and down, pump fuel out of the air bleeding plug until air bubbles stop emerging.

E0215

After comfirming that air bubbles stop emerging, tighten the air bleeding plug.

E0156

Move the knob up and down a few times more, then press it down and screw it into position.

E0217

Completely wipe up any spilled fuel, then start the engine and check for fuel leakage.

The fuel injection pump will be air-bled automatically when the engine is started.

Fuel ........................................................................................................... 36

Engine Oil .. ............................................................................................... 36

Coolant. ..................................................................................................... 37

Battery ....................................................................................................... 37

-35-

Operation in Cold Weather

In extremely cold weather, special measures must be taken to ensure problem-free engine operation. Although the information here refers mainly to operation in snowy and mountainous areas, it is also applicable to winter operation in general.

• Fuel

Engine operating conditions Recommended

fuel

Normal operation at temperatures ASTM 0-975 of -12°C (10°F) or higher Grade 2-D

Operation at temperatures below ASTM 0-975 -12°C (10°F) at prolonged no-load Grade 1-0 operation

Use diesel fuel appropriate to the ambient temperature.

-36-

Keep the fuel tank cap securely tightened to prevent rain and snow from entering the tank. 9:=:: P.4

NOTE • Always refill the fuel tank completely after

engine operation. By minimizing the amount of air in the fuel tank, this reduces the likelihood of moisture (the air's water content) freezing and causing corrosion and starting difficulties.

• Periodically allow dirt and water to escape via the drain plug at the bottom of the tank.

• Engine Oil

'c c'F) 40c ~O 40 (lo4"FJ l:!E 30 /00 15'c ~ c.r> 20 80 o.c m'F) :. 30'Co 1°1 60

'3'tFJ 0'" = (8&'F) o 32 \ a:::;.: <..r> -10 20 0 t.n~ ~'

O....,~ -:>C -~~ -20 ~ 8 -I!:l'c (Zj'F) - ;:U~ (S'F)

Cl:([ v)'-'


E0238

Use oil whose viscosity is appropriate for the ambient temperature. 9[J P.71

.---------~----------~---------

• Coolant

EOOO?

• Battery

Take the following steps to prevent the coolant from freezing: • Add antifreeze to the coolant to prevent freezing and

corrosion. Before the onset of winter, have your dealer check whether the coolant's antifreeze concentration has decreased.

• When replacing the coolant, ensure that the new coolant's antifreeze concentration is suitable for the region in which the engine is used. ~JJ P.62

NOTE If antifreeze is not used, open the crankcase and radiator drain cocks eve!}' time the engine is shut down and aI/ow aI/ the coolant to drain out. If the coolant is not drained, it may freeze and cause cracks .

• Low temperatures detract from battery capacity, so keep the battery fully charged at all times.

• In extremely cold conditions, remove the battery and store it indoors when the engine is not being used. ~D P.55

NOTE To prevent the batte!}, fluid from freezing, always charge the batte!}, after topping up the fluid and when the fluid's specific

EOO?6 gravity is extremely low.

Operation in Cold Weather

-37-

MEMO---------------------------------------------

-~-

Battery ...................................................................................................... .40

Engine Oil ................................................................................................ .40

Cooling System ........................... ....................... ... ... ........... ................ ..... .40

-39-

Operation in Hot Weather

To prevent the engine from overheating in extremely hot weather, special care must be taken to ensure efficient operation of the cooling system.

E0034

-40-

• Battery

The battery fluid may be consumed quickly, so inspect it more frequently than in cold weather and make sure it never drops below the UPPER level. ~c: P.55

-----• Engine Oil

'c c'F) 4o'c ~o (104'1') ~

40 100 15'c [;J <fl 30 80 "F...... 20 o'c (Sq ) LU 30c.

10~ 60 t3tF) ~c-;< = (go"F) o 32 a: ~ ..n -10 20 0 (j');§:l ~"

O ...... ~ -:>C -~~ -20 ~ 8 -I~'c (1,3"F) - ~~ (S"n

cI:<t V)"'"

Engine starting temperature E0238

Use oil whose viscosity is appropriate for the ambient temperature. ~~ P.71

• Cooling System

Water scale and rust will tend to occur in the cooling system. To prevent them from causing the engine to overheat, flush out the cooling system and replace the coolant from time to time. ~~J P.66

NOTE • Keep the coolant topped up completely at all

times, and check frequently for coolant leakage.

• Check frequently that the V-belts are tensioned correctly and free of damage.

deflect by the follOWing amount

when pressed with a force of

approximately 98 N (22 Ibl; to kgl):

<Models with fan drive>

10 to 15 mm (0.39 to 0 59 In)

<Models without fan dnve>

17 to 22 mm (0.67 to 0.87 In)

~CJ P.61

A6253

• If the engine overheats, allow it to idle for a while before stopping it. ~(rl P.31

------------ ---- ----- ---------------

Long-Term Storage

If the engine might be required for immediate use ................................... .42

If the engine will definitely not be required ............................................... .42

Steps to Take before Reusing the Engine ............................................... .44

-41 -

Long-Term Storage

If you do not plan to use the engine for a while, take the steps described here and then store the engine in a dry place.

• If the engine might be required for immediate use ...

NOTE

Once a week, start the engine and allow it to warm up to ensure that all

components are supplied with oil.

E0042

• Before starting the engine, be sure to crank it with the starter and check that the oil pressure gauge indicates an increase in oil pressure.

• Warm up the engine at the lowest speed possible. Do not increase the engine speed until the coolant has reached an appropriate temperature.

-42-

• If the engine will definitely not be required ...

NOTE

Make the appropriate preparations for

the expected storage period, and cover the engine completely prior to storage.

o o

E0019

• If the engine is stored for longer than initially expected, make additional preparations in accordance with the longer storage period.

• If the storage period exceeds one year, repeat the preparatory steps. • Do not cover any engine components with vinyl sheets.

( Planned storage period)

One month or shorter

( Preparations for storage)

• Clean the air cleaner, then spray antirust oil (MIL-L-644B) into it and seal the opening with waterproof tape.

• Clean the starter, alternator, and relays with dry compressed air, and cover them with polyethylene sheets or polyethylene-coated paper. Do not use vinyl sheets.

• Loosen the V-belts. • Top up the battery fluid with

distilled water such that the fluid level is slightly higher than usual, charge the battery fully, clean the battery terminals, and store the battery in a cool, dry place. Recharge the battery once a month during storage.

One to three months

• Touch up painted surfaces and apply a thin coat of antirust oil (MIL-L-21260) to machined surfaces and to aluminum and plated parts.

Three to six months

• Remove the air cleaner, move the control lever to the stop position, then crank the engine with the starter three times at intervals of 15 seconds. While cranking the engine, spray antirust oil (MIL-L-644B) into the intake manifold with an oil spray gun.

• Drain the coolant and remove the thermostat. Then, blow compressed air through the coolant inlet and outlet to expel all remaining moisture. Sprinkle vaporizing-type antirust (MIL-P-3420) into the coolant inlet and outlet. Then, fit the thermostat and close the drain cock.

Long-Term Storage

Six months to one year

• Drain the lubricating oil from the oil pan, oil filter, injection pump, cam chamber, and governor chamber. Then, replace the drained lubricating oil with the same amount of antirust oil (MILL-21260).

• Replace the fuel with a mixture of 50% diesel fuel and 50% antirust oil (MIL-L-644B). Then, let the engine idle at 800 to 1,000 rpm for 10 minutes so that the mixture reaches all parts of the fuel system.

• After stopping on engine, drain out both the antirust oil and gas oil/antirust oil mixture.

-43-

Long-Term Storage

• Steps to Take before Reusing the Engine

When the engine has stored for three months or longer, it is important to perform certain inspections and adjustments before using it. (These inspections and adjustments are not necessary if the engine has been started and warmed up once a week throughout the storage period.)

E0023

-44-

Take the following steps:

• Top up the engine oil to the specified level. • Top up the fuel and coolant, and air-bleed the

fuel system.

• Start the engine and check for correct operation. Check closely for water and gas leakage caused by gasket deterioration.

NOTE Before starting the engine to test its operation, remove the rocker cover and lubricate the rocker arm bearings and push rods sufficiently. Also check for proper valve clearances. Then, use the starter to crank the engine three times, for 15 seconds each time, and check that the oil pressure is correct. After starting the engine, allow it to warm up fully (this ensures that all components are seated snugly against each other) before applying load.

~------------~---------- - --------------

.... --------......j Periodic Inspection and Maintenance Schedule

Inspection and Maintenance Intervals ..................................................... .46

-45 -

Periodic Inspection and Maintenance Schedule

• Inspection and Maintenance Intervals

The periodic inspection schedule shows inspections and maintenance operations that must be performed on a daily and periodic basis for regularly operated engines. To ensure that your engine operates safely and .efficiently, be sure to perform the indicated inspections and maintenance operations at the specified intervals.

-46-

The timing of inspections and maintenance operations should be based on the engine's aggregate operating time, which is indicated by the hour meter. The inspection and maintenance inteNals shown in the schedule are given for an engine operating under normal conditions. The intervals should be shortened if the engine is used in particularly severe conditions.

Ignore any equipment item in the schedule that is not fitted on your engine.

E0077

II) .... ::J

II) Inspection/maintenance item 0 ~

.... ::J

0 0 ,.... ~ .......

0 2- <0 ·iii C

Startability and noise 0

Low-speed operation and acceleration 0

(under normal conditions)

Exhaust gases 0

~

~ Q) Security of cylinder head, manifolds, c Q) and mounting brackets .9 Q) c Compression pressure ·OJ c w

Valve clearances

Condition Air cleaner element (cyclone type air cleaner)

Replacement

Rotation of turbocharger bearings

Interval

II) II) .... .... ::J ::J 0 0 ~ ~ I[) 0 C\I I[) ,.... C\I

0


II) .... ::J 0 ~

0 0 I[)

NOTE: [0]: Inspection interval specified by Mitsubishi Motors [~'r]: Replacement interval specified by Mitsubishi Motors

II) .... ::J Key points 0 ~

0 0 o. ,....

• Call your dealer if adjustments are required.

• Check for hunting. • Call your dealer if adjustments are required.

• Let engine warm up completely before inspecting exhaust gases.

• See page 55 for instructions. • Call your dealer.

0 • Cail your dealer.

0 • Call your dealer.


• When red signal appears in dust indicator, clean or replace element irrespective of inspection interval.

• See page 57 for instructions.

P: • See page 57 for instructions.


-47-


VI .... ::J

VI Inspection/maintenance item 0 ..c: ....

::J 0 0 .- ..c: 2- ° CD 'iii C

Oil leakage 0 (including inspection for hose damage/deterioration)

E Contamination and level 0 Q) -VI >-VI c: 0 .. co

Engine oil u * .;:

..0 Replacement {'.{ ::J

...J

-48-

Interval

VI ~ ~ .... ::J ::J ::J 0 0 0

..c: ..c: ..c: LO 0 0 C\I LO 0 .- C\I LO

'tr

NOTE: [0]: Inspection interval specified by Mitsubishi Motors ['tr]: Replacement interval specified by Mitsubishi Motors

VI .... ::J Key points 0

..c:

° 0 o. .-

• Replace hoses every 3,000 hours or 2 years.


• *: With new engine only • Oil pan capacity

Approx. 27 dm3 {28.5 US qts.; 27 L} (engines for electric power generators) Approx. 25 dm3 {26.5 US qts.; 25 L} (engines for construction machinery)

• See page 71 for instructions. • Required oil type

API classification CD (MIL-L-21 04C) or better

--------------

rJ) "-::l

~ Inspection/maintenance item 0 .s::. ::l 0 0 ,.. .s::. ~ 0

'iii CD

0

E Chogging (center bolt type filter) Q) .... !/) >. !/)

Oil filter c: 0 elements ~ Replacement u 'C .0 ::J ..J

Fuel leakage 0

(including inspection for hose damage/deterioration)

E Fuel level 0

Q) +' rJ)

>-rJ)

Replacement of fuel filter element (filter-paper type) Qj ::l

LI..

Drain water and sediment from water separator

0

Interval

rJ) rJ) "- "-::l ::l 0 0

.s::. .s::. LO 0 C\I LO ,.. C\I

0


rJ) "-::l 0

.s::. 0 0 LO

u

u

NOTE:

[0]: Inspection interval specified by Mitsubishi Motors [u]: Replacement interval specified by Mitsubishi Motors

rJ) "-::l Key points 0

.s::. 0 0 ~ ,..

• If oil filter warning lamp illuminates, replace oil filter elements irrespective of inspection interval.

• See page 59 for instructions. • Oil filter capacity

4.0 to 4.5dm3 {4.2 to 4,7 US qts.; 4.0 to 4.5 L}

• Replace hoses every 3,000 hours or 2 years,

• See page 60 for instructions. • Perform air-bleeding.

(See page 34 for instructions.)

• If water reaches level line, drain it irrespective of inspection interval.

• See page 60 for instructions,

-49-


II) ... :::J

II) I nspection/maintenance item 0 ..r::: ...

:::J 0 0 ,.... ..r::: ~ 0

'co <0

C

Injection nozzle spray pressure/spray condition

E Q) Inspect and clean gauze filter of injection pump +" II) >0-Il)

Qj Drain water and sediment from fuel tank :::J

IJ..

Injection timing

Water leakage 0 (including inspection for hose damage/deterioration)

If FUSO ANTIFREEZE or RADIPET 9 is used

E Flush out Q) +" cooling system II) >0- and replace coolant If FUSO DIESEL II)

Cl LONGLIFE COOLANT c: '0 is used 0 U

V-belt looseness/damage 0

Fan damage/mounting security

-50-

Interval

~ II) ~ ... :::J :::J :::J 0 0 0

..r::: ..r::: ..r::: LO 0 0 C\I LO 0 ,.... C\I LO

0

0

0

{::[

2 years

0

NOTE: [0]: Inspection interval specified by Mitsubishi Motors [u]: Replacement interval specified by Mitsubishi Motors

II) ... :::J Key points 0

..r::: 0 0 0 ,....

• Call your dealer.


• Perform every 500 hours or 6 months.


• Coolant volume (engine-proper only) <6D24, 6D24-T, 6D24-TL> Approx. 22dm3 {23.5 US qts.; 22L} <6D24-TC> Approx. 24dm3 {25.5 US qts.; 24L}

• Flush out cooling system when coolant is replaced.


• Check deflection when belts are pressed in center with force of approx. 98 N {22 Ibf; 10 kgf}.



-------------------~~--~---- ----

!Il ... ::J

Inspection/maintenance item 0 .s= a .... ...... ~ 'ffi C

Coolant level 0

E Radiator

Cap functionality Q) +" !Il >-!Il

Core clogging/damage Cl .S: '0 0 ()

Lubrication of fan drive and tension pulley

Fluid level

E Battery Q) Specific gravity of fluid +" !Il >-!Il

(ij Security/contamination ()

of terminals .;: +" () Q)

iIi Loose wiring connections and loose/damaged insulation

Functionality of meters, gauges, and warning lamps

- --- --------- - -----------------~

Interval

~ !Il !Il .... ...

::J ::J ::J 0 0 0 .s= .s= .s= a In a CD C\I In .... C\I

0

0

0

0

0


!Il .... ::J 0 .s= a a In

0

0

0

NOTE: [0]: Inspection interval specified by Mitsubishi Motors ['tr]: Replacement interval specified by Mitsubishi Motors

!Il .... ::J Key points 0 .s= a a ~ ....

• If core is severely clogged, wash it irrespective of inspection interval.

• See page 74 for instructions. • Required grease type

Wheel bearing grease [NLGI No.2 (Li soap)]

• Inspect every 125 hours or 2 weeks (every 1 week in summer). if sooner than specified interval.


-51 -


Interval

~ :I

1/1 1/1 1/1 Inspection/maintenance item 0 .... ....

.J:. .... :I :I :I 0 0 0 0 .J:. .J:. ,.. .J:.

~ 0 L() 0 co C'II L()

·iii ,.. C'II

0

Operation of emergency engine shutdown device 0

Inspect couplings (rubber bushings) 0

Lubricate clutch fork shaft and shifter 1/1 Q) .;: 0 1/1 1/1 Q)

Lubricate power plant clutch bearing case 0 0

(direct drive) <{

0 Inspect and replace transmission and gear box oils *

i'f

Operation of clutch and transmission

-52-

1/1 .... :I 0

.J:. 0 0 L()

'v7

NOTE: [0]: Inspection interval specified by Mitsubishi Motors [i'f]: Replacement interval specified by Mitsubishi Motors

1/1 .... :I Key points 0

.J:. 0 0 o. ,..

• Call your dealer for adjustments.

• Check exposed rubber.

• See page 74 for instruction.

0 • Required grease type Heat-resisting grease [NLGI No.3 (Li soap); MIL-G-3545C]

• See page 74 for instruction. 0 • Required grease type


• *: With new engine only • Required oil type

Gear oil [API classification GL-3]

0 • Call your dealer for adjustments.

· .

-------------~ Simple Inspection and Maintenance

Safety Precautions .................................................................................... 54

Inspection of Exhaust Color ...................................................................... 55

Battery Maintenance .. ............................................................................... 55

Replacement of Preheating Circuit Fuse ................................................. 56

Cleaning and Replacement of Air Cleaner Element ................................. 57

Replacement of Oil Filter Element ............................................................ 59

Replacement of Fuel Filter Element... ....................................................... 60

Draining Water Separator ........................................................................ 60

Inspection and Adjustment of V-Belt Tension ........................................... 61

Inspection and Replacement of Coolant.. ................................................. 62

Inspection of Intercooler ............................................................................ 67

-53-

Simple Inspection and Maintenance

• Safety Precautions

This chapter contains easy-to-follow instructions for inspections and maintenance operations you can do yourself.

CAUTION &

• Inspections should normally be performed when the engine is not running. If you must perform an inspection while the engine is running for unavoidable reasons, be careful not to touch its moving parts.

• The engine is always hot immediately after being stopped. Be careful not to burn yourself. Whenever possible, inspections should be performed when the engine is cold.

• After performing inspections or maintenance, make sure you do not leave rags or tools in the engine compartment. Flammable items could catch fire during engine operation.

NOTE • Maintenance and inspection intervals should

be shortened if the engine operates under particularly severe conditions.

• The engine's fuel injection pump was adjusted for optimal operation before leaving the factory. Under no circumstances tamper with its seal and/or attempt to make adjustments.

-54 -

Improper adjustments can detract from the engine's performance and can cause the engine to pollute the environment by emitting black smoke and excessive exhaust gases.

Always wear appropriate clothing and use tools correctly.

Before inspecting electrical components, stop the engine, then turn OFF the battery switch or disconnect the (-) terminal of the battery.

E0327

WARNING & Always operate the engine in a well ventilated place. Operation of the engine in a poorly ventilated place can result in a poisonous buildup of exhaust gases.

E0326

• Inspection of Exhaust Color

Let the engine warm up fully before inspecting the exhaust

Colorless/pale blue:Normal

E0035

Black ......... Bad (indicates incomplete combustion)

White ........ Bad (indicates that oil is leaking past piston rings and burning in combustion chambers)

In the winter months, low temperatures may make the exhaust gases appear white even when the engine is operating normally.

• Battery Maintenance

DANGER .& The battery emits explosive hydrogen gas. Never use naked flames or perform operations that may create sparks near the battery.

WARNING .& If battery fluid splashes in your eyes, immediately wash it out with plenty of water and seek medical attention.

CAUTION .&

• Battery fluid contains sulfuric acid, so it can burn the skin and make holes in clothing if spilled. Always handle battery fluid carefully and wash away any spilled fluid with soap and plenty of water.

• Do not use the battery with the fluid level below the LOWER level line. Doing so would shorten the battery's service life and could cause the battery to overheat and explode.

• Store any used battery with its terminals at the top. Storing the battery on its side could result in fluid leakage and in a fire.


Inspect and top up the battery fluid every 125 hours or two weeks J

(once a week in summer).

Acceptable range A5574

The fluid level should be between the UPPER and LOWER level lines or 10 to 15 mm above the plates. Some types of battery have only one level line. In this case, the line indicates the LOWER level.

-55-


10to 15mm (0.39 to 0.59 in)

----------------'=-f~- ----- _-=~Plate ----.------~~ ~------------- -----------------~------------------~------------------

----- ------- -------------- ------

A5575

If the fluid level is too low, remove the caps and top up the fluid with electrolyte or distilled water.

NOTE • Do not allow the fluid level to rise above the

UPPER level line or rise more than 15 mm (0.59 in) above the plates.

• Top up the fluid before charging the battery or running the engine. Note that in winter the fluid can freeze and damage the battery when its specific gravity is low.

• Before inspecting/maintaining the battery or inspecting electrical components, stop the engine, then turn OFF the battery switch or disconnect the (-) terminal of the battery.

• Remove the battery from the machine before charging it.

-56-

Clean the battery terminals every 250 hours.

A5577

• Make sure the caps are tightened securely on the ports to prevent foreign matter from entering the battery case.

• Remove any dirt from the terminals. • If the terminals are contaminated by white

powder (this indicates corrosion), clean them with warm water. If the corrosion is severe, disconnect the battery cables and rub the terminals with sandpaper or a wire brush.

• Lightly smear the terminals with grease after cleaning them.

NOTE When disconnecting the battery cables, disconnect the (-) cable first. When reconnecting the cables, connect the (+) cable first. It is dangerous to have only the (-) battery cable connected since sparks could be produced if a tool or other metal object short-circuited the (+) terminal to the frame.

• Replacement of Preheating Circuit Fuse

CAUTION .&.

Use a Mitsubishi genuine replacement fuse of the specified amperage. A fuse with a different amperage could cause a fire.

For safety, the air heater relay in the engine preheating circuit is fitted with a fuse. If the preheating indicator fails to glow red, check whether the fuse has blown. In the event that the fuse blows, rectify the fault and replace the fuse with a new one.

Amperage rating E0351

NOTE Before replacing the fuse, stop the engine, then turn OFF the battery switch or disconnect the (-) terminal of the battery.

• Cleaning and Replacement of Air Cleaner Element

Inspect and clean the element Every 250 hours and whenever the red signal appears in the dust indicator. (With a doubleelement air filter, only the outer element can be inspected and cleaned.)

Replace the element Every 1,000 hours. (With a double-element air filter, replace the outer and inner elements at the same time.)

NOTE

• Shorten the inspection/cleaning and replacement intervals if the engine is used in a particularly dusty environment.

• It is not possible to clean and reuse the inner element of a double-element air filter.

• Make sure the element(s) and clamp are fitted

Cyclone (Single-Element) Type

Gasket Air cleaner body tN)

Element

~Dust indicator ~ , Wing nut

~ Wi~9 nut cove;With gasket)

~ Vacuator valve Air cleaner body

Cyclone (Double-Element) Type

Air cleaner securely in position. If they are not fitted Dust body


Cleaning Procedure

CAUTION .&

When cleaning the element(s) with compressed air, wear safety spectacles to protect your eyes from dust.

NOTE

• Do not remove the inner element of a daubleelement air filter except for replacement.

• When cleaning the element with compressed air, make sure the air pressure does not exceed 685 kPa {tOO psi; 7 kgf/Crn"}.

• Never attempt to clean the element by · knocking it against another object or by

striking it.

• If the element is blackened by oily soot, replace it with a new one irrespective of the specified replacement interval.

securely, dust or other foreign matter may be Indicator

drawn into the engine and prevent normal

showing

Installed alignment 1 . Remove the element.

operation.

Dust indicator Air cleaner body

b

~ E0159 E0158


2. Check the extent to which the element is contaminated, then clean the element as follows:

Blow clean compressed air along the pleats from the

E0079

3. Shine a lamp through the element from the inside and inspect the filter paper.

Replace the element if the filter

areas, or other damage and/or the seal is damaged.

-58- E0082

4. Clean the dust cup and baffle. Loosen the wing nut to remove the baffle.

A1304

5. When all parts are clean, assemble them by reversing the disassembly sequence.

E0083

If the air cleaner is mounted horizontally on the engine, the dust cup should be fitted such that its alignment marks point upward. (Note that some air cleaners do not have alignment marks.)

Dust Indicator

Reset button

Window (red signal)

C7210B

The dust indicator shows when the air cleaner needs to be cleaned. Whenever the red signal appears in the window, clean the element irrespective of the specified inspection interval. After cleaning or replacing the element, press the reset button to cancel the red signal.

-------~~~~-----

• Replacement of Oil Filter Element

CAUTION &

• Be careful not to spill engine oil. If oil comes into contact with the exhaust manifold or other hot components, it could catch fire. Wipe up any oil that spills accidentally.

• To avoid causing a fire, never smoke or use a lighter or other flame while washing components in solvent..

NOTE • The elements cannot be washed and reused. • Make sure the O-rings are not twisted. They

may be cut or otherwise damaged if they are twisted when fitted.

Replace the elements every 500 hours or when the oil filter warning lamp illuminates.

- - -------------------------------------

Filter head

Gasket

Element (may be fitted either way up)

Spring

Filter case

Drain plug

Gasket

Element (may be fitted either way up)

Spring

Filter case

Drain plug

___ ---- O-ring

O-ring

Washer

Bypass Full-flow Center bolt filter filter (tightening torque: 59 to 69 N·m (43 to 58 tUbs. 6 to 7 kgt·mj)

Washer

Center bolt (tightening torque: 59 to 69 N·m {43 to 58 fUbs. 6 to 7 kgf·mj)

E0253

1. Place a container under the oil filters to hold the oil when it is drained out.

Drain plug E0161


Perform the following steps for each filter:

2. Remove the drain plug and allow the oil to drain out.

3. Remove the center bolt, then remove the filter case, element, spring, and other parts.

4. Wash all parts except the element in solvent.

5. Discard the old element, and prepare a genuine Mitsubishi replacement element. The O-ring must also be replaced with a new one.

6. Fit the new element and other parts by following the disassembly procedure in reverse. Tighten the center bolt to the torque shown in the drawing.

7.lf the engine oil has not been replaced, add 4.0 to 4.5 dm3 {4.2 to 4.7 US qts.; 4.0 to 4.5 L} of oil.

8. Start the engine and check for oil leaks.

9. Stop the engine, wait 30 minutes, then check the oil level.

-59~


• Replacement of Fuel Filter Element

CAUTION &

After replacing the filter element, wipe up any spilled fuel. Also, check that no fuel is leaking from the filter since leaking fuel could cause a fire.

NOTE To avoid damaging the element, be careful not to overtighten the element assembly.

( Replace the element every 500 hours. )

<6024, 6024-T, 6024-TC>

Filter head

Air bleeding plug

Gasket

Element assembly

E0162

-60-

<6024-Tl>

Air bleeding cock" Filter head

Alignment mark /"Gasket

Alignment mark

Element ~ assembly

I Tighten 05365

1. Remove the element assembly by turning it counterclockwise. Use a filter wrench if the element assembly is difficult to turn.

Filter wrench part number: MH061572 <6024, 6024-T, 6024-TC> MH063200 <6024-TL>

2. Fit a Mitsubishi genuine replacement element assembly as follows: Lightly smear engine oil onto the gasket of the new element assembly, then tighten the element assembly by hand until the gasket touches the filter head. Next, tighten the element assembly by the additional number of turns shown below. 6024, 6024-T, and 6024TC: 3/4 to 1 turn 6024-TL: 1 to 1 1/8 turn

3. Air-bleed the fuel system. c}JJ P.34

4. Start the engine and check for fuel leaks.

• Draining Water Separator

CAUTION &

The water separator contains fuel in addition to water. When draining the contents of the water separator, wipe up any fuel that splashes on the surrounding area. Unless wiped up, it could cause a fire.

Orain the contents of the water separator every 60 hours and whenever the float reaches the level line.

Drain plug

E0350

1. Loosen the drain plug and allow the contents of the water separator to drain out.

2. Tighten the drain plug when the float reaches the bottom.

3. Check the water separator for fuel leakage.

-------~--------~~--------------

• Inspection and Adjustment of V-Belt Tension

Excessively slack or tight V-belts can cause defective charging of the battery and malfunctions of the alternator and water pump. Keep the belts adjusted to the correct tension at all times.

The center of each belt should deflect by the amount shown when pressed with a force of approximately 98 N {22 Ibf; 10 kgf}.

Alternator

~ . Mounting bolt

E0165

1 . Slightly loosen the alternator's upper and lower mounting bolts.

2. Using a wrench handle or similar implement as a lever, change the alternator's mounting position to adjust the belt tension.


Tension pulley

Adjusting bolt

Tension pulley

Mounting nut

E0166

1. Slightly loosen the tension pulley's mounting nut.

2. Adjust the V-belt tension by moving the pulley using the adjusting bolt.

3. Securely tighten the tension pulley's mounting 3. Securely tighten the alternator's mounting nut.

E0164

NOTE • Keep the V-belts free of oil and grease.

Contact with these substances can make the belts slip and shorten their service life.

• When replacement is necessary, replace both V-belts at the same time.

bolts.

NOTE Be careful not to damage the stator coils and through bolts when moving the alternator.

- 61-


• Inspection and Replacement of Coolant

Additives for Coolant

When the coolant requires replacement, flush out the cooling system and fill it with coolant that contains the appropriate one of the additives shown below. Additives are necessary to keep the coolant free of water scale and rust and to prevent the coolant from freezing.

Additive Season Replacement interval

Antifreeze: FUSO ANTIFREEZE Cold seasons 500 hours

(color: blue)

Corrosion inhibitor: All seasons RADIPET 9 except 500 hours (color: red) cold seasons

FUSO DIESEL LONGLIFE COOLAN All seasons 2 years

(color: yellow)

CAUTION .L:t.

Remember that the coolant replacement interval depends upon the additive used.

-62-

Water for Coolant

Use soft water with the properties shown below. Do not use hard water from a well or river since it is liable to form water scale and cause corrosion.

Total hardness 300 ppm or less

Sulfate SO; 100 ppm or less

Chloride CI- 100 ppm or less

Total dissolved solids 500 ppm or less

pH 6 to 8

Using FUSO ANTIFREEZE

• Since FUSO ANTIFREEZE has anticorrosion properties, no additional corrosion inhibitor is required.

• Use FUSO ANTIFREEZE at a concentration of 30% to 60%. At a concentration below 30%, Fuso Antifreeze does not prevent corrosion effectively, and at a concentration exceeding 60% it does not effectively prevent the coolant from freezing.

• When the ambient temperature is high enough that there is no risk of the coolant freezing, replace coolant containing antifreeze with coolant containing a corrosion inhibitor. In warm weather, the use of coolant containing antifreeze makes the engine prone to overheating.

00634

---------------~------------- -----

Required Concentration

Determine the correct concentration of FUSO ANTIFREEZE in accordance with the lowest temperature at which the engine is to be used. See the following table.

FUSO ANTIFREEZE concentration (% of coolant volume)

Lowest temperature Concentration (%)

(OC eF})

-10 {14} or higher 30

-15 {5} 35

-20 {-4} 40

-25 {-13} 45

-30 {-22} 50

-35 {-31} 55

-40 {-40} 60

For instructions on coolant replenishment, see" P.65

Using RADIPET 9 (Corrosion Inhibitor)

RADIPET 9 should be added to the coolant at a concentration of 5 %.

00635


-63-


Using FUSO DIESEL LONG LIFE COOLANT

FUSO DIESEL LONGLIFE COOLANT is an ethylene-glycol-based antifreeze (SAE J-814-C) with both antifreeze and anticorrosion properties. Mix it with soft water in the specified ratio.

WARNING it. • FUSO DIESEL LONGLIFE COOLANT is

toxic. If it is accidentally swallowed, immediately induce vomiting and seek medical attention. If it splashes in the eyes, immediately flush it out with plenty of water and seek medical attention.

• Store FUSO DIESEL LONGLIFE COOLANT out of children's reach.

CAUTION it.

FUSO DIESEL LONGLIFE COOLANT is flammable. Keep it away from naked flames.

NOTE Never mix FUSO DIESEL LONGLIFE COOLANT with antifreeze, corrosion inhibitor, or other brands of longlite coolant.

-64 -

00264

• Use only FUSO DIESEL LONGLIFE COOLANT. Do not use other brands of coolant.

• Since FUSO DIESEL LONGLIFE COOLANT has anticorrosion properties, it can be used in the summer months. (Maintain a concentration of 30% or higher.)

• Use FUSO DIESEL LONGLIFE COOLANT at a concentration of 30% to 60%. The exact concentration required depends upon the ambient temperature. At a concentration below 30%, FUSO DIESEL LONGLIFE COOLANT does not prevent corrosion effectively. At a concentration exceeding 60% it does not effectively prevent the coolant from freezing and makes the engine prone to overheating.

• Before the onset of winter, check that the coolant concentration is sufficient.

• When the coolant requires replacement, flush out the cooling system before pouring in the new coolant.

Required Concentration

Determine the correct concentration of FUSO DIESEL LONGLIFE COOLANT in accordance with the lowest temperature at which the engine is to be used. See the following table .

FUSO DIESEL LONGLIFE COOLANT concentration (% of coolant volume)

Lowest temperature Concentration (%)

(OC eF})

-10 {14} or higher 30

-15 {5} 35

-20 {-4} 40

-25 {-13} 45

-30 {-22} 50

-35 {-31} 55

-40 {-40} 60

For instructions on coolant replenishment, see P.65

--------------------------

( _______ A_d_d_in_g_c_O_OI_a_n_t _____ ~)

WARNING .&. Do not open the radiator cap until the coolant temperature has dropped. When removing the radiator cap, cover the cap with a cloth and turn it slowly. Unless the cap is opened carefully, boiling coolant and steam could spray out and scald you.

NOTE • If the coolant in the system contains antifreeze,

a corrosion inhibitor, or longlife coolant, make sure the additional coolant contains the same additive in the same concentration. The addition of plain water would simply dilute the coolant in the system, resulting in less protection against freezing and corrosion.

• Do not use water from a well or river.

83514

Remove the radiator cap and top up the coolant until it reaches the bottom of the opening.

Pressure relief lever

Radiator cap

E0053

If the radiator cap has a pressure relief lever, raise the lever and allow the pressure to escape before slowly removing the cap and topping up the coolant.


Radiator cap

Cap

,=,~~l'<-;:"x Reservoir tank

FULL line

E0204

If the radiator has a reservoir tank, coolant should be poured into the reservoir tank, not directly into the radiator. Add coolant until it reaches the "FULL" line.

-65-


Flush out the cooling system and replace the coolant at the following intervals: With FUSO ANTIFREEZE or RADIPET 9: 500 hours With FUSO DIESEL LONGLIFE COOLANT: 2 years

CAUTION .&. The coolant may be extremely hot when drained. Take care to avoid being scalded.

-66-

Radiator

E0168

Engine crankcase

E0169

Aftercooler (with air bleed opening)

y Air bleeding plug ~

Aftercooler E0329

1. Remove the radiator cap, then loosen the drain plug on the engine and radiator and allow the coolant to drain out. If the aftercooler has an air bleeding plug, remove it. Tighten the drain plugs when the coolant has drained out completely.

2. Pour soft water (preferably hot) into the radiator until it emerges from the aftercooler's air bleeding hole. Then, refit the air bleeding plug.

3. Run the engine slightly faster than its idling speed such that the coolant reaches a temperature of ao°c (176°F) or higher. Keep the engine running in this condition for about 10 minutes, then drain out the water. If the water is dirty, repeat this flushing procedure until clean water emerges.

4. If the front of the radiator core is clogged with mud or dirt, wash it clean to ensure that air can pass through the radiator core smoothly.

5. Pour coolant (soft water with an additive) into the radiator until it reaches the bottom of the opening. If the aftercooler has an air bleeding plug, pour coolant mixture into the radiator with the air bleeding plug removed. Refit the air bleeding plug when coolant mixture

,----------------------------- ---

emerges from the air bleeding hole.

6. Without fitting the radiator cap, run the engine for a while to expel all air from the cooling system.

7. Stop the engine and check the coolant level. If it is too low, pour coolant into the radiator until it reaches the bottom of the opening.

8. Securely fit the radiator cap.

9. If a reserve tank is fitted, drain the coolant from the tank, then fill the tank with the type of mixture that the radiator contains.

NOTE If the radiator is severely clogged or the coolant is exceptionally dirty, have the engine inspected by your dealer.

Coolant capacity (engine-proper only):

<6024, 6024-T, 6024-TL> Approx. 22 dm3 {23.5 US qts.; 22 L} <6024-TC> Approx. 24 dm3 {25.5 US qts.; 24 L}

• Inspection of Intercooler

Clogging of the intercooler core can detract from engine performance. Remove all mud, dust, and other contamination from the front of the core.

NOTE To avoid damaging the intercooler core, clean it with a soft brush. Do not use any sharp or hard implement.


-67-

MEMO----------------------------------------------

-~-

r----------~------------- ----

.. . .....

----------~ Lubricant Replacement and Maintenance

Engine Oil ................................................................................................. 71 Lubrication ................................................................................................ 74

-69-

Lubricant Replacement and Maintenance

NOTE To ensure optimal performance and a long service life, always use lubricants of the specified type.

Area Oil capacity

Oil pan Approx. 27 dm3 {28.5 US qts.; 27 L} (engines for electric power generators) Approx. 25 dm3 {26.5 US qts.; 25 L} (engines for construction machinery)

Oil filter 4 to 4.5 dm3 {4.2 to 4.7 US qts.; 4 to 4.5 L}

Fan drive As required

Tension pulley As required

Power plant As required clutch bearing case

(direct drive)

Clutch fork shaft As required

Clutch shifter As required

-70-

Remarks

Engine oil [API classification CD (MIL-L-2104C) or better]


Heat-resisting grease [NLGI No.3 (Li soap); MIL-G-3545C]

• Engine Oil

The performance, service life, and startability of the engine depend to a large degree upon the engine oil. Always use engine oil of the specified classification and viscosity.

Application API service

Classification Remarks

All engine models

CD MIL-L-2104C

Use a type of engine oil that is appropriate for the ambient temperature

'c c'F) 40(, ~o 40 (io4'F) ~ 30 /00 I !'i'e ~ <f'

10 80 o'c (59"F) :: 30·c. 10160

t3tF)@",=(Sbl) o 32 a:::30..n -10 20 0 lfJ"" ~. o ,..., ~ -:oC -~~ -20 ~ 8 -'~·c (Z3·F) - ;:;:; ~ (son

c:cr v)'-'


E0238


( Inspection and Replenishment ) ---------------~

CAUTION ,&

Be careful not to spill engine oil. If oil comes into contact with the exhaust manifold or other hot components, it could catch fire. Wipe up any oil that spills accidentally.

NOTE • Check the engine oil level on a level surface

with the engine turned off. The engine oil level cannot be checked accurately with the engine tilted, when the engine is running, or immediately after engine operation .

• After topping up the oil, wait 5 to 6 minutes before checking the oil level. The oil will take time to reach the oil pan, so the oil level gauge may give an incorrectly low reading if the level is checked immediately.

Oil level gauge E0328

E0041

Inspection

1. Withdraw the oil level gauge and wipe it clean.

2. Fully insert the oil level gauge, then carefully withdraw it again.

3. The engine oil adhering to the gauge should be within the indicated range. If the level is too low, add oil of the specified type. If the oil on the gauge is extremely dirty, the engine oil must be replaced.

- 71 -


Adding Engine Oil

1. Wipe the area around the oil filler cap to prevent dust and dirt from entering the engine.

2. Remove the oil filler cap and add oil as required.

3. Refit the oil filler cap.

4. Wait 5 to 6 minutes, then check the oil level using the oil level gauge. If the level is too high, allow some oil to escape via the oil pan drain plug.

-72-

Replace the engine oil after the first 60 hours of operation. Thereafter, replace it every 250 hours.

CAUTION .it. Be careful not to spill engine oil. If oil comes into contact with the exhaust manifold or other hot components, it could catch fire. Wipe up any oil that spills accidentally.

NOTE • Be careful not to pour too much oil into the

engine. • The engine oil can be drained quickly while it

is still warm soon after the engine has been stopped.

Oil capacity

Oil pan Approx. 27 dm3 {28.5 US qts.; 27 L} (engines for electric power generators) Approx. 25 dm3 {26.5 US qts.; 25 L} (engines for construction machinery)

Oil filter 4 to 4.5 dm3 {4.2 to 4.7 US qts.; 4 to 4.5 L}

Drain plug

Drain plug Drain plug

Oil filler cap

E0170


1. Wipe the area around the oil filler cap to prevent dust and dirt from entering the engine. Then, remove the cap.

2. Remove the oil pan drain plug and allow the oil to drain out.

Drain plug E0161

3. Remove the oil filter drain plugs and allow the engine oil in the filters to drain out.

4. Replace the oil filter element. ~OJ P.59

5. Refit the drain plug securely, then supply the engine with oil via the oil filler.

6. Crank the engine in accordance with the procedure on ~: P.1B. Then, start the engine and let it idle for several minutes. Check for oil leaks.

7. Stop the engine, wait about 30 minutes, then check the oil level. The oil level gauge may give an incorrectly low reading if the level is checked immediately.

-73-


• Lubrication

Wipe all dust and mud off the grease nipples

(indicated by the arrows in the drawings), and

supply the specified type of grease via each

nipple.

Fan Drive, and Tension Pulley

Required grease type:


Power Plant Clutch Bearing Case (Direct

Drive)



Clutch Fork Shaft and Clutch Shifter


Heat-resisting grease

[NLGI No.3 (Li soap); MIL-G-3545C]

( _______ L_u_b_ric_a_t_io_n_in_t_e_~_a_I:_5_0_0_h_o_u_rs _______ J ( ______ L_u_b_ri_c_at_io_n_i_n_te_~_a_I:_1_,_OO_O __ ho_u_r_s ______ J ( ______ L_u_b_r_ic_at_io_n_i_n_te_~_a_I:_1_,_O_OO __ h_ou_r_s ______ J The fan drive and tension pulley assembly

comes in the two types shown below which are

different in the method of greasing.

<Local greasing type> <Central greasing type>

Fan drive

Water pump Water pump

E0171 E0180

-74 -

E0173 E0172

NOTE Excessive grease application can cause the clutch to slip.

..------~-~---~------------ ---- -------------~

Main Specifications ................................................................................... 76

-75-

Main Specifications

el 6024

6D24-T 6D24-TC

Item (Turbocharged) (Turbocharged, with Aftercooler)

Type Diesel, 4-cycle, water-cooled Diesel, 4-cycle, water-cooled Diesel, 4-cycle, water-cooled

Number and configuration of cylinders. 6 in-line 6 in-line 6 in-line

Bore x stroke mm{in} 130 x 150 {5.12 x 5.91} 130 x 150 {5.12 x 5.91} 130 x 150 {5.12 x 5.91}

Total displacement dm3 {eu-in ; L} 11.945 {729, 11.945} 11.945 {729, 11.945} 11.945 {729, 11.945}

Combustion chambers Direct injection type Direct injection type Direct injection type

Compression ratio 19.5 16.5 16.5

Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Direction of rotation Counterclockwise as seen Counterclockwise as seen Counterclockwise as seen

from flywheel from flywheel from flywheel

Turbocharger - Mitsubishi TD08H type Mitsubishi TD08H type

Engine dimensions

(with fan, without air cleaner) mm{in} 1473 x 866 x 1058 1473 x 881 x 1169 1473 x 881 x 1209

(total length x total width x total height) {58.0 x 34.1 x 41.7} {58.0 x 34.7 x 46.0} {58.0 x 34.7 x 47.6}

Dry weight kg {Ibf} 905 {1995} 930 {2050} 960 {2116}

Fuel Diesel fuel Diesel fuel Diesel fuel

Fuel injection pump Bosch type PE6P Bosch type PE6P Bosch type PE6P

Governor Centrifugal, mechanical Centrifugal, mechanical Centrifugal, mechanical

type allspeed control type allspeed control type allspeed control

Fuel injection nozzles Hole type Hole type Hole type

Lubrication system Geared pump pressure feed type Geared pump pressure feed type Geared pump pressure feed type

Engine oil (Heavy-duty class, API service classification) CD or better CD or better CD or better

Cooling system Forced circulation by centrifugal pump Forced circulation by centrifugal pump Forced circulation by centrifugal pump

Starter 24 V - 5.5 kW 24 V-5.5 kW 24 V-5.5 kW

Alternator 24 V -35 A 24 V - 35 A 24 V - 35 A

• Only standard specifications are shown . • The specifications are subject to change without notice.

-76-

~-------~----~----~---------------

Main Specifications

del 6D24-TL

Item (Turbocharged, with Intercooler)

Type Diesel, 4-cycle, water-cooled

Number and configuration of cylinders. 6 in-line

Bore x stroke mm{in} 130 x 150 {5.12 x 5.91}

Total displacement dm3 leu-in ; L} 11.945 {729, 11.945}

Combustion chambers Direct injection type

Compression ratio 17.5

Firing order 1-5-3-6-2-4

Direction of rotation Counterclockwise as seen

from flywheel

Turbocharger Mitsubishi

TD08H type

Engine dimensions

(with fan, without air cleaner) mm {in} 1473 x 869 x 1246

(total length x total width x total height) {58.0 x 34.2 x 49.1}

Dry weight kg {Ibf} 940 {2070}

Fuel Diesel fuel

Fuel injection pump Bosch type PE6P

Governor Centrifugal, mechanical

type allspeed control

Fuel injection nozzles Hole type

Lubrication system Geared pump pressure feed type

Engine oil (Heavy-duty class, API service classification) CD or better

Cooling system Forced circulation by centrifugal pump

Starter 24 V - 5.5 kW

Alternator 24 V - 35 A

• Only standard specifications are shown . • The specifications are subject to change without notice.

-77-

MEMO----------------------------------------------

-ffl-

~~~~--~---------------------- --- -----

Maintenance Manual diesel engine (for industrial use)

SC2 JANUARY 2003

MITSUBISHI FUSO TRUCK & BUS CORPORATION

j.. maintenance manual - det mitsubishi · 2017. 11. 7. · machine in which the engine is fitted....

Documents